Source: http://www.patentgenius.com/patent/8603201.html
Timestamp: 2018-02-25 19:56:03
Document Index: 286454283

Matched Legal Cases: ['art 1', 'Application No. 08790499', 'art 1', 'Application No. 57', 'Application No. 58', 'Application No. 5']

Method of synthesizing chemical industry raw materials and fuel compositions - Patent # 8603201 - PatentGenius
Method of synthesizing chemical industry raw materials and fuel compositions
8603201 Method of synthesizing chemical industry raw materials and fuel compositions
Inventor: Tsuchida, et al.
U.S. Class: 44/452; 568/902; 568/903; 568/904; 568/905; 568/906
Field Of Search: ;44/452; ;44/307; ;568/902; ;568/903; ;568/904; ;568/905; ;568/906
International Class: C07C 29/34; C10L 1/18
Foreign Patent Documents: 2319006; 2319006; 2589123; 1052234; 1 052 234; 57-102822; 58-59928; 3279336; 418042; 5-305238; 2004261751; WO-99/38822; WO-2006/059729; WO-2009/028166; WO-2009/034719
Other References: Ancillotti, F. et al. (Aug. 1, 1998). "Oxygenate Fuels: Market Expansion and Catalytic Aspect of Synthesis," Fuel Processing Technology57:163-194. cited by applicant.
Anonymous. (Dec. 20, 2001). "Gasoline Blending Streams Test Plan," Submitted to the US EPA by The American Petroleum Institute Petroleum HPV Testing Group, pp. 1-38. cited by applicant.
Anonymous. (May 2005). "Motor Fuels Understanding the Factors that Influence the Retail Price of Gasoline," United States Government Accountability Office, GAO-05-525SP, pp. 1-60. cited by applicant.
Baker, B.G. et al. (1988). "Synthesis Gas to Motor Fuel via Light Alkenes," in Methane Conversion, Bibby, D.M. et al. eds., Elsevier Science Publishers B.V., Amsterdam, pp. 497-501. cited by applicant.
Bhattacharyya, S.K. et al. (Mar. 12, 1962). "One-Step Catalytic Conversion of Ethanol to Butadiene in the Fixed Bed I. Single-Oxide Catalysis," J. Appl. Chem. pp. 97-104. cited by applicant.
Bhattacharyya, S.K. et al. (Mar. 12, 1962). "One-Step Catalytic Conversion of Ethanol to Butadiene in the Fixed Bed II. Binary and Ternary-Oxide Catalysis," J. Appl. Chem. pp. 105-110. cited by applicant.
Burk, P.L. et al. (1985). "The Rhodium-Promoted Guerbet Reaction Part 1. Higher Alcohols from Lower Alcohols," J. of Molecular Catalysis 33:1-14. cited by applicant.
Corson, B.B. et al. (Feb. 1950). "Butadiene from Ethyl Alcohol Catalysis in the One-and Two-Step Processes," Industrial and Engineering Chemistry 42(2):359-373. cited by applicant.
Demirbas, A. (2007, e-pub. Aug. 22, 2006). "Progress and Recent Trends in Biofuels," Progress in Energy and Combustion Science 33:1-18. cited by applicant.
Hamelinck, C.N. et al. (2006, e-pub. Aug. 8, 2005). "Outlook for Advanced Biofuels," Energy Policy 34:3268-3283. cited by applicant.
Knothe, G. (Sep. 2002). "Synthesis, Applications, and Characterization of Guerbet Compounds and Their Derivatives," Lipid Technology pp. 101-104. cited by applicant.
Maiden, C.J. et al. (1988). "The New Zealand Gas-to-Gasoline Project," in Methane Conversion, Bibby, D.M. et al. eds., Elsevier Science Publishers B.V., Amsterdam, pp. 1-16. cited by applicant.
Malca, J. et al. (Mar. 13, 2006). "Renewability and Life-Cycle Energy Efficiency of Bioethanol and Bio-Ethyl Tertiary Butyl Ether (bioETBE): Assessing the Implications of Allocation," Energy 31:3362-3380. cited by applicant.
Meisel, S.L. et al. (Feb. 1976). "Gasoline from Methanol in One Step," Chemtech. pp. 86-89. cited by applicant.
Mysov, V.M. et al. (2005). "Synthesis Gas Conversion Into Hydrocarbons (Gasoline Range) Over Bifunctional Zeolite-Containing Catalyst: Experimental Study and Mathematical Modelling," Chemical Engineering Journal 107:63-71. cited by applicant.
Nagarajan, V. (Oct. 1971). "Kinetics of a Complex Reaction System-Preparation of n-Butanol from Ethanol in One Step," Indian Journal of Technology 9:380-386. cited by applicant.
Ndou, A.S. et al. (2003). "Dimerisation of Ethanol to Butanol Over Solid-Base Catalysts," Applied Catalysis A: General 251:337-345. cited by applicant.
Olson, E.S. et al. (2004). "Higher-Alcohols Biorefinery Improvement of Catalyst for Ethanol Conversion," Applied Biochemistry and Biotechnology 113-1 16:913-932. cited by applicant.
Snelling, J. et al. (Jan. 21, 2003). "Synthesis of Higher Carbon Ethers from Olefins and Alcohols I. Reactions with Methanol," Fuel Processing Technology 83:219-234. cited by applicant.
Ueda, W. et al. (1990). "A Low-Pressure Guerbet Reaction over Magnesium Oxide Catalyst," J. Chem. Soc., Chem. Commun. pp. 1558-1559. cited by applicant.
Ueda, W. et al. (1992). "Condensation of Alcohol over Solid-Base Catalyst to Form Higher Alcohols," Catal. Letters 12:97-104. cited by applicant.
Yang, C. et al. (1993). "Bimolecular Condensation of Ethanol to 1-Butanol Catalyzed by Alkali Cation Zeolites," Journal of Catalysis 142:37-44. cited by applicant.
Supplementary European Search Report for EP Application No. 08790499.1 based on PCT/JP2008002295 dated Aug. 1, 2013. cited by applicant.
Abstract: The present invention is to provide a novel method for manufacturing various organic compounds from two or more kinds of alcohol, or one kind of alcohol having three or more carbon atoms. It is a method for synthesizing one kind of, or two or more kinds of organic compounds comprising allowing two or more kinds of alcohol or one kind of alcohol having three or more carbon atoms to contact a calcium phosphate catalyst such as hydroxyapatite, or hydrotalcite.
1. A method for synthesizing an alcohol having three or more carbon atoms comprising allowing a mixture of two or more kinds of starting alcohols to contact a catalystcomprising a calcium phosphate compound, wherein one of the two or more kinds of the starting alcohols is ethanol, and wherein the initial molar percentage of each of ethanol and a second starting alcohol is at least 5% of the total moles of the startingalcohols.
2. The method according to claim 1, wherein the calcium phosphate compound is hydroxyapatite.
3. The method according to claim 2, wherein the catalyst does not support a metal catalyst or metal ion catalyst.
4. The method according to claim 1 or 2, wherein the mixture of starting alcohols comprises ethanol and a linear alcohol other than ethanol to synthesize linear alcohol having three or more carbon atoms.
5. The method according to claim 4, wherein the linear alcohol is methanol, 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or an unsaturated alcohol thereof.
6. The method according to claim 5, wherein the linear alcohol is 1-propanol.
7. The method according to claim 5, wherein the linear alcohol is 1-butanol.
8. The method according to claim 4, wherein the yield of the synthesized linear alcohol is 3C-mol % or more.
9. A method for synthesizing a branched alcohol comprising allowing a mixture of two or more kinds of starting alcohols to contact a catalyst comprising a calcium phosphate compound, wherein the mixture of starting alcohols comprises methanoland an alcohol having three or more carbon atoms.
10. The method according to claim 9, wherein the alcohol having three or more carbon atoms is a linear alcohol.
11. The method according to claim 10, wherein the linear alcohol is 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or an unsaturated alcohol thereof.
12. A method for synthesizing an alcohol having six or more carbon atoms, comprising allowing one kind of starting alcohol having three or more carbon atoms to contact a catalyst comprising a calcium phosphate compound.
13. The method according to claim 12, wherein the calcium phosphate compound is hydroxyapatite.
14. The method according to claim 12 or 13, wherein the one kind of alcohol is propanol, butanol, pentanol, hexanol, heptanol, octanol, or unsaturated alcohols thereof.
15. The method according to any one of claims 1, 9 and 12, wherein the reaction is conducted at about 200.degree. C. to about 600.degree. C.
16. The method according to claim 12, wherein the calcium phosphate compound does not support a metal catalyst or metal ion catalyst.
Presently, oxo process comprising synthesizing normal aldehyde by oxidation of normal paraffin and hydrogenating the obtained aldehyde is the mainstream of methods for synthesizing industrial linear alcohol. However, as the price of naphtha,raw material of normal paraffin, is escalating, the profitability is decreasing. Besides the oxo method, a method using methanol (alcohol) and synthetic gas (carbon monoxide and hydrogen) as raw materials is known. However, as carbon monoxide which isharmful is used in the method and that it is a high-pressure reaction, the plant is of a large scale and the profitability is not good. Further, Ziegler method comprising oligomerizing ethylene by trialkylaluminum, forming a long-chain aluminum alkoxideby air-oxidation, and hydrolyzing the resultant to obtain a long-chain primary alcohol is used. With that method, only alcohol having even numbers of carbon atoms having a distribution of 2-28 carbon atoms can be obtained. Moreover, a method forsynthesizing 1-propanol from methanol and ethanol by Guerbet method has been proposed, while the yield is not good, as the reaction conditions are specific and thus not suitable for practical use. Furthermore, alcohol is also synthesized from plantssuch as copra oil (oleochemical), while only alcohol having 8 or 16 carbon atoms can be obtained, and for alcohol having other numbers of atoms, it is necessary to depend on naphtha.
As a method for synthesizing higher alcohol from methanol and ethanol, a method using ununiformed catalysts such as MgO can be exemplified (see non-patent documents 1-5, patent documents 1-4), while these methods are not suitable forindustrialization as they are many side reaction products, or the reaction conditions are specific. Further, as a method for synthesizing butanol from ethanol, a method using oxidative products of alkaline-earth metals as catalysts (see non-patentdocument 6), a method using zeolite substituted with alkaline metal (see non-patent document 7), a method using a mixture of metal oxidative products (see non-patent document 8) can be exemplified. As for a method for manufacturing butadiene fromethanol, a method using a metal oxidative product or a mixture thereof (see non-patent documents 9-11), a method using a sepiolite catalyst which is a cellular acicular clay can be exemplified. However, these methods are not industrially suitable as thecatalysts are difficult to prepare, or that the reaction temperature is high.
