Catalyst support and process for the preparation thereof

Abstract

An amorphous catalyst support comprising at least a first oxide selected from the group consisting of: silica, germanium oxide, titanium oxide, zirconium oxide or mixtures thereof, preferably silica gel beads or diatomaceous earth; a group 3 metal oxide; and anions in an amount not greater than 10% by weight of the catalyst support; wherein the group 3 metal oxide is incorporated in the first oxide structure at the molecular level. The catalyst support is prepared by (a) mixing the first oxide, with an anhydrous source of the group 3 metal oxide, and water, at a pH above 11, thus forming a suspension, (b) washing the catalyst support with water, (c) separating the catalyst support from the water, and (d) optionally drying and/or calcining the catalyst support. A catalyst based on such a support has improved catalytic properties.

1 . An amorphous catalyst support comprising at least:
 (1) a first oxide selected from the group consisting of: silica, germanium oxide, titanium oxide, zirconium oxide and mixtures thereof,   (2) a group 3 metal oxide, and   (3) anions in an amount not greater than 10% by weight of the catalyst support,   
       wherein the group 3 metal oxide is incorporated in the first oxide structure at the molecular level. 
     
     
         2 . The catalyst support according to  claim 1 , wherein the group 3 metal oxide is present in a tetrahedral arrangement, shown by NMR analysis. 
     
     
         3 . The catalyst support according to  claim 1 , wherein the first oxide comprises silica, and wherein the group 3 metal oxide comprises alumina. 
     
     
         4 . The catalyst support according to  claim 3 , wherein the first oxide comprises silica gel beads, and the average diameter of the silica gel beads is of from 20 to 4000 μm. 
     
     
         5 . The catalyst support according to  claim 1 , wherein the concentration of the group 3 metal oxide is of from 1 to 50% by weight of the catalyst support. 
     
     
         6 . The catalyst support according to  claim 1 , wherein the anions are selected from the group consisting of Cl − , (CO 3 ) 2− , (SO 4 ) 2− , NO 3  and mixtures thereof. 
     
     
         7 . The catalyst support according to  claim 1 , wherein the amount of anions is of at most 5 wt %. 
     
     
         8 . A catalyst comprising the catalyst support according to  claim 1 , and a catalytically active component selected from the group consisting of: platinum, palladium, iridium, rhodium, gold, silver and mixtures thereof. 
     
     
         9 . The catalyst according to  claim 8 , wherein the catalytically active component is palladium and wherein the catalyst is for the catalysis of hydrogenation reactions in the alkylanthraquinone(s) process for the manufacture of hydrogen peroxide. 
     
     
         10 . A process for the preparation of a catalyst support comprising at least: a first oxide selected from the group consisting of: silica, germanium oxide, titanium oxide, zirconium oxide, and mixtures thereof; a group 3 metal oxide; and anions in an amount not greater than 10% by weight of the catalyst support, wherein the group 3 metal oxide is incorporated in the first oxide structure at the molecular level, the process comprising:
 (a) mixing the first oxide with an anhydrous source of the group 3 metal oxide, and water, at a pH above 11, thus forming a suspension,   (b) optionally washing the catalyst support with water,   (c) separating the catalyst support from the water,   (d) optionally drying and/or calcining the catalyst support.   
     
     
         11 . The process according to  claim 10 , wherein the temperature in step (a) is in the range of from 30 to 90° C. 
     
     
         12 . The process according to  claim 10 , wherein the anhydrous source of the group 3 metal oxide comprises a metal-[group 3 metal] oxide. 
     
     
         13 . The process according to  claim 10 , wherein the mixture in step (a) is stirred for from 5 to 90 minutes. 
     
     
         14 . (canceled) 
     
     
         15 . A method for catalyzing a reduction or oxidation reaction, comprising using a catalyst containing a catalytically active component and an amorphous catalyst support,
 said catalytically active component being selected from the group consisting of: platinum, palladium, iridium, rhodium, gold, silver, and mixtures thereof, and   said amorphous catalyst support comprising at least:   (1) a first oxide selected from the group consisting of: silica, germanium oxide, titanium oxide, zirconium oxide, and mixtures thereof,   (2) a group 3 metal oxide, and   (3) anions in an amount not greater than 10% by weight of the catalyst support,   
       wherein the group 3 metal oxide is incorporated in the first oxide structure at the molecular level. 
     
     
         16 . The method according to  claim 15 , wherein the catalytically active component is palladium. 
     
     
         17 . The method according to  claim 15 , wherein the reaction is a hydrogenation reaction. 
     
     
         18 . The method according to  claim 15 , wherein the reaction is a hydrogenation reaction in the alkylanthraquinone(s) process for the manufacture of hydrogen peroxide. 
     
     
         19 . The process according to  claim 15 , wherein the first oxide comprises silica selected from the group consisting of silica gel beads and diatomaceous earth. 
     
     
         20 . The process according to  claim 10 , wherein the first oxide comprises silica. 
     
     
         21 . The process according to  claim 10 , wherein the anhydrous source of the group 3 metal oxide comprises sodium aluminate.