Palladium containing metal oxide catalyst

Abstract: A catalyst composed of metal oxide particles among which are uniformly incorporated, in order to reduce the operating temperature of the catalyst, palladium particles.

Description: This invention relates to a metal oxide catalyst, its production, a method of conducting a chemical reaction employing it, and a hazardous gas sensor containing a particular example of it. It has been discovered how a metal oxide catalyst can be operated at a lower temperature. The invention provides a catalyst composed of metal oxide particles, the metal oxide being catalytically active and being capable of reduction to another oxide of the metal, the metal oxide being one or more of iron(III) oxide, cerium(IV) oxide and bismuth molybdate, among which metal oxide particles are uniformly incorporated palladium particles in order to reduce the operating temperature of the catalyst. The invention provides also a process for preparing the catalyst, which process comprises co-precipitating the metal oxide particles and the palladium particles. The invention also provides a method of conducting a chemical reaction employing the catalyst. The invention provides also a sensor of hazardous gas at ambient temperature, which sensor comprises means to allow gas to contact the present catalyst wherein the metal oxide comprises iron(III) oxide and means to indicate the rise in temperature of the catalyst if hazardous gas is present. The invention provides, in a catalyst composed of metal oxide particles, the metal oxide being capable of reduction to another oxide of the metal, the improvement which comprises incorporating palladium particles uniformly among the metal oxide particles to reduce the operating temperature of the catalyst. The invention similarly provides, in a method of conducting a chemical reaction employing a catalyst composed of metal oxide particles, the metal oxide being capable of reduction to another oxide of the metal, the improvement comprising incorporating palladium particles uniformly among the metal oxide particles to reduce the temperature of the reaction. Our European patent application EP-A-0 602 865, which was filed on the same day as the present application and has the same priority date, discloses a method of conducting a chemical reaction comprising the oxidation of carbon monoxide to carbon dioxide employing a catalyst composed of metal oxide particles among which are uniformly incorporated noble metal particles, the catalyst haveing such a high interaction between the noble metal particles and the metal oxide particles that, without hydrogen reduction pre-treatment, it exhibits the formation of anionic vacancies on the metal oxide surface at a temperature lower than does the corresponding catalyst, without hydrogen reduction pre-treatment, containing the same amount of the metal oxide particles and noble metal particles and prepared by impregnating the metal oxide particles with noble metal precursor and calcining to convert the precursor to the noble metal particles. EP-A-0 505 863 discloses a moulded catalyst for hardening crude unsaturated fatty acids, comprising an intimate mixture of titanium oxide and finely divided palladium metal, wherein the titanium oxide is pyrogenic titanium oxide obtained from titanium tetrachloride by flame hydrolysis. In the Examples, the palladium moiety is impregnated into the oxide. EP-A-0 299 485 discloses an activated catalyst of the general formula Pd x (ZrO z ) y , wherein x is a number between 1 and 99, y is the difference between x and 100 and z is a value between 0.5 and 2. Zirconia is not a metal oxide capable of reduction to another oxide of the metal. FR-A-2 058 817 discloses an oxidation catalyst comprising vanadium pentoxide and palladium, and in addition at least one alkalie and/or alkaline earth element in the form of metal or of metal compound, in proportion between 0.1 and 30% of the weight of the final catalyst, the palladium content being between 0.0001 and 1% of the weight of the final catalyst. The Examples concern impregnating vanadium pentoxide with a solution of palladium nitrate and the chloride of a metal whose oxide is not capable of reduction to another oxide of the metal. EP-A-0 102 067 discloses a CO gas detecting device which comprises; a CO gas sensor provided with a gas-sensitive member comprising an oxide semiconductor of which resistance value is changed when contacted with a reducing gas, a pair of electrodes provided on said gas-sensitive member, and a catalyst layer comprising at least one kind of catalyst metals of Pt, Pd and Rh and at least one kind of carriers of Al 2 O 3 , ZrO 2 and SiO 2 , provided on said gas-sensitive member; and a reference sensor substantially without sensitivity to CO gas provided with a gas-sensitive member comprising an oxide semiconductor of which resistance value is changed when contacted