On the other hand, a method for synthesizing butanol, butadiene, or fuel compositions by using a hydroxyapatite catalyst (see patent documents 7, 8) has been proposed, while as it is a method using only ethanol as raw material, organic compoundsthat can be synthesized were limited. In other words, as ethanol is a material having 2 carbon atoms, it is not suitable for synthesizing organic compounds having odd numbers of carbon atoms, and particularly, alcohol having odd numbers of carbon atomscannot be synthesized.
The following non-patent documents, as cited above, are incorporated herein in their entirety. Non-patent document 1: Ueda, W.; Kuwabara, T.; Ohshida, T.; Morikawa, Y. A Low-pressure Guerbet Reaction over Magnesium Oxide Catalyst. J. Chem.Soc., Chem. Commun., 1990, 1558-1559; Non-patent document 2: Ueda, W.; Ohshida, T.; Kuwabara, T.; Morikawa, Y. Condensation of alcohol over solid-base catalyst to form higher alcohols. Catal. Letters, 1992, 12, 97-104; Non-patent document 3: Olson, E.S., Sharma, R. K. and Aulich T. R. Higher-Alcohols Biorefinery Improvement of Catalyst for Ethanol Conversion. Applied Biochemistry and Biotechnology, 2004, vol. 113-116, 913-932; Non-patent document 4: Burk, P. L.; Pruett, R. L. and Campo, K. S. TheRhodium-Promoted Guerbet Reaction Part 1. Higher Alcohols from Lower Alcohols. J. of Molecular Catalysis, 1985, 33, 1-14; Non-patent document 5: Knothe, G. Synthesis, applications, and characterization of Guerbet compounds and their derivatives. LipidTechnology, 2002, September, 101-104; Non-patent document 6: "Dimerisation of ethanol to butanol over solid-base catalysts" A. S. Ndou, N. plint, N. J. Coville, Applied catalysis A: General, 251, p. 337-345 (2003); Non-patent document 7: "BimolecularCondensation of Ethanol to 1-Butanol Catalyzed by Alkali Cation Zeolites" C. Yang, Z. Meng, J. of Catalysis, 142, p. 37-44 (1993); Non-patent document 8: "Kinetics of a Complex Reaction System-Preparation of n-Butanol from Ethanol in One Step", V.NAGARAJAN, Indian Journal of Technology Vol. 9, October 1971, pp. 380-386; Non-patent document 9: "Butadiene from ethyl alcohol" B. B. Corson, H. E. Jones, C. E. Welling, J. A. Hincley, and E. E. Stahly, Industrial and Engineering Chemistry, Vol. 42. No. 2; Non-patent document 10: One-Step Catalytic Conversion of Ethanol to Butadiene in the Fixed Bed. I. Single-Oxide Catalysis, S. K. Bhattacharyya and N. D. Ganguly, J. Appl. Chem., 12, March 1962; Non-patent document 11: One-Step CatalyticConversion of Ethanol to Butadiene in the Fixed Bed. II. Binary- and Ternary-Oxide Catalysis, S. K. Bhattacharyya and N. D. Ganguly, J. Appl. Chem., 12, March 1962;
The following patent documents, as cited above, are incorporated herein by reference in their entirety. Patent document 1: U.S. Pat. No. 2,971,033; Patent document 2: U.S. Pat. No. 3,972,952; Patent document 3: U.S. Pat. No. 5,300,695;Patent document 4: U.S. Pat. No. 2,050,788; Patent document 5: Japanese Laid-Open Patent Application No. 57-102822; Patent document 6: Japanese Laid-Open Patent Application No. 58-59928; Patent document 7: WO 99/38822; Patent document 8: WO2006/059729;
In one aspect of the invention is a method for synthesizing 1 or more kinds of organic compounds comprising allowing 2 or more kinds of alcohols to contact hydroxyapatite. In some embodiments, the hydroxyapatite supports metal catalysts ormetal ion catalysts acting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments, the hydroxyapatite does not support metal catalysts or metal ion catalysts acting on alcohol. In some embodiments,at least 1 kind of alcohol is methanol or ethanol. In some embodiments, the method comprises allowing ethanol and linear alcohol other than ethanol to contact hydroxyapatite to synthesize a linear alcohol having 3 or more carbon atoms. In someembodiments, the linear alcohol other than ethanol is methanol, 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or unsaturated alcohols thereof. In some embodiments, the yield of the synthesized linear alcohol is 3C-mol % or more. In some embodiments, the method comprises allowing methanol and alcohol having 3 or more carbon atoms to contact hydroxyapatite to synthesize branched-chain alcohol. In some embodiments, the alcohol having 3 or more carbon atoms is a linear alcohol. Insome embodiments, the linear alcohol is 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or unsaturated alcohols thereof.
In another aspect of the invention is a method for synthesizing 1 or more kinds of organic compounds, comprising allowing 1 kind of alcohols having 3 or more carbons to contact hydroxyapatite. In some embodiments, the hydroxyapatite supportsmetal catalysts or metal ion catalysts acting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments, the hydroxyapatite does not support metal catalysts or metal ion catalysts acting on alcohol. In some embodiments, the alcohol having 3 or more carbon atoms is propanol, butanol, pentanol, hexanol, heptanol, octanol, or unsaturated alcohols thereof. In some embodiments, the synthesized organic compound is a fuel composition. In someembodiments, the reaction is conducted at 200-600.degree. C.
In another aspect of the invention is a method for synthesizing 1 or more kinds of organic compounds comprising allowing 2 or more kinds of alcohols to contact hydrotalcite. In some embodiments, the hydrotalcite supports metal catalysts ormetal ion catalysts acting on alcohol such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments, the hydrotalcite does not support metal catalysts or metal ion catalysts acting on alcohol. In some embodiments,the method comprises allowing ethanol and linear alcohol other than ethanol to contact hydrotalcite to synthesize a linear alcohol having 3 or more carbon atoms. In some embodiments, the linear alcohol other than ethanol is methanol, 1-propanol,1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or unsaturated alcohols thereof.
Another aspect of the invention provides a method for synthesizing one or more kinds of organic compounds comprising allowing a mixture of two or more kinds of alcohols to contact a catalyst comprising a calcium phosphate compound, wherein theinitial molar percentage of each kind of alcohol is at least 5% of the total moles of initial alcohols in the mixture. In some embodiments, the calcium phosphate compound is hydroxyapatite. In some embodiments, the catalyst is hydrotalcite. In someembodiments, the catalyst supports a metal catalyst or metal ion catalyst such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments, the catalyst does not support a metal catalyst or metal ion catalyst. In someembodiments, the mixture includes ethanol and a starting linear alcohol other than ethanol, and at least one of the kinds of organic compounds synthesized is a synthesized linear alcohol having three or more carbon atoms. In some embodiments, thestarting linear alcohol other than ethanol is methanol, 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or an unsaturated alcohol thereof. In some embodiments, the yield of the synthesized linear alcohol is 3C-mol % or more.
In some embodiments, the mixture of two or more kinds of alcohols includes methanol and a starting linear alcohol having at least three carbons, and at least one of the kinds of organic compounds synthesized is a synthesized branched alcohol. In some embodiments, the catalyst supports metal catalysts or metal ion catalysts acting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments, the catalyst does not support metal catalysts ormetal ion catalysts acting on alcohol. In some embodiments, the starting linear alcohol having three or more carbon atoms is a linear alcohol. In some embodiments, the linear alcohol is 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol,1-octanol, or an unsaturated alcohol thereof.
In some embodiments, the mixture of two or more kinds of alcohols includes methanol, ethanol and a starting linear alcohol having at least three carbons, and at least one of the kinds of organic compounds synthesized is a compound having onemore carbons than the number of carbons in the starting linear alcohol. In some embodiments, the starting linear alcohol is 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or an unsaturated alcohol thereof.
Another aspect of the invention provides a method for synthesizing one or more kinds of organic compounds comprising allowing one kind of alcohol having at least three carbons to contact a catalyst comprising a calcium phosphate compound, theone kind of alcohol is initially substantially free of other kinds of alcohol. In some embodiments, the catalyst does not support a metal catalyst or metal ion catalyst. In some embodiments, the catalyst supports metal catalysts or metal ion catalystsacting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments, the calcium phosphate compound is hydroxyapatite. In some embodiments, the catalyst is hydrotalcite. In some embodiments, the onekind of alcohol is propanol, butanol, pentanol, hexanol, heptanol, octanol, or unsaturated alcohols thereof.
In some embodiments of the methods of the present invention, the synthesized organic compound is a fuel composition. In some embodiments of the methods of the present invention, the method reaction is conducted at about 200.degree. C. to about600.degree. C. In some embodiments of the methods of the present invention, the initial molar percentage of each kind of alcohol is at least 14%, at least 20% or at about 50%, of the total moles of initial alcohols in the mixture.
FIG. 1 is a figure showing the yield of alcohol against the reaction temperature, when ethanol and 1-propanol (ethanol:1-propanol=1:1) are used as raw material alcohol;
FIG. 2 is a figure showing the yield of alcohol against the reaction temperature, when ethanol and 1-propanol (ethanol:1-propanol=1:4) are used as raw material alcohol;
FIG. 3 is a figure showing the yield of alcohol against the reaction temperature, when ethanol and 1-propanol (ethanol:1-propanol=4:1) are used as raw material alcohol;
FIG. 4 is a figure showing the results of measurement of the inner state of the reactor by in situ FT-IR after 1 hour of exposure to ethanol/He mixed gas, followed by 30 min of emission;
FIG. 5 is a figure showing the detailed results after 30 min of emission of FIG. 4;
FIG. 6 is a table showing product selectivity from an exemplary methanol and ethanol (1:1) reaction;
FIG. 7 is a table showing product selectivity from an exemplary methanol and ethanol (20:1) reaction;
FIG. 8 is a table showing product selectivity from an exemplary ethanol and 1-propanol (4:1) reaction;
FIG. 9 is a table showing product selectivity from an exemplary ethanol and 1-propanol (1:1) reaction;
FIG. 10 is a table showing product selectivity from an exemplary ethanol and 1-propanol (1:4) reaction;
FIG. 11 is a table showing product selectivity from an exemplary ethanol, methanol and 1-propanol (1:5:1) reaction over HAP catalyst;
FIG. 12 is a table showing product selectivity from an exemplary ethanol, methanol and 1-propanol (1:5:1) reaction over MgO catalyst;
FIG. 13 is a table showing product selectivity from an exemplary ethanol, methanol and 1-butanol (1:6:1) reaction over HAP catalyst;
FIG. 14 is a table showing product selectivity from an exemplary ethanol, methanol and 1-butanol (1:6:1) reaction over MgO catalyst;
FIG. 15 is a table showing alcohol product composition under the described exemplary reaction conditions; and
FIGS. 16A-19B are graphs showing distribution of products based on carbon number for certain exemplary conditions.
