Combinatorial preparation and testing of heterogeneous catalysts

Abstract

The array of heterogeneous catalysts and/or their precursors, is made up of a body which has, preferably parallel, through-channels and in which at least n channels comprise n different heterogeneous catalysts and/or their precursors, where n is 2, preferably 10, particularly preferably 100, in particular 1000, especially 10,000. A process for preparing arrays comprising the following steps: a1) preparing solutions, emulsions and/or dispersions of elements and/or element compounds of the elements present in the catalyst and/or catalyst precursor and, if appropriate preparing dispersions of inorganic support materials, a2) if appropriate introducing adhesion promoters, binders, viscosity regulators, pH regulators and/or solid inorganic supports into the solutions, emulsions and/or dispersions, a3) simultaneously or successively coating the channels of the body with the solutions, emulsions and/or dispersions, a predetermined amount of the solutions, emulsions and/or dispersions being introduced into each channel to obtain a predetermined composition and a4) if appropriate heating the coated body in the presence or absence of inert gases or reactive gases to a temperature in the range from 20 to 1500° C. to dry, with or without sintering or calcining, the catalysts and/or catalyst precursors.

1 - 4 . (canceled)  
   
   
       5 . A process for preparing an array of heterogeneous catalysts and/or their precursors made up of a body which has, preferably parallel, through-channels and in which at least n channels comprise n different heterogeneous catalysts and/or their precursors, where n is at least 2, comprising the following steps: 
 a1) preparing solutions, emulsions and/or dispersions of elements and/or element compounds of the chemical elements present in the catalyst and/or catalyst precursor and, if appropriate preparing dispersions of inorganic support materials,    a2) if appropriate introducing adhesion promoters, binders, viscosity regulators, pH regulators and/or solid inorganic supports into the solutions, emulsions and/or dispersions,    a3) simultaneously or successively coating the channels of the body with the solutions, emulsions and/or dispersions, a predetermined amount of the solutions, emulsions and/or dispersions being introduced into each channel to obtain a predetermined composition and    a4) if appropriate heating the coated body in the presence or absence of inert gases or reactive gases to a temperature in the range from 20 to 1500° C. to dry, with or without sintering or calcining, the catalysts and/or catalyst precursors.    
   
   
       6 . A process for preparing an array of heterogeneous catalysts and/or their precursors made up of a body which has, preferably parallel, through-channels and in which at least n channels comprise n different heterogeneous catalysts and/or their precursors where n is at least 2, comprising the following steps: 
 b1) preparing solutions, emulsions and/or dispersions of elements and/or element compounds of the chemical elements present in the catalyst and/or catalyst precursor and, if appropriate preparing dispersions of inorganic support materials,    b2) if appropriate introducing adhesion promoters, binders, viscosity regulators, pH regulators and/or solid inorganic supports into the solutions, emulsions and/or dispersions,    b3) simultaneously or successively coating catalyst supports present in the channels of the body with the solutions, emulsions and/or dispersions, a predetermined amount of the solutions, emulsions and/or dispersions being introduced into each channel to obtain a predetermined composition on the catalyst supports and    b4) if appropriate heating the body comprising the coated catalyst supports in the channels in the presence or absence of inert gases or reactive gases to a temperature in the range from 20 to 1500° C. to dry, with or without sintering or calcining, the catalysts and/or catalyst precursors.    
   
   
       7 . A process for preparing an array of heterogeneous catalysts and/or their precursors made up of a body which has, preferably parallel, through-channels and in which at least n channels comprise n different heterogeneous catalysts and/or their precursors, where n is at least 2, comprising the following steps: 
 c1) preparing solutions, emulsions and/or dispersions of elements and/or element compounds of the chemical elements present in the catalyst and/or catalyst precursor and, if appropriate preparing dispersions of inorganic support materials,    c2) mixing predetermined amounts of the solutions, emulsions and/or dispersions with or without precipitation aids in one or more reaction vessels run in parallel,    c3) if appropriate introducing adhesion promoters, binders, viscosity regulators, pH regulators and/or solid inorganic supports into the resultant mixture(s),    c4) coating one or more predetermined channels of the body with the mixture or a plurality of mixtures,    c5) repeating steps c2) to c4) for other channels of the body until the channels containing the respective predetermined catalyst and/or catalyst precursor compositions are coated,    c6) if appropriate heating the coated body in the presence or absence of inert gases or reactive gases to a temperature in the range from 20 to 1500° C. to dry, with or without sintering or calcining, the catalysts and/or catalyst precursors.    
   