with a reducing gas, a pair of electrodes provided on said gas-sensitive member, and a catalyst layer comprising Ag and at least one kind of carriers of Al 2 O 3 , ZrO 2 and SiO 2 , provided on said gas -sensitive member. Al 2 O 3 , ZrO 2 and SiO 2 are not metal oxides capable of reduction to another oxide of the metal. It has been discovered that the operating temperature of a catalyst composed of metal oxide particles, the metal oxide being capable of reduction to another oxide of the metal, can be reduced by incorporating palladium particles uniformly among them. In this structure, there is high and even interaction between the two sets of particles. This contrasts, for instance, with metal oxide particles whose surface has simply been impregnated with the palladium. As is conventional in this art, references herein to a catalyst component being palladium embrace the possibility of some or all of it being in the form of the oxide. The present catalyst usually contains 0.1 to 25%, preferably 1 to 20%, by mass of the palladium particles based on the total mass of the palladium particles and the metal oxide particles. Additives can be incorporated into the catalyst to convey advantageous properties or avoid disadvantageous properties. The additives can be conventional. The additives can be for instance antimony oxide, or alkali metal ions to improve selectivity in partial oxidation reactions. Additives can be present for instance in amounts of 0.1-50% of the total mass of the catalyst. The lower amounts are appropriate for additives such as alkali metal ions, and the higher for additives such as antimony oxide. The usual antimony oxide can be employed, generally antimony(V) oxide or that known as diantimony tetroxide. The lowering of the operating temperature of catalysts composed of metal oxide particles, the metal oxide being capable of reduction to another oxide of the metal, is a general phenomenon (providing, of course, thermodynamic considerations do not render this impossible). The metal oxide is reducible metal oxide, ie the metal oxide is capable of reduction to another oxide of the metal. The metal oxide capable of reduction to another oxide of the metal is one or more of iron(III) oxide, cerium(IV) oxide and bismuth molybdate. The particle diameter of the catalyst, as measured by sieving, is usually less than 150 µm. Preferably the catalyst is such that in one or more of the following reactions, it reduces the temperature at which 9%mol conversion occurs by at least 50°C, preferably at least 100°C, compared to that in the case of the catalyst without the palladium: (A) the conversion of but-1-ene to butadiene using a gas mixture of but-1-ene and air (1/6 by volume) at a flow-rate of 100cm 3 min -1 per g of the catalyst; (B) the conversion of carbon monoxide to carbon dioxide using a gas mixture of carbon monoxide and air (1/99 by volume) at a flow-rate of 2000cm 3 min -1 per g of the catalyst; (C) the conversion of carbon monoxide and steam to carbon dioxide and hydrogen using a gas mixture of by volume 0.1% carbon monoxide, 10% steam and the balance nitrogen, at a flow-rate of 1250cm 3 min -1 per g of the catalyst; and (D) the conversion of isobutane to isobutene using a gas mixture of isobutane and air (1/2 by volume) at a flow-rate of 100cm 3 min -1 per g of the catalyst. The catalyst is preferably that preparable by co-precipitation of the metal oxide particles and the palladium particles. Co-precipitation is a very effective method of incorporating the palladium particles into the metal oxide particles, but an alternative preparation which gives the same result would suffice. The co-precipitation can be carried out in a manner known generally per se, conveniently at ambient temperature. The co-precipitation is preferably carried out so that it occurs in a controlled rather than a sudden manner. It will be understood that the co-pecipitation may produce a precipitate which does not have the metal oxide present as such, but in a form, such as an hydroxide, which is then converted to the metal oxide. The conversion can be accomplished for instance by heating, for example at 50-500°C. The chemical reaction in which the present catalyst is employed can be any in which a catalyst without the palladium can be employed. Where the unmodified metal oxide acts as a catalyst in several different reactions, each reaction may be made to occur at a lower operating temperature by means of the present invention. The present reaction is usually conducted at a temperature below 700°C, usually at a temperature within the range of ambient temperature up to 700°C. By being able to operate a reaction at a lower temperature, a saving of energy can be achieved and the catalyst will tend to last longer. In addition, reactions can now be conducted at ambient temperature which previously required heating the catalyst. In a particular embodiment, the