The object of the present invention is to provide a novel method for manufacturing various organic compounds from 2 or more kinds of alcohol or from 1 kind of alcohol having 3 or more carbon atoms. Particularly, it is to provide a method forsynthesizing linear alcohol or branched-chain alcohol in good yield, by using 2 or more kinds of alcohols.
The present inventors made a study for manufacturing organic compounds to be used as a chemical industry raw material, and found out that by using hydroxyapatite or hydrotalcite as a catalyst, various organic compounds can be manufactured from 2or more kinds of alcohol, or from 1 kind of alcohol having 3 or more carbon atoms. The present invention has been thus completed.
Further, the present inventors made a keen study for synthesizing linear alcohols, under conditions that almost all of the alcohols synthesized by using alcohol raw material were branched-chain alcohols, and that it was estimated to be extremelydifficult to synthesize linear alcohols. As a result, they found out that by allowing ethanol and linear alcohol other than ethanol to contact hydroxyapatite or hydrotalcite, a linear alcohol can be synthesized in good yield. Currently, ethanol issynthesized through the conversion of sugars obtained from sugarcanes, beets, etc., by a fermentation method. Recently, a technique for synthesizing ethanol from biomass, agricultural and forestry residues, has been established, and a striking increasein the production of ethanol can be expected in future. Further, as the production cost of ethanol is becoming comparable or less than the crude oil, it is an important object to synthesize chemical industry raw materials using ethanol as a rawmaterial. The process of the present invention uses ethanol derived from plants as a raw material, and the reaction proceeds easily at normal pressure. Thus, comparing with the conventional synthesizing method using fossil or mineral resource, whichemit carbon dioxide and promote global heating, as a raw material, it is an important synthesizing method for global environment.
Further, the present inventors found out that by allowing methanol and alcohol having 3 or more carbon atoms to contact hydroxyapatite or hydrotalcite, a branched-chain alcohol can be synthesized in good yield.
In other words, the present invention relates to ("1") a method for synthesizing 1 or more kinds of organic compounds comprising allowing 2 or more kinds of alcohols to contact hydroxyapatite; ("2") the method according to "1", wherein at least1 kind of alcohol is methanol or ethanol; ("3") the method according to "1" or "2", wherein a linear alcohol having 3 or more carbon atoms is synthesized by allowing ethanol and linear alcohol other than ethanol to contact hydroxyapatite; ("4") themethod according to "3", wherein the linear alcohol other than ethanol is methanol, 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or unsaturated alcohols thereof; ("5") the method according to "3" or "4", wherein the yield of thesynthesized linear alcohol is 3C-mol % or more; ("6") the method according to ("1") or ("2"), comprising allowing methanol and alcohol having 3 or more carbon atoms to contact hydroxyapatite to synthesize branched-chain alcohol; ("7") the methodaccording to ("6"), wherein the alcohol having 3 or more carbon atoms is a linear alcohol; ("8") the method according to "7", wherein the linear alcohol is 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or unsaturated alcoholsthereof. In some embodiments of this aspect of the present invention, the hydroxyapatite supports metal catalysts or metal ion catalysts acting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In someembodiments of this aspect of the present invention, the hydroxyapatite does not support metal catalysts or metal ion catalysts acting on alcohol.
Further, the present invention relates to ("9") a method for synthesizing 1 or more kinds of organic compounds, comprising allowing 1 kind of alcohols having 3 or more carbons to contact hydroxyapatite; ("10") the method according to "9",wherein the alcohol having 3 or more carbon atoms is propanol, butanol, pentanol, hexanol, heptanol, octanol, or unsaturated alcohols thereof; ("11") the method according to "1," "2", "9" or "10", wherein the synthesized organic compound is a fuelcomposition; ("12") the method according to any one of "1" to "11", wherein the reaction is conducted at 200-600.degree. C. In some embodiments of this aspect of the present invention, the hydroxyapatite supports metal catalysts or metal ion catalystsacting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments of this aspect of the present invention, the hydroxyapatite does not support metal catalysts or metal ion catalysts acting on alcohol.
Further, the present invention relates to ("13") a method for synthesizing 1 or more kinds of organic compounds comprising allowing 2 or more kinds of alcohol to contact hydrotalcite; ("14") the method according to "13", comprising allowingethanol and linear alcohol other than ethanol to contact hydrotalcite to synthesize a linear alcohol having 3 or more carbon atoms; ("15") the method according to "14", wherein the linear alcohol other than ethanol is methanol, 1-propanol, 1-butanol,1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or unsaturated alcohols thereof.
According to the method for synthesizing alcohol of the present invention, various organic compounds can be manufactured from 2 or more kinds of alcohols or from 1 kind of alcohol having 3 or more carbon atoms. Particularly, when using 2 ormore kinds of alcohols, linear alcohol or branched-chain alcohol can be synthesized in good yield.
As for a method for synthesizing an organic compound of the present invention (first synthesizing method), it is not particularly limited as long as it is a method comprising allowing 2 or more kinds of alcohols to contact hydroxyapatite. Insome embodiments of this aspect of the present invention, the hydroxyapatite supports metal catalysts or metal ion catalysts acting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments of thisaspect of the present invention, the hydroxyapatite does not support metal catalysts or metal ion catalysts acting on alcohol. Examples of organic compounds synthesized by the method for synthesizing of the present invention include: paraffins, olefins,dienes, trienes, alcohols, ethers, ketones, aldehydes, and esters. Specific examples include: ethane, ethylene, acetoaldehyde, propylene, propanol, acetone, butene, 1,3-butadiene, 1-butanol, 3-butene-1-ol, t-crotylalcohol, c-crotylalcohol, diethylether,butyraldehyde, 2-butanone, t-crotonaldehyde, c-crotonaldehyde, 1-pentanol, 2-pentanol, 2-pentanone, butylethylether, 1-hexanol, 2-ethyl-1-butanol, hexanal, 1-heptanol, 2-ethyl-1-propanol, octanol, 2-ethyl-1-hexanol, octanol, and nonanol. These organiccompounds having 2 or more carbon atoms can be used as a chemical industry raw material, and among these, a mixture of organic compounds having 4 or more carbon atoms can be used as a fuel composition.
As for a raw material alcohol used in the first synthesizing method of the present invention, it is 2 or more kinds of alcohol, and it may be 2 kinds of alcohol, or 3 or more kinds of alcohol. Further, raw material alcohol may be a linearalcohol or branched-chain alcohol, and may be a saturated alcohol or unsaturated alcohol. Further, the number of carbon atoms is not particularly limited, but it is preferred to be an alcohol having 1-22 carbon atoms, from the point of view of easinessto obtain.
Particularly, according to a method allowing ethanol and linear alcohol other than ethanol to contact hydroxyapatite, it is possible to synthesize a linear alcohol having 3 or more atoms in good yield. The yield is for example, 3C-mol % ormore, and preferably 5C-mol % or more. C-mol denotes the number of carbon atoms of the synthesized alcohol/the number of carbon atoms of raw material alcohol used. As for the linear alcohol other than ethanol, from the view point of easiness to obtainor cost, a saturated or unsaturated alcohol having 1-22 carbon atoms is preferred, and a saturated or unsaturated alcohol having 1-8 carbon atoms is more preferred. Specific examples include methanol, 1-propanol, 1-butanol, 1-pentanol, 1-hexanol,1-heptanol, 1-octanol, and unsaturated alcohol thereof. Further, the amount used (mixing ratio) of ethanol and linear alcohol other than ethanol is not particularly limited, while in order to synthesize linear alcohol more efficiently, it is preferredthat the mixing ratio is approximately equimolar (about 1:0.9-1.1) when the conversion rates of the two alcohols are almost the same. When the conversion rates of the two alcohols are different, it is preferred to mix a larger amount of alcohol with thelower conversion rate. Specifically, when using ethanol and 1-propanol, it is particularly preferred to use ethanol in an amount of about 0.9-1.1 (molar ratio) per 1 portion of 1-propanol.
According to a method comprising allowing methanol and alcohol having 3 or more carbon atoms to contact hydroxyapatite, it is possible to synthesize a branched-chain alcohol in good yield. As for the above alcohol having 3 or more carbon atoms,from the view point of easiness to obtain or cost, a saturated or unsaturated alcohol having 3-22 carbon atoms is preferred, and a saturated or unsaturated alcohol having 3-8 carbon atoms is more preferred. Specific examples include propanol, butanol,pentanol, hexanol, heptanol, octanol, and unsaturated alcohol thereof. Among these, linear alcohol is preferred, and specific examples include 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, and unsaturated alcohol thereof. Further, the amount used (mixing ratio) of methanol and alcohol having 3 or more carbon atoms is not particularly limited, while it is preferred to use 0.9 or more (molar ratio) of methanol per 1 alcohol having 3 or more carbon atoms, from the view pointthat a branched-chain alcohol is synthesized in good yield.
Further, as for a method for synthesizing an organic compound of the present invention (second synthesizing method), is not particularly limited as long as it is a method allowing 1 kind of alcohol having 3 or more carbon atoms to contacthydroxyapatite. In some embodiments of this aspect of the present invention, the hydroxyapatite supports metal catalysts or metal ion catalysts acting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In someembodiments of this aspect of the present invention, the hydroxyapatite does not support metal catalysts or metal ion catalysts acting on alcohol. Examples of organic compounds synthesized by the synthesizing method of the present invention include,similarly as the above first synthesizing method, paraffins, olefins, dienes, trienes, alcohols, ethers, ketones, aldehydes, and esters. Among these, each organic compound having 2 or more carbon atoms can be used as chemical industry raw material. Further, a mixture of organic compounds having 4 or more carbon atoms can be used as a fuel composition.
