Catalyst for preparing chlorine by oxidation of hydrogen chloride and preparation thereof

Abstract

The present invention relates to a catalyst for producing chlorine by oxidation of hydrogen chloride and a method for preparing the same. The catalyst comprises a support and active ingredients that comprise 1-20 wt % of copper, 0.01-5 wt % of boron, 0.1-10 wt % of alkali metal element(s), 0.1-15 wt % of one or more rare earth elements, and 0-10 wt % of one or more elements selected from magnesium, calcium, barium, manganese, iron, nickel, cobalt, zinc, ruthenium or titanium based on the total weight of the catalyst. The catalyst is prepared by a two-step impregnation method. Comparing with the available catalysts of the same type, the catalyst according to the present invention has greatly improved conversion and stability.

1 . A catalyst for producing chlorine by oxidation of hydrogen chloride comprising a support and active ingredients, wherein the active ingredients comprise: 1-20 wt % of copper, 0.01-5 wt % of boron, 0.1-10 wt % of alkali metal element(s), 0.1-15 wt % of one or more rare earth elements, and 0-10 wt % of one or more elements selected from the group consisting of: magnesium, calcium, barium, manganese, iron, nickel, cobalt, zinc, ruthenium and titanium, based on the total weight of the catalyst. 
     
     
         2 - 14 . (canceled) 
     
     
         15 . The catalyst according to  claim 1 , wherein the active ingredients comprise: 4-15 wt % of copper, 0.1-4 wt % of boron, 2-7 wt % of alkali metal element(s), 1-11 wt % of one or more rare earth elements, and 1-8 wt % of one or more elements selected from the group consisting of: magnesium, calcium, barium, manganese, iron, nickel, cobalt, zinc, ruthenium and titanium. 
     
     
         16 . The catalyst according to  claim 15 , wherein the active ingredients comprise: 5-12 wt % of copper, 0.15-3 wt % of boron, 2.5-6 wt % of alkali metal element(s), 2-9 wt % of one or more rare earth elements, and 2-6 wt % of one or more elements selected from the group consisting of: magnesium, calcium, barium, manganese, iron, nickel, cobalt, zinc, ruthenium and titanium. 
     
     
         17 . The catalyst according to  claim 1 , wherein the support comprises one or more of: a molecular sieve, kaolin, diatomite, silica, alumina, titania or zirconia, and the support comprises 60-90 wt % of the total weight of the catalyst. 
     
     
         18 . The catalyst according to  claim 17 , wherein the alkali metal element is lithium, sodium, potassium or cesium. 
     
     
         19 . The catalyst according to  claim 18 , wherein the rare earth element comprises one or more lanthanide elements. 
     
     
         20 . A method of making the catalyst of  claim 1 , comprising:
 (a) preparing a solution by dissolving a copper-containing compound and optionally a compound containing a transition metal other than copper in water, then impregnating a support with the solution, and drying the impregnated support;   (b) dissolving a boron-containing compound, an alkali metal-containing compound, an alkaline earth metal-containing compound and a rare earth metal-containing compound in water, then impregnating the dried solid obtained in step (a) therein, and drying the impregnated solid; and   (c) calcining the solid obtained in step (b) at a temperature of 450-650° C. for 1-5 h so as to obtain the catalyst.   
     
     
         21 . The method according to  claim 20 , wherein the copper-containing compound is a soluble salt of copper. 
     
     
         22 . The method according to  claim 20 , wherein the compound containing a transition metal other than copper is a soluble salt of manganese, iron, nickel, cobalt, zinc, ruthenium or titanium. 
     
     
         23 . The method according to  claim 20 , wherein the boron-containing compound is a soluble boron compound. 
     
     
         24 . The method according to  claim 20 , wherein the alkali metal-containing compound is a soluble salt of lithium, sodium or potassium. 
     
     
         25 . The method according to  claim 20 , wherein the alkaline earth metal-containing compound is a soluble salt of magnesium, calcium or barium. 
     
     
         26 . The method according to  claim 20 , wherein the rare earth metal-containing compound is a soluble salt of a rare earth element. 
     
     
         27 . The method according to  claim 20 , wherein the copper-containing compound is one or more of: cupric nitrate, cupric chloride or cupric acetate; the boron-containing compound is one or more of: boric acid, sodium borate or potassium borate; the compound containing the transition metal other than copper is one or more of: nitrates, chlorides or acetates of manganese, iron, nickel, cobalt or zinc; the alkali metal-containing compound is one or more of: a chloride, a nitrate, an acetate, a carbonate or a borate of sodium or potassium; the alkaline earth metal-containing compound is one or more of: chlorides, nitrates, acetates, carbonates or borates of magnesium or calcium; and the rare earth metal-containing compound is one or more of: nitrates of cerium, lanthanum, praseodymium or neodymium. 
     
     
         28 . The method according to  claim 20 , wherein the active ingredients comprise: 4-15 wt % of copper, 0.1-4 wt % of boron, 2-7 wt % of alkali metal element(s), 1-11 wt % of one or more rare earth elements, and 1-8 wt % of one or more elements selected from the group consisting of: magnesium, calcium, barium, manganese, iron, nickel, cobalt, zinc, ruthenium and titanium. 
     
     
         29 . The method according to  claim 28 , wherein the active ingredients comprise: 5-12 wt % of copper, 0.15-3 wt % of boron, 2.5-6 wt % of alkali metal element(s), 2-9 wt % of one or more rare earth elements, and 2-6 wt % of one or more elements selected from the group consisting of: magnesium, calcium, barium, manganese, iron, nickel, cobalt, zinc, ruthenium and titanium. 
     
     
         30 . The method according to  claim 20 , wherein the support comprises one or more of: a molecular sieve, kaolin, diatomite, silica, alumina, titania or zirconia, and the support comprises 60-90 wt % of the total weight of the catalyst.