present reaction is conducted at ambient temperature. The low temperature activity of the present catalyst is sustained rather than being transitory. It usually lasts, without regeneration, for at least 5 hours, preferably at least 100 hours, particularly when the catalyst is prepared by co-precipitation. It is another advantage of the present invention that the catalyst can be employed without prior calcination to activate it. It can simply be washed and dried (at no more than 130°C) and then used for low temperature catalysis. However, calcination may be desirable to ensure physical stability. The present chemical reaction is usually oxidation. A preferred reaction is oxidative dehydrogenation, particularly of alkene, especially of but-1-ene to butadiene. A metal oxide according to the invention is bismuth molybdate. Another metal oxide according to the invention is iron(III) oxide. A further metal oxide according to the invention is cerium(IV) oxide optionally in admixture with antimony oxide. Catalysts containing these metal oxides can catalyse the reactions normally associated with the unmodified metal oxide from which they are derived. The catalyst wherein the metal oxide is iron(III) oxide is able to oxidise carbon monoxide to carbon dioxide, even at ambient temperature. It is not deactivated by the presence of water vapour. Hence, in an advantageous embodiment it is employed to oxidise carbon monoxide to carbon dioxide in the presence of 0 to 15% water vapour. Gas mixtures referred to in this specification are by volume unless otherwise indicated. This catalyst will also tolerate gas mixtures containing nitrogen oxides and/or sulphur compounds. Hence, in advantageous embodiments it is employed to oxidise carbon monoxide to carbon dioxide in the presence of 0 to 0.2% nitrogen oxides and/or 0 to 0.005% sulphur compounds. It has been found that the rate of CO conversion by this catalyst is linearly dependent on CO concentration, over a range of up to 5% or more by volume in gas such as air. The energy released during reaction is, therefore, proportional to the CO concentration in the gas, making this catalyst particularly suitable to be used for CO sensing. It may also be used to sense, in the absence of CO, other hazardous gases, usually a reducing gas, such as hydrogen or alkene, for instance but-1-ene. In a preferred embodiment, the sensing is at ambient temperature, hence without the need for pellister technology. The sensor can be of type known in itself. Usually the sensor comprises means to allow gas to contact the catalyst wherein the metal oxide is iron(III) oxide and means to indicate the rise in temperature of the catalyst if hazardous gas, especially CO, is present. A particular advantage of sensing at ambient temperature is that the catalyst does not have to be kept at a raised temperature, so avoiding the risk of igniting combustible gas. The present catalyst wherein the metal oxide is iron(III) oxide is useful for monitoring the performance of catalytic material for oxidising carbon monoxide to carbon dioxide, for instance in an engine exhaust. Accordingly, in a preferred embodiment, this catalyst is downstream of catalytic material in the exhaust system of an engine, the catalytic material being for oxidising carbon monoxide to carbon dioxide and the sensor monitoring the performance of the catalytic material in this oxidation. This catalyst is particularly suited to automobile applications, and can there be used in on-board diagnostics, such as monitoring the performance of catalytic material for treating the automotive exhaust to combat air pollution. Hence, in a preferred embodiment, the engine is an internal combustion engine in a vehicle and the monitoring indicates when the performance of the catalytic material (for instance a three-way catalyst) falls below a set level. Compared to a prior art low temperature CO oxidation catalyst (Au/Fe 2 O 3 , see page 33 of "Successful Design of Catalysts", edited by T Inui, published by Elsevier, Amsterdam, 1988), the present catalyst wherein the metal oxide is iron(III) oxide has the advantages of (a) lower material costs, (b) lower light-off temperature at the same loading of precious metals, and (c) greater resistance to deactivation. In the presence of CO and H 2 O, the present catalyst wherein the metal oxide is iron(III) oxide functions as a water-gas shift catalyst. This activity begins about 100°C. The catalyst activates in situ, so pre-reduction is not necessary. It can be used in the water-gas shift reaction at, for instance, 100-200°C. The present catalysts, particularly those wherein the metal oxide is iron(III) oxide or bismuth molybdate, are active in the oxidative dehydrogenation of alkene. The alkene is usually acyclic, and can be straight or branched chain. It generally is of 2-6 carbon atoms. The oxidative dehydrogenation of but-1-ene to butadiene is of particular