As for the above alcohol having 3 or more carbon atoms, it may be a linear alcohol or branched-chain alcohol, and it may be a saturated alcohol or unsaturated alcohol. Further, the number of carbon atoms is not particularly limited, while fromthe view point of easiness to obtain or cost, a saturated or unsaturated alcohol having 3-22 carbon atoms is preferred, and a saturated or unsaturated alcohol having 3-8 carbon atoms is more preferred. Specific examples include propanol, butanol,pentanol, hexanol, heptanol, octanol, and unsaturated alcohol thereof. Among these, linear alcohol is preferred, and specific examples include 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, and unsaturated alcohol thereof.
Hydroxyapatite used in the synthesizing method of the present invention (first and second synthesizing methods) is one kind of calcium phosphate, and is generally indicated by the stoichiometric composition Ca.sub.10(PO.sub.4).sub.6(OH).sub.2. However, it can form an apatite structure, showing a property of hydroxyapatite, even it is a hydroxyapatite with a non-stoichiometric composition wherein the Ca/P molar ratio does not reach 1.67. Such synthesized hydroxyapatite with a Ca/P molar ratioof approximately 1.4-1.8 is also encompassed within the hydroxyapatite of the present invention. Particularly, in a method for synthesizing an organic compound of the present invention, a hydroxyapatite with a Ca/P molar ratio of 1.60-1.80 is preferred. The hydroxyapatite may be in any form including granule, sphere, pellet, and honeycomb.
Further, in some embodiments, the hydroxyapatite used in the synthesizing method of the present invention does not encompass those supporting metal catalysts or metal ion catalysts acting on alcohol. In some embodiments of this aspect of thepresent invention, the hydroxyapatite supports metal catalysts or metal ion catalysts acting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. Examples of metal catalyst or metal ion catalyst acting on alcoholinclude metals or metal ions described in Japanese Laid-Open Patent Application No. 5-305238.
The hydroxyapatite used in the synthesizing method of the present invention may support in advance 1 kind of raw material alcohol such as methanol or ethanol. In other words, before conducting the synthesizing reaction of organic compounds, itis possible to allow hydroxyapatite to react with 1 kind of raw material alcohol, and to use alcohol-supported hydroxyapatite, wherein hydroxyapatite is supporting alcohol. The absorption peak derived from alcohol of the alcohol-supported hydroxyapatitecan be observed by infrared spectroscopy. By using the alcohol-supported hydroxyapatite, distribution of reaction products can be controlled. In other words, many products derived from supported alcohol can be synthesized.
In the synthesizing method of the present invention, at least one compound selected from the group consisting of metal oxidative product, zeolite, silica light, clay mineral of the family of kaolin, clay mineral of the family of pyrophyllite,clay mineral of the family of smectite, hydrotalcite, sepiolite, calcium silicate, calcium fluoride, calcium sulfate, apatite fluoride, magnesium hydroxide, chitin, lithium phosphate, aluminum phosphate, and magnesium phosphate, can be mixed to the abovehydroxyapatite for controlling the reaction. 2 or more of these compounds can be used in combination.
In the present invention, when synthesizing an organic compound useful as a chemical industry raw material, in order to increase the selectivity of desired organic compounds, the size, surface area, reaction conditions (contact time, reactiontemperature, pressure, etc.) of granules used can be appropriately selected.
As for a reaction form in the present invention, it may be a batch method or a sequential method, while a continuous method is preferred from the view point of industrial economic efficiency. Further, a reactor in any form including a fixedbed, a moving bed, a fluidized bed or a slurry bed can be used. Moreover, it may be a liquid phase reaction or a gas phase reaction, and the reaction may be conducted at normal pressure, under pressure, or reduced pressure. In case of a gas phasereaction, a mixed alcohol gas alone may be in contact with hydroxyapatite, or it may be in contact with hydroxyapatite together with an inert carrier gas such as nitrogen or helium. By allowing to contact together with a carrier gas, unnecessaryretention of raw material and products may be suppressed, and the reaction may be conducted more efficiently. At that time, in order to maintain the catalyst activity, reactive gas such as hydrogen, hydrocarbon, and water may be accompanied in thecarrier gas. Further, in order to prevent that carbons are precipitated on the surface of hydroxyapatite, which may decrease the alcohol conversion rate and change the nature of reactions, it is preferred that a regeneration treatment wherein thehydroxyapatite is heated under oxygen atmosphere, is periodically conducted. In other words, it is preferred that a catalyst regeneration apparatus that is capable of conducting a regeneration treatment as above-mentioned is provided on the reactor.
It is not possible to determine categorically the contact time of alcohol and hydroxyapatite as it affects also the reaction temperature. Generally, in case of a gas phase reaction by a continuous method, the contact time is about 0.1-20 sec.and preferably about 0.4-5 sec. Further, the reaction temperature is generally 100-700.degree. C., and preferably 200-600.degree. C. Particularly, when synthesizing in good yield a linear alcohol by using ethanol and linear alcohol other than ethanol,the reaction temperature is preferably 250-450.degree. C., and more preferably 300-450.degree. C. Further, when synthesizing a branched-chain alcohol in good yield by using methanol and alcohol having 3 or more carbon atoms, the reaction temperature ispreferably 250-500.degree. C., and more preferably 300-450.degree. C.
When conducting a gas phase reaction with 2 or more kinds of alcohol, it is preferred to vaporize the alcohol-mixed solution, and it is preferred to vaporize rapidly, without allowing the reaction of 2 or more kinds of alcohol to be conducted. Therefore, as for the vaporizing temperature, a temperature that is higher than the boiling point of the alcohol having the higher boiling point, and at which the alcohol with the lower boiling point does not react is preferred. Specifically, thepreferred temperature is, in case of methanol and ethanol, 150-200.degree. C., and in case of ethanol and 1-octanol, 200-250.degree. C.
As the boiling points of 2 or more kinds of alcohol are different, 1 kind of alcohol having been vaporized may be firstly introduced to form a complex catalyst supporting alcohol, and then the other alcohol in form or liquid or gas may beintroduced to start the reaction (liquid phase reaction, gas phase reaction). When using methanol or ethanol, it is preferred to firstly introduce methanol or ethanol having a low boiling point, and to form a complex catalyst supporting methanol orethanol. Generally, the order of alcohol to be introduced may be determined according to the boiling point as in the above, while when using ethanol, it is preferred to introduce ethanol in the first order.
A mixture of organic compounds thus obtained, may be used as a fuel composition etc. directly in form of mixture. Alternatively, a desired organic compound may be separated or purified according to a conventional separation or purificationmethod, for example by rectification, microporous membrane separation, extraction, or adsorption.
Further, as for a method for synthesizing an organic compound of the present invention (third synthesizing method), it is not particularly limited as long as it is a method allowing 2 or more kinds of alcohol to contact hydrotalcite. Organiccompounds synthesized by the synthesizing method of the present invention, are similar to the above case using hydroxyapatite, and various organic compounds may be synthesized in good yield. Particularly, when ethanol and linear alcohol other thanethanol is used, a linear alcohol having 3 or more carbon atoms can be synthesized in good yield.
Hydrotalcite used in the present invention is a clay mineral having a composition of Mg.sub.6Al.sub.2(OH).sub.16CO.sub.3.4H.sub.2O. Similarly to the above-mentioned hydroxyapatite, it may support alcohol beforehand. In certain embodiments,hydrotalcite can be used in embodiments of the present invention without supporting an additional metal or metal ion. In some embodiments of this aspect of the present invention, the hydrotalcite supports metal catalysts or metal ion catalysts acting onalcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn.
Referring to Example 14 and FIG. 15, Another aspect of the present invention include the use of calcium phosphate catalysts, such as hydroxyapatite, or hydrotalcite, in processes and methods to synthesize normal cross-Guerbet alcohol productsbetween ethanol and another normal alcohol. In certain embodiments, the other normal (i.e., unbranched) alcohol can include methanol, 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or any other suitable normal alcohol. In someembodiments, the normal alcohols may include at least one unsaturated bond (i.e., alkenols or alkynols) as is understood in the art. In some embodiments of this aspect of the present invention, the calcium phosphate catalyst supports metal catalysts ormetal ion catalysts acting on alcohol, such as one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments, the calcium phosphate catalyst does not support another substantial metal or metal ion catalyst.
In some embodiments, the starting molar ratio between ethanol and the other normal alcohol is about 20:1, about 18:1, about 16:1, about 15:1, about 12:1, about 10:1, about 8:1, about 6:1, about 5:1, about 4:1, about 3:1, about 2.5:1, about 2:1,about 1.5:1, about 1:1, about 1:1.5, about 1:2, about 1:2.5, about 1:3, about 1:4, about 1:5, about 1:6, about 1:8, about 1:10, about 1:12, about 1:15, about 1:16, about 1:18 or about 1:20. In certain preferred embodiments, the starting molar ratiobetween ethanol and the other normal alcohol is about 1:20, about 1:4, about 1:1 or about 4:1.
Referring to FIG. 15, an analysis of the products resulting from the reaction of ethanol and 1-propanol under a variety of conditions and catalysts are shown. For each condition, the normal percentage ratio (i.e., the ratio of normal C5 alcoholproduct over the total normal and branched C5 alcohol products) and the yield of normal cross-Guerbet alcohol are shown. In these examples, the yield of normal cross-Guerbet alcohol in a reaction of ethanol and 1-propanol is the yield of 1-pentanol (thenon-branched alcohol cross-product of ethanol and 1-propanol) as a percentage of total alcohols supplied. The results show that the use of calcium phosphate-based catalysts (i.e., hydroxyapatite) or hydrotalcite results in an unexpected increase inselectivity of the normal cross-product, particular in the higher temperature ranges of between at or about 300.degree. C. to at or about 450.degree. C. when compared to the other catalysts. Such increased selectivity is advantageous when used atthese higher reaction temperatures, which are conditions that would have been expected to have a relatively higher percentage of corresponding or other branched alcohol products.
