Composition of catalysts for conversion of ethanol to n-butanol and higher alcohols

Abstract

A method of producing a catalyst comprises forming a decomposed material comprising a decomposed hydrotalcite, a decomposed hydrocalumite, or a combination of both, combining the decomposed material with a mixture to form a catalyst mixture, and heating the catalyst mixture to convert the metal salt to a metal oxide. The mixture comprises a metal salt and a chelating agent, and the resulting metal oxide combined with the decomposed material forms the catalyst.

What is claimed is: 
     
         1 . A method for producing a higher alcohol comprising:
 contacting a reactant comprising ethanol with a catalyst at a reaction temperature and pressure sufficient to produce a reaction product, wherein the catalyst comprises a decomposed hydrotalcite, a decomposed hydrocalumite, or a combination of both mixed with one or more metal oxides, wherein the reaction product comprises a higher alcohol, unreacted ethanol, and an ester;   separating the unreacted ethanol from the reaction product;   separating substantially all of the ester from the unreacted ethanol to form an ethanol recycle stream; and   recycling the ethanol recycle stream to contact the catalyst.   
     
     
         2 . The method of  claim 1 , wherein the catalyst is formed by combining a decomposed material with a mixture to form a catalyst mixture, wherein the mixture comprises a metal salt and a chelating agent; and heating the catalyst mixture to convert the metal salt to a metal oxide, wherein the resulting metal oxide combined with the decomposed material forms the catalyst. 
     
     
         3 . The method of  claim 1 , wherein the higher alcohol comprises a C 4 -C 13  alcohol. 
     
     
         4 . The method of  claim 1 , wherein the higher alcohol is butanol. 
     
     
         5 . The method of  claim 1 , wherein a conversion of ethanol to the higher alcohol is at least about 10%. 
     
     
         6 . The method of  claim 1 , wherein a selectivity of the conversion of ethanol to the higher alcohol is at least about 90%. 
     
     
         7 . The method of  claim 1 , wherein the one or more metal oxides comprise one or more metals selected from the group consisting of: Pd, Cu, Pt, Cr, Ni, Fe, Ru, Rh, and Co. 
     
     
         8 . The method of  claim 1 , wherein the one or more metal oxides comprises an alkaline salt, an alkaline earth salt, or any combination thereof. 
     
     
         9 . The method of  claim 1 , wherein the catalyst further comprises a support material. 
     
     
         10 . The method of  claim 1 , wherein the reactant and the ethanol recycle stream are substantially free of esters. 
     
     
         11 . The method of  claim 7 , wherein the one or more metal oxides comprise one or more metals of Pd or Cu. 
     
     
         12 . The method of  claim 7 , wherein the one or more metal oxides comprise one or more metals of Pd. 
     
     
         13 . A method of producing a catalyst comprising:
 decomposing material to form a decomposed hydrotalcite, a decomposed hydrocalumite, or a combination of both;   combining the decomposed material with a mixture to form a catalyst mixture, wherein the mixture comprises a metal salt; and   heating the catalyst mixture to convert the metal salt to a metal oxide, wherein the resulting metal oxide combined with the decomposed material forms the catalyst, and wherein at least one of the decomposing or the heating comprises applying heat at a temperature between 600° C. and 750° C.   
     
     
         14 . The method of  claim 13 , wherein forming the decomposed material comprises heating a material comprising hydrotalcite, hydrocalumite, or both, to a temperature in a range of 350° C. to 800° C. 
     
     
         15 . The method of  claim 14 , wherein heating the catalyst mixture comprises heating the material to a temperature between about 300° C. and about 800° C. 
     
     
         16 . The method of  claim 13 , wherein the process further comprises:
 mixing a second metal salt with the material prior to heating the material.   
     
     
         17 . The method of  claim 16 , wherein the second metal salt comprises an alkaline salt, an alkaline earth salt, or any combination thereof. 
     
     
         18 . The method of  claim 13 , wherein the metal salt comprises one or more metals selected from the group consisting of: Pd, Cu, Pt, Cr, Ni, Fe, Ru, Rh, and Co. 
     
     
         19 . The method of  claim 13 , wherein the catalyst has a surface area of between about 20 m 2 /g to about 100 m 2 /g. 
     
     
         20 . The method of  claim 13 , wherein the catalyst has a pore volume of between about 0.05 cm 3 /g and about 0.4 cm 3 /g.