importance, and the present catalyst effects this at much lower temperatures than expected. This reaction with the present catalyst wherein the metal oxide is iron(III) oxide will begin even if the initial temperature of the reactor is below 100°C; once the reaction has started, for instance after several minutes, it can become self-sustaining without the further supply of heat. In a preferred embodiment, the oxidative dehydrogenation of but-1-ene to butadiene is conducted employing as catalyst the present catalyst wherein the metal oxide is iron(III) oxide at a temperature below 200°C, for instance at a temperature between 80 and 200°C. When the present catalyst wherein the metal oxide is iron(III) oxide or bismuth molybdate is employed in the oxidative dehydrogenation of but-1-ene to butadiene, the selectivity to butadiene improves with time on line. The operating temperature of the present catalyst wherein the metal oxide is iron(III) oxide for (a) CO oxidation, (b) water-gas shift, and (c) oxidative dehydrogenation is about 250°C below that for the corresponding catalyst without the palladium. Similarly, other of the present catalysts, for instance that wherein the metal oxide comprises bismuth molybdate, have a substantially lower minimum operating temperature than the corresponding catalyst without the palladium. When the metal oxide comprises bismuth molybdate, the oxidative dehydrogenation of but-1-ene to butadiene is preferably conducted at a temperature of 200 to 300°C. This is some 100-150°C lower than conventional selective oxidation catalysts require. The present catalysts, particularly those wherein the metal oxide is cerium(IV) oxide, optionally with antimony tetroxide incorporated by mixing into the catalyst, are active in the dehydrogenation, oxidative or not, of alkane of at least 2 carbon atoms to alkene. The alkane is usually acyclic, and can be straight or branched chain. It generally is of 2-6 carbon atoms. A preferred such reaction is the dehydrogenation of isobutane to isobutene. When the metal oxide is cerium(IV) oxide, and as additive diantimony tetroxide is incorporated by mixing into the catalyst, a given yield in the dehydrogenation of isobutane to isobutene occurs about 100°C lower than in the case of the corresponding catalyst without the palladium. Isobutene is useful for instance for manufacturing the petrol additive methyl t-butyl ether. Analysis indicates that the present catalyst is usually at least partially amorphous, with metal ions and Pd 2+ ions on the surface. Chemical analysis of the present dry precipitate wherein the metal oxide is iron(III) oxide shows the presence of Fe 3+ and Pd 2+ ions on the surface of a predominantly amorphous bulk. A high degree of interaction between the Pd and Fe phases is inferred from temperature-programmed reduction, which shows substantial shifts (to lower temperatures) of the peaks associated with the reduction of Fe 3+ . Chemical analysis of the present dry precipitate wherein the metal oxide is bismuth molybdate shows a mixture of α-bismuth molybdate (Bi 2 Mo 3 O 12 ; monoclinic) and β-bismuth molybdate (Bi 2 Mo 2 O 9 ; monoclinic), with there being no evidence of a crystalline Pd-phase. A conventional Bi-Mo-O catalyst (used for comparison in Comparative Example 2 hereafter) is also a mixture of two bismuth molybdates, but these are the β and γ (Bi 2 MoO 6 ; orthorhombic) allotropes. Surface analysis of the present dry precipitate wherein the metal oxide is cerium(IV) oxide shows that essentially all the palladium is present as Pd 2+ , and all the cerium as Ce 4+ . The present catalyst can be employed as the sole catalyst or together with another catalyst, usually comprising one or more of Pt, Pd, Rh and base metal oxide. The present catalyst can be formulated in the usual way to catalyse chemical reactions. When it is employed as sole catalyst, it generally does not need to be dispersed on a separate high surface area carrier. When it is employed together with another catalyst, a high surface area carrier is often useful to carry both catalysts. For instance, the present catalyst can be dispersed on the carrier and, either before or usually afterwards, the other catalyst can be dispersed on the carrier, for instance in the usual way by impregnating with a precursor and calcining to convert the precursor to the other catalyst. The present catalyst itself preferably has a Brunauer Emmett Teller surface area of at least 50, especially at least 100, m 2 g -1 . The catalyst can be employed in the form of pellets. It can be employed on a support, preferably a monolith, for instance a honeycomb monolith. The monolith can be metal, in which case it can readily be heated, for instance by passing an electrical current through the metal. Alternatively the monolith can be ceramic. A separate heater of gas can be utilised up-stream of the catalyst to heat gas to facilitate