Referring to Examples 15 and 16, and FIGS. 16A-19B, another aspect of the present invention include the use of calcium phosphate catalysts, such as hydroxyapatite, or hydrotalcite, in processes and methods to synthesize alcohol products inincreased yield and selectivity. In certain embodiments, these methods and processes include three alcohols in as starting reagents: a first and a second alcohol each having a length of at least two carbons, and a third alcohol, methanol. In preferredembodiments, the first alcohol is ethanol and the second alcohol has a length of at least three carbons. In certain preferred embodiments, the third alcohol of at least three carbons is unbranched. In certain embodiments, the third alcohol is selectedfrom 1-propanol, 1-butanol, 1-pentanol, 1-hexanol, 1-heptanol, 1-octanol, or any other suitable normal alcohol. In some preferred embodiments, the third alcohol is preferably 1-propanol or 1-butanol. In some embodiments, the normal alcohols may includeat least one unsaturated bond (i.e., alkenols or alkynols) as is understood in the art. In some embodiments of this aspect of the present invention, the calcium phosphate catalyst supports metal catalysts or metal ion catalysts acting on alcohol, suchas one or more of Ti, Mn, Fe, Co, Ni, Cu, Pt, Ir, Rh, Ag, Zn, Al and Sn. In some embodiments of this aspect of the present invention, the calcium phosphate catalyst does not support another substantial metal or metal ion catalyst.
In some embodiments, the starting molar ratio between the first alcohol and the second alcohol is about 20:1, about 18:1, about 16:1, about 15:1, about 12:1, about 10:1, about 8:1, about 6:1, about 5:1, about 4:1, about 3:1, about 2.5:1, about2:1, about 1.5:1, about 1:1, about 1:1.5, about 1:2, about 1:2.5, about 1:3, about 1:4, about 1:5, about 1:6, about 1:8, about 1:10, about 1:12, about 1:15, about 1:16, about 1:18 or about 1:20. In certain preferred embodiments, the starting molar ratiobetween the first alcohol and the second alcohol is about 1:1.
In some embodiments, the starting molar ratio between the first alcohol and the third alcohol is about 1:1, about 1:1.5, about 1:2, about 1:2.5, about 1:3, about 1:4, about 1:5, about 1:6, about 1:8, about 1:10, about 1:12, about 1:15, about1:16, about 1:18 or about 1:20. In certain preferred embodiments, the starting molar ratio between the first alcohol and the third alcohol is about 1:5 or about 1:6.
Referring to FIGS. 16A and 16B, as described in Example 15, an analysis of the products resulting from a reaction of ethanol, methanol and 1-propanol under a variety of conditions over hydroxyapatite is shown. In FIG. 16A, the reaction betweenethanol and 1-propanol under the described conditions results in a relatively high yield (about .about.40%) and high selectivity for five-carbon compounds with respect to the products of other sizes. In comparison, the reaction between ethanol,1-propanol, and a several-fold molar excess of methanol resulted in the production of four-carbon compounds with an increase of both yield (>60%) and selectivity for products of this size. The distribution indicates that this apparent "shift" isevident over most of the distribution. As depicted in FIG. 16B, this "shift" of the products to a higher-yield and selectivity of four-carbon products remains true when only the alcohol products are measured.
Referring to FIGS. 17A and 17B, the exemplary reactions depicted in FIGS. 16A and 16B and described in Example 15 are performed in essentially the same way at 500.degree. C. Here, as shown in FIG. 17A, the increased selectivity and yield offour-carbon products in the three-alcohol reaction, relative to the two-alcohol reaction, remains evident. As shown in FIG. 17B, this apparent shift and increase in yield and selectivity cannot be completely attributed to side-products of aldehydes orolefins.
Referring to FIGS. 18A and 18B, as described in Example 16, an analysis of the products resulting from a reaction of ethanol, methanol and 1-butanol under a variety of conditions over hydroxyapatite is shown. In FIG. 18A, the reaction betweenethanol and 1-butanol under the described conditions results in a relatively high yield (about .about.45%) and high selectivity for six-carbon compounds with respect to the products of other sizes. In comparison, the reaction between ethanol, 1-butanol,and a several-fold molar excess of methanol resulted in the production of five-carbon compounds with an increase of both yield (>50%) and selectivity for products of this size. The distribution indicates that this apparent "shift" is evident overmost of the distribution. As depicted in FIG. 18B, this "shift" of the products to a higher-yield and selectivity of five-carbon products remains true when only the alcohol products are measured.
Referring to FIGS. 19A and 19B, the exemplary reactions depicted in FIGS. 18A and 18B and described in Example 15 are performed in essentially the same way at 500.degree. C. Here, as shown in FIG. 17A, the increased selectivity and yield offive-carbon products in the three-alcohol reaction, relative to the two-alcohol reaction, remains evident. As shown in FIG. 19B, this apparent shift and increase in yield and selectivity cannot be completely attributed to side-products of aldehydes,dienes or olefins.
Thus, such increased and yield and selectivity resulting from the three-alcohol reaction shown in these examples are advantageous to obtain a desired product in both increased yield and specificity. Further, these examples of the presentinvention indicate that certain products that are typically difficult to obtain, such as products having an odd-number of carbons, can be obtained with increase yield and specificity. Further, another advantage of the present invention is that suchincreased yield and specificity can be achieved at relatively higher reaction temperatures.
First Synthesizing Method
As for a catalyst used in the Example, a hydroxyapatite prepared by a common method was used. In the Table, "HAP1" denotes a hydroxyapatite which Ca/P molar ratio is 1.66, "HAP2" denotes a hydroxyapatite which Ca/P molar ratio is 1.64, and"HAP3" denotes a hydroxyapatite which Ca/P molar ratio is 1.61. As for a catalyst used in the comparative example, MgO reagent (Wako Pure Chemicals) boiled and hydrated in distilled water (see Ueda, W.; Kuwabara, T.; Ohshida, T.; Morikawa, Y. ALow-pressure Guerbet Reaction over Magnesium Oxide Catalyst. J. Chem. Soc., Chem. Commun., 1990, 1558-1559), as for ZrO.sub.2, a reference catalyst of Catalyst (JRC-ZRO-5), and as for others, reagents from Wako Pure Chemicals were used, respectively.
Evaluation of Catalyst Property
A fixed bed gas flow catalytic reactor (Ohkura Riken) was used as a reactor. 0.2-4 cc of hydroxyapatite was filled in a silica reaction tube with a diameter of 5 mm. As a pretreatment, thermal dehydration treatment was conducted for 30 minunder a carrier gas atmosphere (1% Ar/He base; flow 112 ml/min) at 500.degree. C. Following the pretreatment, mixed alcohol gas diluted with helium (alcohol concentration 20 vol %) was introduced so that GHSV becomes 500-10000 (1/h) to allow reaction atnormal pressure. For the reaction temperature, a sampling was conducted every 50.degree. C. from 100-500.degree. C. A gas chromatography mass spectrometer (GC-MS) was used for the identification of the components of the reaction gas, and a gaschromatography (GC) (detector: FID) was used for the measurement of the alcohol conversion rate and the selectivity of the synthetic gas, to quantify the amount of each component from the peak surface value of each component. For each test, the yield oforganic compounds having 2 or more carbon atoms (C2+), organic compounds having 4 or more carbon atoms (C4+), alcohol (linear and branched-chain), and linear alcohol were measured. The results are shown in Tables 1-4. In the Tables, "n-C" denotesnormal alcohol, "b-C" denotes branched chain alcohol, and "C.dbd." denotes unsaturated alcohol.
Organic Compounds Having 2 or More Carbon Atoms (C2+)
Yield of organic compounds of C2 or more in various combinations of raw material alcohols is shown in Table 1.
TABLE-US-00001 TABLE 1 Yield of C2+ organic compounds (%) Test examples 1 2 3 4 5 6 7 8 9 10 catalysts HAP1 HAP1 HAP1 HAP2 HAP1 HAP1 HAP1 HAP1 HAP3 HAP2 combination of C1 C1 C1 C2 C2:n-C3 = C2:n-C3 = C2:n-C3 = C2:n-C3 = C2 C2 alcohol C2 n-C3n-C5 n-C3 1:9 1:4 4:1 9:1 b-C3 n-C4 reaction temperature (.degree. C.) 100 0.2 0.1 0.0 0.1 0.1 0.1 0.2 0.1 0.2 0.2 150 1.1 1.3 1.4 1.7 1.3 1.3 1.6 1.0 2.1 1.6 200 2.2 2.6 2.9 2.8 2.5 2.4 2.8 2.9 3.5 2.5 250 5.4 4.3 5.8 4.6 6.8 5.2 6.3 6.0 7.7 4.1 30014.8 13.3 20.8 9.8 20.6 16.0 18.8 19.9 31.7 8.8 350 18.0 29.4 37.6 19.4 41.2 27.2 26.2 26.8 84.0 14.1 400 40.6 58.5 66.1 41.7 81.9 61.2 56.7 57.6 96.9 32.8 450 82.1 86.6 96.6 86.6 97.3 93.9 93.3 89.2 99.7 79.0 500 95.7 95.8 99.2 98.2 99.2 99.2 99.0 99.499.5 99.4 550 Yield of C2+ organic compounds (%) Test examples 11 12 13 14 15 16 17 18 19 20 catalysts HAP1 HAP3 HAP1 HAP2 HAP2 HAP2 HAP2 HAP2 HAP1 HAP2 combination of C2 C2 C2 C2 C2 C2 C2 n-C3 b-C3 n-C3 alcohol n-C4.sup.= b-C4 n-C5 n-C6 b-C6 n-C8 b-C8n-C4 b-C4 n-C5 reaction temperature (.degree. C.) 100 1.6 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.1 150 9.0 1.3 1.6 1.8 1.5 1.9 0.8 1.7 2.6 1.9 200 15.9 2.4 2.7 2.9 1.8 2.6 1.7 2.5 3.3 2.7 250 25.7 4.6 6.1 7.4 3.6 8.8 2.3 6.6 9.5 8.6 300 46.8 9.5 21.8 12.55.8 13.3 7.4 16.8 24.2 18.6 350 82.2 17.4 30.8 27.2 12.7 31.0 15.9 28.6 60.9 29.2 400 90.6 70.5 60.9 64.2 24.5 67.7 26.2 55.7 67.2 57.7 450 98.2 99.1 93.7 90.1 64.8 91.2 63.6 91.1 83.0 94.4 500 99.8 99.9 99.6 99.6 96.8 99.5 96.0 98.6 97.6 99.7 550Comparative examples 1 2 3 4-1 4-2 4-3 4-4 6 catalysts MgO MgO MgO MgO CaF.sub.2 CaSiO.sub.3 ZrO.sub.2 MgO combination of C1 C1 C1 C2 C2 C2 C2 C2:n-C3 = alcohol C2 n-C3 n-C5 n-C3 n-C3 n-C3 n-C3 1:4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.00.1 0.1 0.0 0.0 150 0.1 0.1 0.4 0.1 0.3 0.2 0.0 0.1 200 0.2 0.1 0.7 0.1 0.2 0.2 0.1 0.1 250 0.3 0.3 1.0 0.3 0.2 0.2 0.5 0.2 300 2.1 2.1 3.8 1.9 1.0 0.4 4.6 1.3 350 9.0 12.0 15.3 8.3 6.1 2.3 15.9 5.9 400 24.1 29.5 29.3 24.1 16.1 8.8 36.7 20.7 450 51.751.6 53.6 42.3 11.6 22.0 58.4 41.9 500 72.7 65.9 74.3 70.8 22.9 47.9 76.1 70.0 550 Comparative examples 7 10-1 10-2 11 12 16 19 catalysts MgO MgO CaF.sub.2 MgO MgO CaSiO.sub.3 MgO combination of C2:n-C3 = C2 C2 C2 C2 C2 b-C3 alcohol 4:1 n-C4 n-C4n-C4.sup.= b-C4 n-C8 b-C4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.5 0.0 0.0 0.1 150 0.1 0.1 0.1 1.3 0.1 0.1 0.6 200 0.1 0.2 0.1 1.8 0.1 0.1 1.2 250 0.3 0.5 0.1 2.5 0.3 0.3 2.9 300 2.3 2.2 0.2 10.2 1.5 0.5 3.7 350 11.8 7.8 1.7 27.6 3.6 1.812.0 400 27.8 19.8 7.6 45.7 13.5 5.6 24.8 450 47.0 45.0 12.1 63.1 41.8 15.9 36.3 500 75.7 73.4 24.9 81.8 75.4 42.3 61.0 550
Organic Compounds Having 4 or More Carbon Atoms (C4+)
Yield of organic compounds of C4 or more in various combinations of raw material alcohols is shown in Table 2.