   
       8 . A process for preparing an array of heterogeneous catalysts and/or their precursors made up of a body which has, preferably parallel, through-channels and in which at least n channels comprise n different heterogeneous catalysts and/or their precursors, where n is at least 2, comprising the following steps: 
 d1) preparing solutions, emulsions and/or dispersions of elements and/or element compounds of the chemical elements present in the catalyst and/or catalyst precursor and, if appropriate preparing dispersions of inorganic support materials,    d2) mixing predetermined amounts of the solutions, emulsions and/or dispersions with or without precipitation aids in one or more reaction vessels run in parallel,    d3) if appropriate introducing adhesion promoters, binders, viscosity regulators, pH regulators and/or solid inorganic supports into the resultant mixture(s),    d4) coating catalyst supports present in one or more predetermined channels of the body with the mixture or one or more mixtures,    d5) repeating steps d2) to d4) for other channels of the body until the catalyst supports present in the channels of the body are coated with the respective predetermined catalyst compositions and/or catalyst precursor compositions,    d6) if appropriate heating the body comprising the coated catalyst supports in the channels in the presence or absence of inert gases or reactive gases to a temperature in the range from 20 to 1500° C. to dry, with or without sintering or calcining, the catalysts and/or catalyst precursors.    
   
   
       9 . A process as claimed in  claim 5 , wherein the adhesiveness of the channels of the body is increased prior to the coating by chemical, physical or mechanical pretreatment of the inner walls of the channels or by applying an adhesive coating.  
   
   
       10 . A process for preparing an array of heterogeneous catalysts and/or their precursors made up of a body which has, preferably parallel, through-channels and in which at least n channels comprise n different heterogeneous catalysts and/or their precursors, where n is at least 2, comprising the following steps: 
 e1) preparing different heterogeneous catalysts and/or their precursors in the form of unsupported catalysts having a predetermined composition,    e2) charging in each case one or more predetermined channels of the body, which are secured against the heterogeneous catalyst falling out, with in each case one or more of the heterogeneous catalysts and/or their precursors having a predetermined composition,    e3) if appropriate heating the body comprising the heterogeneous catalysts and/or their precursors in the channels in the presence or absence of inert gases or reactive gases to a temperature in the range from 20 to 1500° C. to dry, with or without sintering or calcining, the catalysts and/or the precursors.    
   
   
       11 . A process for preparing an array of heterogeneous catalysts and/or their precursors made up of a body which has, preferably parallel, through-channels and in which at least n channels comprise n different heterogeneous catalysts and/or their precursors, where n is at least 2, comprising the following steps: 
 f1) coating and if appropriate heating predetermined catalyst supports to prepare predetermined supported catalysts in the manner defined in  claim 6  outside the body,    f2) introducing the supported catalysts into predetermined channels of the body,    f3) if appropriate heating the packed body in the presence or absence of inert gases or reactive gases to a temperature in the range from 20 to 1500° C. to dry, with or without sintering or calcining, the catalysts.    
   
   
       12 . A process as claimed in  claim 11 , wherein the external shape of the supported catalyst at least essentially corresponds to the shape of the channel interior in the body.  
   
   
       13 . An array obtainable by a process as claimed in  claim 5 .  
   
   
       14 . A process for determining the activity and/or long-term stability of the catalysts in an array as claimed in  claim 13 , comprising the following steps: 
 g1) if appropriate activating the catalysts in the body,    g2) heating or cooling the body to a desired reaction temperature,    g3) passing a fluid reactant or a fluid reaction mixture through-channels of the body,    g4) discharge of the reacted fluids from individual or a plurality of collective channels of the body,    g5) analysis of the discharged reacted fluids,    g6) id appropriate comparative evaluation of the analytical results of a plurality of analyses.    
   
   
       15 . A process as claimed in  claim 14 , wherein after heating or cooling the body to a first reaction temperature in step g2), step g3) to step g6) are carried out successively for a plurality of different fluid reactants or fluid reaction mixtures, where in each case a purge step with a purge gas can be introduced, and then the body can be heated or cooled to a second reaction temperature and the abovementioned reactions can be repeated at this temperature.  
   
   
       16 . A process as claimed in  claim 14 , wherein the fluid reactant or fluid reaction mixture is a gas or gas mixture.  
   
   
       17 . A process as claimed in  claim 14 , wherein the reaction is a gas-phase oxidation.  
   
   
       18 . A process as claimed in  claim 17 , wherein a reaction mixture comprising molecular oxygen is used.  
   
   
       19 . A process as claimed in  claim 6 , wherein the adhesiveness of the catalyst support in the body is increased, prior to the coating, by chemical, physical or mechanical pretreatment of the catalyst support or by applying an adhesive layer.  
   
   
       20 . A process as claimed in  claim 5 , wherein the process is carried out in an automated manner.