its reaction on the catalyst. The invention is illustrated by the accompanying drawings, whose sole Figure is described in Example 1 hereafter. The invention is illustrated by the following Examples. EXAMPLE 1 A Pd-Fe-O catalyst with a nominal Pd loading of 20% (by mass) was prepared using crystalline Fe(NO 3 ) 3 .9H 2 O (52.2g), aqueous Pd(NO 3 ) 3 (28.0g of solution ≡ 2.30g Pd) and solid Na 2 CO 3 (30.1g). The two nitrates were added to demineralised water (1dm 3 ) in a large beaker (2dm 3 ) fitted with a pH probe and a mechanical stirrer. After dissolving the Na 2 CO 3 (in 250cm 3 demineralised water), the aqueous precipitant was added to the stirred Pd/Fe solution at a rate of 2cm 3 min -1 (using a peristaltic pump). The Pd/Fe solution was initially orange and had a pH of 1.3, but turned darker as the precipitant was added. The precipitate began to form at a pH of 2.5, and was accompanied by the evolution of carbon dioxide. As the end-point was approached, the suspension became very dark and viscous, and the pH changed more rapidly. At this point, the rate of addition of the precipitant was decreased (to 1cm 3 min -1 ), and then stopped when a pH of 8.5 was reached. The brown gelatinous precipitate was isolated (by filtration), washed thoroughly and dried (110°C; 16h). The dry material (12g) was found to contain 19% Pd (and <0.01% Na) by mass. A sample (0.20g) of the dry material (sieved to a particle diameter <150µm) was tested under a gas mixture of CO/air at a flow rate of 400cm 3 min -1 . Gas mixtures in this specification are by volume unless otherwise indicated. The initial temperature of the catalyst bed was 50°C. Figure 1 of the accompanying drawings shows the effect of varying the CO concentration on: (i) CO conversion (the amount of CO converted as % of total gas flow) , (ii) the size of the exotherm generated. (i) shows a linear dependence on CO concentration (over the range 0-5%), indicating that Pd-Fe-O could be used for CO-sensing. (ii) shows a particularly convenient way of doing this (over the range 0-4%). EXAMPLE 2 Several Pd-Fe-O catalysts with different Pd loadings were prepared by the controlled addition of aqueous Na 2 CO 3 to a mixed solution of iron(III) nitrate and sodium tetrachloropalladite; the addition of the precipitant was stopped when the pH reached 8.5. An analogous series of prior art Au/Fe 2 O 3 (page 33 of "Successful Design of Catalysts", edited by T Inui, published by Elsevier, Amsterdam, 1988) catalysts was prepared by substituting tetrachloroauric acid for the Pd-precursor. The dry materials were tested under a CO/air (1/99) gas mixture at a gas hourly space velocity of 33000h -1 . The conversion of CO was measured as a function of gas inlet temperature. Values for T 50 (temperature at which CO conversion reaches 50%) were recorded and averaged for several temperature programmed tests. For each loading, the T 50 value for the Pd-containing catalyst was lower than for the Au-containing analogue (Table 1). Light-off (T 50 ) temperatures for the oxidation of CO over Pd-Fe-O and Au/Fe 2 O 3 . Precious Metal loading / mass % T 50 /°C Pd-Fe-O Au/Fe 2 O 3 0 275 275 1 75 230 2 66 120 4 23 86 8 60 81 When the best Au-containing catalyst (8%Au/Fe 2 O 3 ) was exposed to the gas mixture at 140°C, the initial CO conversion was 100%, but declined to <20% over a period of 140 hours. The Pd-Fe-O catalysts did not show the same deactivation. Their activity remained at 100% during the first 10 hours, and was still >80% after 140 hours. EXAMPLE 3 The ability of 20%Pd-Fe-O (nominal composition; prepared as in Example 1) to convert the CO in an exhaust gas was tested at low temperature (100°C). A sample (1g) of the dry material was exposed to a simulated mixture of automotive exhaust gas, at an equivalence ratio (λ) of 0.98 (Table 2) and flow rate of 2dm 3 min -1 . The conversion of CO was 95%, and showed no signs of declining with repeated testing (amounting to a total of 20 hours' use). Composition of simulated exhaust gas mixture at λ = 0.98. Component Concentration / mol% H 2 0.43 O 2 0.72 CO 1.30 CH 4 0.067 CH 3 H 8 0.0223 C 3 H 6 0.0223 CO 2 15.0 H 2 O 9.2 NO 0.15 SO 2 0.002 N 2 balance EXAMPLE 4 Samples of 20%Pd-Fe-O (prepared as in Example 1) were aged under a variety of conditions before being re-tested under the exhaust gas mixture (at λ = 0.98; Table 2). The ageing conditions and the activity results are summarised in Table 3. Effect of catalyst ageing on CO activity under an exhaust gas at 100°C. Ageing conditions CO conversion % at λ = 0.98 SO 2 H 2 O Temperature, °C Duration, hour H 2 or O 2 (a) 0.002% 10% 400 0.5 1% H 2 0 (b) 0.002% 10% 200 5.0 1% O 2 82 (c) 0.002% absent 400 0.5 1% O 2 55 (d) absent 10% 200 0.5 1% H 2 86 (e) 0.002% absent 200 5.0 1% H 2 35 (f) absent absent 400 5.0 1% H 2 0 (g) absent 10% 400 5.0 1% O 2 75 (h) absent absent 200 0.5 1% O 2 93 Complete loss of low-temperature activity occurred