TABLE-US-00002 TABLE 2 Yield of C4+ organic compounds (%) Test examples 1 2 3 4 5 6 7 8 9 10 catalysts HAP1 HAP1 HAP1 HAP2 HAP1 HAP1 HAP1 HAP1 HAP3 HAP2 combination of C1 C1 C1 C2 C2:n-C3 = C2:n-C3 = C2:n-C3 = C2:n-C3 = C2 C2 alcohol C2 n-C3n-C5 n-C3 1:9 1:4 4:1 9:1 b-C3 n-C4 reaction temperature (.degree. C.) 100 0.2 0.1 0.0 0.0 0.1 0.1 0.1 0.1 0.1 0.1 150 0.8 1.0 1.2 1.2 1.2 1.1 1.3 0.9 1.8 1.4 200 1.8 2.2 2.6 2.2 2.2 2.2 2.3 2.8 2.9 1.9 250 4.6 3.8 5.5 3.6 5.9 4.5 5.6 5.9 6.7 3.2 30011.5 12.8 20.7 7.2 18.8 15.4 18.0 19.7 25.8 5.7 350 14.5 27.5 37.6 17.9 38.6 25.2 24.6 26.6 62.4 13.6 400 33.9 55.4 65.9 37.7 58.2 56.7 53.0 52.3 48.0 31.5 450 77.6 83.8 95.5 77.0 84.7 86.0 85.8 82.8 39.1 76.5 500 89.1 91.3 94.5 85.4 86.5 87.5 88.1 86.431.0 97.6 550 Yield of C4+ organic compounds (%) Test examples 11 12 13 14 15 16 17 18 19 20 catalysts HAP1 HAP3 HAP1 HAP2 HAP2 HAP2 HAP2 HAP2 HAP1 HAP2 combination of C2 C2 C2 C2 C2 C2 C2 n-C3 b-C3 n-C3 alcohol n-C4.sup.= b-C4 n-C5 n-C6 b-C6 n-C8 b-C8n-C4 b-C4 n-C5 reaction temperature (.degree. C.) 100 1.5 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.1 0.0 150 8.9 1.2 1.5 1.7 1.4 1.8 0.7 1.6 2.6 1.8 200 15.5 2.3 2.5 2.7 1.7 2.5 1.5 2.2 3.3 2.4 250 25.5 4.4 5.8 7.2 3.5 8.6 2.1 6.1 9.5 6.9 300 46.0 9.2 21.7 12.35.7 13.1 7.2 15.4 24.2 16.7 350 80.6 16.1 30.4 27.0 12.5 30.4 15.5 26.7 60.8 26.9 400 88.9 63.7 60.1 64.0 23.5 67.5 25.2 46.3 66.1 48.4 450 95.7 82.4 92.3 89.8 62.4 89.7 62.5 80.1 79.0 81.7 500 95.7 98.9 95.0 98.9 93.6 99.1 92.8 87.6 92.5 89.3 550Comparative examples 1 2 3 4-1 4-2 4-3 4-4 6 catalysts MgO MgO MgO MgO CaF.sub.2 CaSiO.sub.3 ZrO.sub.2 MgO combination of C1 C1 C1 C2 C2 C2 C2 C2:n-C3 = alcohol C2 n-C3 n-C5 n-C3 n-C3 n-C3 n-C3 1:4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.00.0 0.0 0.0 0.0 150 0.1 0.1 0.4 0.1 0.1 0.1 0.0 0.1 200 0.1 0.1 0.7 0.1 0.0 0.0 0.0 0.1 250 0.2 0.2 1.0 0.2 0.0 0.0 0.1 0.1 300 1.1 1.7 3.8 1.2 0.2 0.1 1.4 0.8 350 5.5 10.3 15.3 6.0 2.1 0.6 8.7 4.0 400 16.6 24.3 29.3 17.5 4.7 3.1 20.4 14.0 450 41.4 43.752.8 29.3 2.4 8.4 29.3 28.3 500 56.6 55.5 71.5 49.9 6.2 20.7 36.9 47.4 550 Comparative examples 7 10-1 10-2 11 12 16 19 catalysts MgO MgO CaF.sub.2 MgO MgO CaSiO.sub.3 MgO combination of C2:n-C3 = C2 C2 C2 C2 C2 b-C3 alcohol 4:1 n-C4 n-C4 n-C4.sup.= b-C4n-C8 b-C4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.4 0.0 0.0 0.1 150 0.0 0.1 0.1 1.2 0.1 0.1 0.5 200 0.0 0.1 0.1 1.7 0.1 0.1 1.0 250 0.2 0.4 0.1 2.3 0.2 0.3 2.6 300 1.4 1.8 0.1 10.0 1.4 0.5 1.7 350 8.7 6.4 1.3 27.1 3.4 1.7 4.6 400 21.2 16.35.7 44.9 12.6 5.5 10.8 450 33.2 37.5 8.7 62.5 38.2 15.7 16.6 500 50.3 62.1 17.2 80.2 64.8 41.9 34.6 550
Alcohol (Linear and Branched-chain)
Yield of alcohol (linear and branched-chain) in various combinations of raw material alcohols is shown in Table 3.
TABLE-US-00003 TABLE 3 Yield of synthesized alcohol (%) Test examples 1 2 3 4 5 6 7 8 9 10 catalysts HAP1 HAP1 HAP1 HAP2 HAP1 HAP1 HAP1 HAP1 HAP3 HAP2 combination of C1 C1 C1 C2 C2:n-C3 = C2:n-C3 = C2:n-C3 = C2:n-C3 = C2 C2 alcohol C2 n-C3 n-C5n-C3 1:9 1:4 4:1 9:1 b-C3 n-C4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 150 0.7 0.7 1.0 0.9 1.0 0.8 0.9 0.8 1.5 0.8 200 1.5 1.7 2.2 1.8 1.6 2.1 1.9 2.0 2.2 1.5 250 4.1 3.2 4.8 3.0 3.3 3.6 4.8 4.4 5.7 2.6 300 10.59.6 19.2 6.0 16.7 12.8 14.9 15.8 13.2 4.0 350 12.4 19.9 32.1 15.4 26.9 20.8 19.5 21.7 6.3 9.8 400 23.6 39.0 51.2 28.3 40.2 42.0 37.2 38.3 0.6 18.8 450 27.8 33.4 34.4 31.6 28.6 32.1 27.1 26.5 0.0 24.9 500 8.7 9.0 7.8 6.5 6.1 8.2 5.5 5.9 0.0 2.6 550 Yieldof synthesized alcohol (%) Test examples 11 12 13 14 15 16 17 18 19 20 catalysts HAP1 HAP3 HAP1 HAP2 HAP2 HAP2 HAP2 HAP2 HAP1 HAP2 combination of C2 C2 C2 C2 C2 C2 C2 n-C3 b-C3 n-C3 alcohol n-C4.sup.= b-C4 n-C5 n-C6 b-C6 n-C8 b-C8 n-C4 b-C4 n-C5 reactiontemperature (.degree. C.) 100 0.8 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.1 0.0 150 4.9 0.6 1.1 1.4 0.7 1.5 0.4 1.1 1.6 1.3 200 9.2 1.3 2.2 2.3 0.8 2.1 0.8 1.8 2.3 2.2 250 13.7 2.5 4.9 6.6 1.5 7.3 1.1 5.1 5.2 6.6 300 23.2 5.4 17.6 9.5 3.1 11.8 2.8 12.9 14.3 15.3350 44.4 8.1 23.2 23.4 5.6 23.4 5.1 13.6 26.4 24.1 400 30.4 5.7 41.5 55.3 9.9 41.5 8.2 23.1 13.2 42.6 450 9.5 2.3 34.0 39.3 7.7 38.8 9.4 26.7 3.6 32.7 500 2.7 0.7 5.4 3.1 1.4 2.3 1.9 6.3 1.2 5.8 550 Comparative examples 1 2 3 4-1 4-2 4-3 4-4 6 catalystsMgO MgO MgO MgO CaF.sub.2 CaSiO.sub.3 ZrO.sub.2 MgO combination of C1 C1 C1 C2 C2 C2 C2 C2:n-C3 = alcohol C2 n-C3 n-C5 n-C3 n-C3 n-C3 n-C3 1:4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 150 0.0 0.0 0.1 0.0 0.0 0.0 0.0 0.0 2000.0 0.0 0.2 0.0 0.0 0.0 0.0 0.0 250 0.1 0.1 0.5 0.1 0.0 0.0 0.0 0.1 300 0.6 1.2 2.4 0.6 0.0 0.0 0.1 0.3 350 3.1 8.2 9.3 3.3 1.0 0.3 4.0 2.0 400 8.2 16.7 16.4 9.8 2.4 1.1 5.0 7.6 450 17.2 24.9 26.8 14.7 1.2 2.3 0.7 14.5 500 13.2 22.8 23.2 16.1 2.5 3.5 0.317.2 550 Comparative examples 7 10-1 10-2 11 12 16 19 catalysts MgO MgO CaF.sub.2 MgO MgO CaSiO.sub.3 MgO combination of C2:n-C3 = C2 C2 C2 C2 C2 b-C3 alcohol 4:1 n-C4 n-C4 n-C4.sup.= b-C4 n-C8 b-C4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.20.0 0.0 0.0 150 0.0 0.0 0.0 0.7 0.0 0.0 0.0 200 0.0 0.0 0.0 0.8 0.0 0.0 0.0 250 0.1 0.1 0.0 0.9 0.1 0.0 0.0 300 0.8 0.4 0.0 3.7 0.3 0.0 0.6 350 4.7 2.0 0.1 12.8 1.3 0.4 1.8 400 11.5 4.1 0.7 16.4 2.8 1.6 3.6 450 15.7 7.4 0.6 14.9 3.8 2.8 3.5 500 15.8 4.31.2 4.6 2.6 3.9 3.1 550
Yield of linear alcohol in various combinations of raw material alcohol is shown in Table 4. Yield of linear alcohol in Table 4 shows the yield of linear alcohol synthesized directly from 2 kinds of raw material alcohol. For example, whenmethanol (C1) and ethanol (C2) are used as raw materials, yield of 1-propanol is shown. When ethanol (C2) and 1-propanol (C3) are used as raw materials, yield of 1-pentanol (C5) is shown.
TABLE-US-00004 TABLE 4 Yield of linear alcohol (%) Test examples 1 2 3 4 5 6 7 8 9 10 catalysts HAP1 HAP2 HAP1 HAP2 HAP1 HAP1 HAP1 HAP1 HAP3 HAP2 combination of C1 C1 C1 C2 C2:n-C3 = C2:n-C3 = C2:n-C3 = C2:n-C3 = C2 C2 alcohol C2 n-C3 n-C5 n-C31:9 1:4 4:1 9:1 b-C3 n-C4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 150 0.6 0.0 0.0 0.8 0.4 0.8 0.6 0.3 0.0 0.7 200 0.9 0.0 0.0 1.1 0.8 1.2 0.7 0.4 0.0 1.1 250 1.9 0.0 0.0 1.4 1.5 2.3 1.8 0.9 0.0 1.8 300 4.2 0.0 0.02.5 1.8 3.2 2.8 1.2 0.0 2.2 350 5.7 0.0 0.0 5.2 2.1 4.6 3.1 1.8 0.0 4.4 400 8.6 0.0 0.0 8.4 3.6 7.8 5.5 3.1 0.0 6.8 450 2.4 0.0 0.0 6.2 0.9 4.2 3.5 1.3 0.0 4.5 500 0.3 0.0 0.0 1.0 0.0 1.4 0.9 0.1 0.0 0.3 550 Yield of linear alcohol (%) Test examples 1112 13 14 15 16 17 18 19 20 catalysts HAP1 HAP3 HAP1 HAP2 HAP2 HAP2 HAP2 HAP2 HAP1 HAP2 combination of C2 C2 C2 C2 C2 C2 C2 n-C3 b-C3 n-C3 alcohol n-C4.sup.= b-C4 n-C5 n-C6 b-C6 n-C8 b-C8 n-C4 b-C4 n-C5 reaction temperature (.degree. C.) 100 0.0 0.0 0.00.0 0.0 0.0 0.0 0.0 0.0 0.0 150 0.2 0.0 0.9 1.2 0.0 1.4 0.0 0.0 0.0 0.0 200 0.3 0.0 1.5 1.7 0.0 1.5 0.0 0.0 0.0 0.0 250 0.5 0.0 2.3 3.1 0.0 3.3 0.0 0.0 0.0 0.0 300 1.6 0.0 5.7 3.8 0.0 3.7 0.0 0.0 0.0 0.0 350 2.2 0.0 6.7 6.2 0.0 4.9 0.0 0.0 0.0 0.0 4001.8 0.0 8.3 11.6 0.0 6.3 0.0 0.0 0.0 0.0 450 1.2 0.0 2.5 7.3 0.0 6.7 0.0 0.0 0.0 0.0 500 0.4 0.0 0.7 0.1 0.0 0.0 0.0 0.0 0.0 0.0 550 Comparative examples 1 2 3 4-1 4-2 4-3 4-4 6 catalysts MgO MgO MgO MgO CaF.sub.2 CaSiO.sub.3 ZrO.sub.2 MgO combination ofC1 C1 C1 C2 C2 C2 C2 C2:n-C3 = alcohol C2 n-C3 n-C5 n-C3 n-C3 n-C3 n-C3 1:4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 150 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 200 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 250 0.1 0.0 0.0 0.0 0.0 0.0 0.00.0 300 0.7 0.0 0.0 0.2 0.0 0.0 0.0 0.1 350 2.7 0.0 0.0 0.9 0.6 0.1 0.9 0.4 400 4.2 0.0 0.0 2.1 1.2 0.6 0.8 1.4 450 3.6 0.0 0.0 2.5 0.5 1.1 0.4 1.9 500 2.3 0.0 0.0 1.8 1.1 1.6 0.0 1.5 550 Comparative examples 7 10-1 10-2 11 12 16 19 catalysts MgO MgOCaF.sub.2 MgO MgO CaSiO.sub.3 MgO combination of C2:n-C3 = C2 C2 C2 C2 C2 b-C3 alcohol 4:1 n-C4 n-C4 n-C4.sup.= b-C4 n-C8 b-C4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.0 0.0 0.0 0.0 150 0.0 0.0 0.0 0.0 0.0 0.0 0.0 200 0.0 0.0 0.0 0.0 0.0 0.00.0 250 0.0 0.1 0.0 0.1 0.0 0.0 0.0 300 0.1 0.3 0.0 0.3 0.0 0.0 0.0 350 0.8 1.0 0.1 0.4 0.0 0.1 0.0 400 1.7 1.7 0.6 0.3 0.0 0.3 0.0 450 1.8 2.6 0.5 0.2 0.0 0.5 0.0 500 1.6 1.2 1.1 0.1 0.0 0.7 0.0 550
As it is clear from Tables 1 and 2, according to the synthesizing method of the present invention, organic compounds useful as a chemical industry raw material can be synthesized in good yield. Further, as it is clear from Tables 3 and 4, whenethanol and linear alcohol other than ethanol are used, linear alcohol is synthesized in good yield. When methanol and alcohol having 3 or more carbon atoms are used, branched-chain alcohol is synthesized in good yield.
As it is clear from FIGS. 1-3, kinds of alcohol produced vary depending on the mixing ratio (molar ratio). When the mixing ratio is 1:1, 1-pentanol which is a linear alcohol is synthesized the most. Therefore, when synthesizing linear alcoholhaving odd number of carbon atoms, such as 1-pentanol, when the converting ratio of raw material alcohol is almost equal, it is preferred that the mixing ratio is about 1:1.
Second Synthesizing Method
Catalysts: The same catalysts as Example 1 were used.
Estimation of Catalyst Properties
Reaction was conducted similarly as Example 1, except for using 1 kind of alcohol having 3 or more carbon atoms as raw material alcohol. For each test, yield of organic compounds of C2 or more, organic compounds of C4 or more, alcohol (linearand branched-chain), and linear alcohol were measured. The results are shown in Tables 5-7. Linear alcohol was not produced in any of the Examples or Comparative Examples.
Yield of organic compounds of C2 or more for each raw material alcohol is shown in Table 5.
TABLE-US-00005 TABLE 5 Yield of C2+ organic compounds (%) Test examples 21 22 23 24 25 catalysts HAP2 HAP2 HAP2 HAP1 HAP2 combination of n-C3 b-C3 n-C4 n-C4= b-C4 alcohol reaction temperature (.degree. C.) 100 0.1 0.1 0.2 3.8 0.1 150 1.5 1.81.5 5.9 1.6 200 2.7 3.1 2.3 10.5 2.8 250 4.2 9.9 3.8 12.8 5.6 300 22.5 33.4 8.0 23.7 17.3 350 43.2 94.0 14.5 45.8 66.7 400 84.6 99.9 35.8 99.6 96.8 450 99.7 99.7 88.1 99.9 99.2 500 99.5 99.5 96.8 99.9 99.8 550 Comparative examples 21 22 23 24 25catalysts MgO CaF.sub.2 ZrO.sub.2 MgO CaSiO.sub.3 combination of n-C3 b-C3 n-C4 n-C4= b-C4 alcohol reaction temperature (.degree. C.) 100 0.0 0.0 0.0 1.3 0.1 150 0.1 0.2 0.1 2.3 0.2 200 0.2 0.2 0.1 2.7 0.2 250 0.3 0.3 0.2 3.5 0.2 300 2.1 1.5 5.6 4.2 0.8350 8.5 6.8 9.3 6.7 1.8 400 24.9 12.0 25.2 26.6 5.5 450 43.6 17.1 51.6 48.5 19.8 500 72.1 23.7 67.7 76.1 55.7 550
TABLE-US-00006 TABLE 6 Yield of C4+ organic compounds (%) Test examples 21 22 23 24 25 catalysts HAP2 HAP2 HAP2 HAP1 HAP2 combination of n-C3 b-C3 n-C4 n-C4= b-C4 alcohol reaction temperature (.degree. C.) 100 0.1 0.1 0.2 3.6 0.1 150 1.4 1.21.4 5.8 1.6 200 2.6 2.3 2.2 10.3 2.7 250 4.0 6.2 3.7 12.5 5.5 300 21.8 23.6 7.9 23.3 17.1 350 38.8 63.7 14.4 45.2 66.6 400 65.2 37.9 35.7 98.3 96.7 450 61.2 22.3 87.4 98.5 99.0 500 55.5 17.2 94.6 97.7 99.2 550 Comparative examples 21 22 23 24 25catalysts MgO CaF.sub.2 ZrO.sub.2 MgO CaSiO.sub.3 combination of n-C3 b-C3 n-C4 n-C4= b-C4 alcohol reaction temperature (.degree. C.) 100 0.0 0.0 0.0 1.2 0.0 150 0.1 0.1 0.1 2.2 0.1 200 0.1 0.1 0.1 2.5 0.1 250 0.2 0.2 0.2 3.1 0.2 300 1.1 0.7 5.5 3.6 0.7350 6.3 4.2 9.1 6.2 1.6 400 17.4 5.4 24.6 25.3 5.3 450 27.6 8.6 57.7 46.1 18.3 500 43.7 11.4 64.2 73.8 52.6 550
Yield of alcohol (linear and branched-chain) for each raw material alcohol is shown in Table 7.