only when the material was aged under a reducing gas at high temperature (ie samples (a) and (f) in Table 3). EXAMPLE 5 The ability of 20%Pd-Fe-O (prepared as in Example 1) to catalyse the water-gas shift reaction at low CO concentration (in the presence of a large excess of H 2 O) was measured over the temperature range 100-200°C. A, sample (2g) was tested in a spinning-basket reactor (2500 rpm), using a gas mixture containing CO/H 2 O (1/100) in nitrogen at a flow rate of 2.5dm 3 min -1 . The results are shown in Table 4. Steady-state activity data for water-gas shift reaction. (Inlet and outlet concentrations / mol ppm) Catalyst Temperature °C Inlet (CO) Outlet (CO) Outlet (H 2 ) 20%Pd-Fe-O 100 998 830 112 110 1002 818 154 120 998 787 186 150 998 706 251 200 1000 650 340 α-Fe 2 O 3 100 1010 998 0 150 999 995 0 250 998 979 0 Fe-O 250 1006 978 0 The difference between the rate of CO conversion and the rate of H 2 release, at temperatures between 100 and 150°C, suggests that 20%Pd-Fe-O was being reduced by the hydrogen being generated. At 200°C, this in situ reduction appeared complete, and the two rates became almost identical. The commercial sample of α-Fe 2 O 3 showed negligible H 2 formation under identical conditions, even after mild reduction. EXAMPLE 6 In order to determine the extent to which water-gas shift can contribute when 20%Pd-Fe-O (prepared as in Example 1) is exposed to an exhaust gas, the CO conversion was measured both in the presence and absence of O 2 in the simulated exhaust gas (see Table 2 for composition). At 100°C, the CO conversion dropped substantially (Table 5) when O 2 was removed from the simulated exhaust gas; the effect was much less at 165°C. The results show that direct oxidation of CO occurs at the lowest temperatures, but the water-gas shift reaction begins to predominate above ca 150°C. Effect of O 2 removal from exhaust gas on CO-conversion over 20%Pd-Fe-O. CO-conversion / % Temperature °C Full exhaust gas Exhaust gas without O 2 100 95 32 140 99 43 165 99 77 EXAMPLE 7 4%Pd-Fe-O (nominal composition) was prepared as described in Example 1, except the mass of Pd in the nitrate precursor was 0.46g. A sample (1g) of the dry precipitate was tested under a gas mixture of but-1-ene/air (1/6) at a flow-rate of 100cm 3 min -1 . Unlike the performance expected for catalysts derived from iron oxide (eg see Zhang et al, J. Chem. Soc. Faraday Trans., 88 (1992) 637), Pd-Fe-O showed substantial activity (including oxidative dehydrogenation) at temperatures below 200°C (Table 6). Butene oxidation activity of fresh 4%Pd-Fe-O as a function of furnace temperature; activity measured after 20 min on line. Selectivity % Temperature °C Conversion % CO 2 Trans but-2-ene Cis but-2-ene butadiene 180 74 30.5 30 22 4.5 135 61 43 23 18 15 80 44.5 45 17.5 15 22 (molar conversions and selectivities) At a furnace temperature of 80°C, the catalyst bed temperature rose to ca 130°C during reaction. The heat generated was then sufficient to sustain the reaction without further heat input from the furnace. The selectivity of Pd-Fe-O to butadiene improved as a function of lime on line (Table 7a), and could be further enhanced by adjusting the butene/air ratio in the gas feed (Table 7b). Enhancing oxidative dehydrogenation of butene over 4%Pd-Fe-O at 100°C. (a) Effect of conditioning (activity measured for butene/air = 1/6) Selectivity Conversion % CO 2 Trans but-1-ene Cis but-2-ene butadiene 2 min on line 65 45 14 12 15 5h on line 54 36 3 2 59 2 min on line 70 42 13 11 21 (b) Effect of gas composition (activity of sample aged on line for 5 h) Selectivity % Butene/Air Conversion % CO 2 Trans but-2-ene Cis but-2-ene butadiene 1/6 54 36 3 2 59 1/4 51 28 2 1 69 1/2 23 31 4 5 60 COMPARATIVE EXAMPLE 1 In order to assess the significance of the results presented in Example 7, a number of related materials were prepared and tested: (i) Impregnated 4%Pd-Fe-O was prepared by adding aqueous Pd(NO 3 ) 3 (containing 0.153g Pd) to FeO(OH) (3.73g) to form a thick paste, which was heated gently on a hot plate. The warm paste was transferred to an oven (110°C) for drying (16h), before calcination (500°C; air; 2h). (ii) Precipitated Pd-O was prepared by adding aqueous Na 2 CO 3 to aqueous Pd(NO 3 ) 3 (containing 2.30g Pd). The precipitate was isolated, washed and dried (110°C; 16h). (iii) Precipitated Fe-O was prepared by adding aqueous Na 2 CO 3 to aqueous Fe(NO 3 ) 3 .9H 2 O (52.2g). The precipitate was isolated, washed and dried (110°C; 16h). (iv) Precipitated 4%Au/Fe 2 O 3 was prepared by the method described in Example 2. A sample (1g) of each material was tested under a gas feed of but-1-ene/air (1/6) at a flow rate of 100cm 3 min -1 (Table 8). None of these materials was active at temperatures below 150°C. Between 150 and 200°C, precipitated Pd-O showed reasonable activity, but the selectivity to butadiene was very low. Over a similar temperature range, impregnated 4%Pd-Fe-O was more selective, but the activity was poor; 4%Au/Fe 2 O 3 showed high initial activity, but this was not sustainable. Precipitated Fe-O needed to be used above 300°C before the yield of butadiene was comparable to that of precipitated Pd-Fe-O at 80-100°C. Butene oxidation performance at minimum operating temperature (ie, the minimum temperature at which measurable amounts of product are formed) (T); activity measured after 20 min on line. Selectivity, % Catalyst T °C Conversion, % CO 2 but-2-ene butadiene Precipitated Pd-O 150 42 54 43 2.5 Precipitated Fe-O 300 41 51 14 35 Impregnated 4%Pd-Fe-O 150 5 30 38 31.5 Precipitated Au/Fe 2 O 3 150 70 38 30 20 EXAMPLE 8 Pd-Bi-Mo-O, with a nominal Pd-loading of 10% (by mass) and Bi/Mo molar ratio of 2/1, was prepared by co-precipitation. Initially, aqueous Pd(NO 3 ) 3 (containing 0.45g Pd) was added to a solution of Bi(NO 3 ) 3 .5H 2 O (6.06g) dissolved in 30% HNO 3 (20cm 3 ). Ammonium molybdate (7.86g dissolved in 10% aqueous ammonia) was then added dropwise, with very rapid stirring; some precipitation occurred during addition. The pH of the resultant suspension was adjusted to 7.4 (using concentrated aqueous ammonia), completing the precipitation of a fine yellow powder. The precipitate was isolated, washed, dried (110°C; 16h) and calcined (500°C; air; 4.5h). When a sample (1g) of this material was tested under but-1-ene/air (1/7) at a flow-rate of 100cm 3 min -1 , the minimum operating temperature was ca 200°C. The yield of butadiene gradually increased over the first few minutes, before stabilising after 20-25 min (Table 9). This activity was at a temperature 150-200°C lower than the minimum expected for mixed-metal oxide catalysts (C F Cullis et al in "Catalysis", edited by G C Bond and G Webb, Royal Society of Chemistry, London, 1982, page 273). Butene oxidation activity of 10%Pd-Bi-Mo-O at 200°C, as a function of time on line. Selectivity, % Elapsed time, min Conversion, % CO 2 but-2-ene butadiene 2 55 30.5 24.5 45 25 65 23 19.5 57.5 50 60 20 22 58 COMPARATIVE EXAMPLE 2 For comparison (to Example 8), an unmodified bismuth molybdate catalyst (in which the molar ratio of Bi/Mo = 2/1) was prepared by a standard route (Ph Batist et al, J. Catal., 25 (1972), 1). Ground Bi(NO 3 ) 3 .5H 2 O (6.06g) was added to concentrated aqueous ammonia (15cm 3 ), and stirred for 5 min. The resultant suspension was filtered to isolate the white powder, which was then washed free of ammonia. The powder was added to H 2 MoO 4 (1.03g) in distilled water (150cm 3 ), and the mixture was heated under reflux (18h). The solid product was isolated, dried (110°C; 2h) and calcined (500°C; 2h). A sample of the bismuth molybdate (1g) was tested at 200°C, under but-1-ene/air (1/7) at a flow-rate of 100cm 3 min -1 (Table 10a). Some initial activity was observed, but only for the first few minutes. Sustainable activity was not achieved until the temperature was raised to 350-400°C, when the material functioned as a very selective catalyst for butadiene formation (Table 10b). On lowering the temperature back down to 200°C, no activity was observed. Butene oxidation activity of unmodified bismuth molybdate, as a function of time on line. (a) 200°C Selectivity, % Elapsed time, min Conversion, % CO 2 but-2-ene butadiene 2 25 3 61 36 25 3 1 44 55 50 0 - -- -- (b) 350°C Selectivity, % Elapsed time, min Conversion, % CO 2 but-2-ene butadiene 2 75 8 13.5 70 25 83 5.5 14 62.5 45 83 6.5 14 67.5 EXAMPLE 9 Pd/CeO 2 , with a nominal Pd-loading of 4% (by mass) was prepared by co-precipitation. A mixed solution was prepared by adding at ambient temperature Ce(NO 3 ) 3 .6H 2 O (126g of solid) to aqueous Pd(NO 3 ) 3 (26.04g of solution ≡ 2.0g Pd). This solution was added dropwise to a boiling solution of NaOH (37.08g) dissolved in the minimum amount of distilled water required to dissolve it. The resultant suspension was maintained at 100°C for 1.25 hours. The precipitate was then isolated (by filtration), washed, dried (110°C; 16h) and calcined (700°C; air; 2h). Elemental analysis of the material showed it to contain 3.87% Pd (and <0.01% Na) by mass. When a sample (1g) was tested under either isobutane/N 2 (1/5) or isobutane/air (1/2) at a flow-rate of 100cm 3 min -1 , optimum activity for the formation of isobutene occurred at 400°C (Table 11). The Table also shows that the short-term yield of isobutene could be improved by using a physical mixture of the Pd/CeO 2 (0.6g) and Sb 2 O 4 (0.4g). Conversion of isobutane at 400°C, as a function of time on line (a) Direct dehydrogenation (under isobutane/N 2 ) Catalyst Elapsed Time, min Conversion, % Isobutene selectivity % 4%Pd/CeO 2 2 7.5 >98 20 7 >98 35 5.5 >98 Catalyst Elapsed Time, min Conversion, % Isobutene selectivity % 4%Pd/CeO 2 +Sb 2 O 4 2 8.5 >98 20 5 >98 (b) Oxidative dehydrogenation (under isobutane/air) Catalyst Elapsed Time, min Conversion, % Selectivity, % *CO x Isobutene 4%Pd/CeO 2 2 10 61 39 20 10 58 42 4%Pd/CeO 2 +Sb 2 O 4 2 15 45 55 20 7 80 20 COMPARATIVE EXAMPLE 3 For comparison (to Example 9), a physical mixture of CeO 2 (0.6g) and Sb 2 O 4 (0.4g) was tested under isobutane/N 2 (1/5) and isobutane/air (1/2), at flow-rates of 100cm 3 min -1 (Table 12). The yields of isobutene were much lower than for either 4%Pd/CeO 2 or 4%Pd/CeO 2 + Sb 2 O 4 , with negligible activity under isobutane/N 2 at temperatures below 500°C. Isobutane dehydrogenation activity of CeO 2 +Sb 2 O 4 (a)Direct dehydrogenation (under isobutane/N 2 ) Temperature, °C Maximum isobutane conversion, % 400 0 500 1 550 1.5 (b)Oxidative dehydrogenation (under isobutane/air) at 400°C Elapsed time, min Conversion % Selectivity % CO x Isobutene 2 7 76 11 20 6 73 15

Claims: A catalyst composed of metal oxide particles, the metal oxide being catalytically active & being capable of reduction to another oxide of the metal, the metal oxide being one or more of iron(III) oxide, cerium(IV) oxide and bismuth molybdate, among which metal oxide particles are uniformly incorporated palladium particles in order to reduce the operating temperature of the catalyst. A catalyst according to claim 1 which contains 0.1-25% by mass of the palladium particles based on the total mass of the palladium particles and the metal oxide particles. A catalyst according to claim 1 or 2 wherein the metal oxide is iron(III) oxide. A catalyst according to claim 1 or 2 wherein the metal is bismuth molybdate. A catalyst according to claim 1 or 2 wherein the metal oxide is cerium(IV) oxide. A catalyst according to any one of the preceding claims which contains antimony oxide as additive. A catalyst according to any one of the preceding claims which is prepared by co-precipitation of the metal oxide particles and the palladium particles. A process for preparing a catalyst claimed in any one of the preceding claims, which process comprises co-precipitating the metal oxide particles and the palladium particles. A method of conducting a chemical reaction employing a catalyst claimed in any one of claims 1-7. A method according to claim 9 wherein the catalyst is employed without prior calcination to activate it. A method according to claim 9 or 10 wherein the reaction is oxidation. A method according to claim 11 wherein the reaction is the oxidative dehydrogenation of alkene. A method according to claim 12 wherein the reaction is the oxidative dehydrogenation of but-1-ene to butadiene. A method according to claim 13 which is conducted at a temperature of 200 to 300°C and the catalyst is as claimed in claim 4. A method according to claim 13 wherein the reaction is self-sustaining without the further supply of heat once the reaction has started, and the catalyst is as claimed in claim 3. A method according to claim 13 or 15 which is conducted at a temperature below 200°C and the catalyst is as claimed in claim 3. A method according to claim 11 wherein the reaction is the water-gas shift reaction and the catalyst is as claimed in claim 3. A method according to claim 17 which is conducted at a temperature of 100-200°C. A method according to claim 9 or 10 wherein the reation is the dehydrogenation of alkane of at least 2 carbon atoms to alkene. A method according to claim 19 wherein the reaction is the dehydrogenation of isobutane to isobutene. A method according to claim 19 or 20 wherein the catalyst is as claimed in claim 5. A method according to claim 11 wherein the reaction is the oxidation of carbon monoxide to carbon dioxide and the catalyst is as claimed in claim 3. A method according to claim 22 which is conducted at ambient temperature. A sensor of hazardous gas at ambient temperature, which sensor comprises means to allow gas to contact a catalyst claimed in claim 3 and means to indicate its rise in temperature if hazardous gas is present. A sensor according to claim 24 wherein the hazardous gas is carbon monoxide. A sensor according to claim 25 wherein the catalyst, when sensing, is at a temperature below 200°C. A sensor according to claim 25 or 26 wherein the catalyst is downstream of catalytic material in the exhaust system of an engine, the catalytic material being for oxidising carbon monoxide to carbon dioxide and the sensor monitoring the performance of the catalytic material in this oxidation. A sensor according to claim 27 wherein the engine is an internal combustion engine in a vehicle, and the monitoring indicates when the performance of the catalytic material falls below a set level.

Inventors: FULFORD ANTHONY, GASCOYNE JOHN MALCOLM, GOLUNSKI STANISLAW EDMUND, JENKINS JOHN WARD, FULFORD, ANTHONY, GASCOYNE, JOHN MALCOLM, GOLUNSKI, STANISLAW EDMUND, JENKINS, JOHN WARD
Applicants: JOHNSON MATTHEY PLC, JOHNSON MATTHEY PUBLIC LIMITED COMPANY
Application year: 1993
Main classification: B01J23
IPC codes: B01J23, C07C11, C07C5, C07B61, B01D53, C01B3, C01B31