TABLE-US-00007 TABLE 7 Yield of total synthesized alcohol (%) Test examples 21 22 23 24 25 catalysts HAP2 HAP2 HAP2 HAP1 HAP2 combination of n-C3 b-C3 n-C4 n-C4= b-C4 alcohol reaction temperature (.degree. C.) 100 0.0 0.0 0.0 1.1 0.0 150 1.21.0 1.2 2.3 0.8 200 2.2 1.7 1.8 2.8 1.2 250 3.5 3.2 2.7 3.2 2.3 300 18.4 5.6 3.8 4.6 3.5 350 28.2 2.5 5.3 15.6 6.0 400 14.9 0.8 8.8 27.9 2.0 450 2.4 0.2 17.4 8.6 0.7 500 1.8 0.0 18.0 3.0 0.0 550 Comparative examples 21 22 23 24 25 catalysts MgO CaF.sub.2ZrO.sub.2 MgO CaSiO.sub.3 combination of n-C3 b-C3 n-C4 n-C4= b-C4 alcohol reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.2 0.0 150 0.0 0.0 0.0 0.3 0.0 200 0.1 0.0 0.1 0.2 0.0 250 0.2 0.0 0.2 0.2 0.0 300 0.7 0.2 0.7 0.3 0.1 350 3.2 0.6 0.9 1.5 0.2400 7.7 0.7 1.7 2.6 0.3 450 11.4 1.2 3.9 4.4 0.5 500 14.6 1.5 5.5 1.3 0.7 550
Third Synthesizing Method
Catalyst: Hydrotalcite (Wako Pure Chemicals) was used as a catalyst.
Reaction was conducted similarly as Example 1, except for using hydrotalcite instead of hydroxyapatite. For each test, yield of organic compounds of C2 or more (C2+), organic compounds of C4 or more (C4+), alcohol (linear and branched-chain),and linear alcohol were measured. The results are shown in Table 8.
TABLE-US-00008 TABLE 8 Test examples 26 26 26 26 Yield (%) C2+ C4+ total alcohol linear alcohol catalysts hydrotal- hydrotal- hydrotal- hydrotal- cite cite cite cite combination C2 + C2 + C2 + C2 + of alcohol n - C3 n - C3 n - C3 n - C3 reactiontemperature (.degree. C.) 100 0.0 0.0 0.0 0.0 150 0.5 0.4 0.2 0.1 200 1.1 0.7 0.4 0.3 250 2.2 1.9 1.0 0.6 300 4.9 4.2 1.9 1.0 350 12.8 10.3 4.2 2.3 400 35.8 26.1 9.4 4.1 450 71.5 44.5 13.6 3.6 500 92.4 55.6 6.6 0.9 550 Test examples 27 27 27 27 Yield(%) C2+ C4+ total alcohol linear alcohol catalysts hydrotal- hydrotal- hydrotal- hydrotal- cite cite cite cite combination C2 + C2 + C2 + C2 + of alcohol n - C4 n - C4 n - C4 n - C4 reaction temperature (.degree. C.) 100 0.0 0.0 0.0 0.0 150 1.4 1.2 0.80.5 200 2.0 1.7 1.1 0.6 250 3.4 3.1 1.3 0.8 300 5.1 4.8 1.6 1.0 350 14.7 13.6 3.1 2.2 400 31.6 27.5 5.2 3.4 450 69.6 58.5 6.4 2.6 500 88.7 76.8 2.7 0.8 550
Hydroxyapatite (HAP1) was exposed to about 7 vol % ethanol/He mixed gas for 1 hour in a reactor, and then emission was conducted. The inner state of the reactor after 1 hour of exposure to the mixed gas and the following 30 min of emission wasmeasured by in situ FT-IR with a diffuse reflection method. The results are shown in FIGS. 4 and 5. In FIG. 4, the upper spectrum shows the state after 1 hour exposure to the mixed gas, and the lower spectrum shows the state after 30 min emission. Asit is clear from FIGS. 4 and 5, it can be observed that ethanol is absorbed and supported by hydroxyapatite.
Referring to the table of FIG. 6, hydroxyapatite (HAP1) catalyst is exposed to a mixed gas of ethanol and methanol at about 1:1 molar ratio and He, with the alcohols at about 20% of the mixture by volume. The mixed gas is exposed to thecatalyst with a contact time of about 1.0 sec at various temperatures, as indicated in the depicted table. The selectivity of various specific products and product classes are determined, as also shown in the table.
Referring to the table of FIG. 7, hydroxyapatite (HAP1) catalyst is exposed to a mixed gas of ethanol and methanol at about 1:20 molar ratio and He, with the alcohols at about 20% of the mixture by volume. The mixed gas is exposed to thecatalyst with a contact time of about 1.0 sec at various temperatures, as indicated in the depicted table. The selectivity of various specific products and product classes are determined, as also shown in the table.
Referring to the table of FIG. 8, hydroxyapatite (HAP1) catalyst is exposed to a mixed gas of ethanol and 1-propanol at about 4:1 molar ratio and He, with the alcohols at about 20% of the mixture by volume. The mixed gas is exposed to thecatalyst with a contact time of about 1.0 sec at various temperatures, as indicated in the depicted table. The selectivity of various specific products and product classes are determined, as also shown in the table.
Referring to the table of FIG. 9, hydroxyapatite (HAP1) catalyst is exposed to a mixed gas of ethanol and 1-propanol at about 1:1 molar ratio and He, with the alcohols at about 20% of the mixture by volume. The mixed gas is exposed to thecatalyst with a contact time of about 1.0 sec at various temperatures, as indicated in the depicted table. The selectivity of various specific products and product classes are determined, as also shown in the table.
Referring to the table of FIG. 10, hydroxyapatite (HAP1) catalyst is exposed to a mixed gas of ethanol and 1-propanol at about 1:4 molar ratio and He, with the alcohols at about 20% of the mixture by volume. The mixed gas is exposed to thecatalyst with a contact time of about 1.0 sec at various temperatures, as indicated in the depicted table. The selectivity of various specific products and product classes are determined, as also shown in the table.
Referring to the table of FIG. 11, hydroxyapatite (HAP1) catalyst is exposed to a mixed gas of ethanol, methanol and 1-propanol at about 1:5:1 molar ratio and He, with the alcohols at about 20% of the mixture by volume. The mixed gas is exposedto the catalyst with a contact time of about 1.0 sec at various temperatures, as indicated in the depicted table. The selectivity of various specific products and product classes are determined, as also shown in the table.
Referring to the table of FIG. 12, MgO catalyst is exposed to a mixed gas of ethanol, methanol and 1-propanol at about 1:5:1 molar ratio and He, with the alcohols at about 20% of the mixture by volume. The mixed gas is exposed to the catalystwith a contact time of about 1.0 sec at various temperatures, as indicated in the depicted table. The selectivity of various specific products and product classes are determined, as also shown in the table.
Referring to the table of FIG. 13, hydroxyapatite (HAP1) catalyst is exposed to a mixed gas of ethanol, methanol and 1-butanol at about 1:6:1 molar ratio and He, with the alcohols at about 20% of the mixture by volume. The mixed gas is exposedto the catalyst with a contact time of about 1.0 sec at various temperatures, as indicated in the depicted table. The selectivity of various specific products and product classes are determined, as also shown in the table.
Referring to the table of FIG. 14, MgO catalyst is exposed to a mixed gas of ethanol, methanol and 1-butanol at about 1:6:1 molar ratio and He, with the alcohols at about 20% of the mixture by volume. The mixed gas is exposed to the catalystwith a contact time of about 1.0 sec at various temperatures, as indicated in the depicted table. The selectivity of various specific products and product classes are determined, as also shown in the table.
Referring to the table of FIG. 15, the normal ratio percentage of C5 alcohol products are shown (i.e., the percentage of 1-pentanol product of the total saturated C5-alcohol products), in case beginning with the starting alcohols at a givenratio, and using the catalysts at the indicated temperatures, all as indicated on the table. Also shown is the percent-yield of the normal cross-Guerbet alcohols, which refers to the alcohols that are the product between the two different alcoholspecies (e.g., ethanol and propanol) rather than between two molecules of the same species.
Referring to FIGS. 16A and 16B, the graphs show the distribution of products resulting from a reaction of two alcohols (ethanol and 1-propanol at about a 1:1 molar ratio) and a reaction of three alcohols (ethanol, methanol and 1-propanol atabout a 1:5:1 respective molar ratio). Both reactions are performed at about 400.degree. C. over hydroxyapatite, resulting in a conversion rate of the ethanol of about 50%. The graph depicted in FIG. 16A shows the distribution of all products fromeach reaction as a distribution based on the number of carbon atoms in the product. The graph depicted in FIG. 16B shows the distribution of alcohol products from each reaction as a distribution based on the number of carbon atoms in the alcohol.
Referring to FIGS. 17A and 17B, the graphs show the distribution of products resulting from a reaction of two alcohols (ethanol and 1-propanol at about a 1:1 molar ratio) and a reaction of three alcohols (ethanol, methanol and 1-propanol atabout a 1:5:1 respective molar ratio). Both reactions are performed at about 500.degree. C. over hydroxyapatite, resulting in a conversion rate of the ethanol of about 100%. The graph depicted in FIG. 17A shows the distribution of all products fromeach reaction as a distribution based on the number of carbon atoms in the product. The graph depicted in FIG. 17B shows the distribution of aldehyde and olefin products from each reaction as a distribution based on the number of carbon atoms in thealdehyde or olefin.
Referring to FIGS. 18A and 18B, the graphs show the distribution of products resulting from a reaction of two alcohols (ethanol and 1-butanol at about a 1:1 molar ratio at about 400.degree. C.) and a reaction of three alcohols (ethanol,methanol and 1-butanol at about a 1:6:1 respective molar ratio at about 350.degree. C.). Both reactions are performed over hydroxyapatite, resulting in a conversion rate of the ethanol of about 50%. The graph depicted in FIG. 18A shows thedistribution of all products from each reaction as a distribution based on the number of carbon atoms in the product. The graph depicted in FIG. 18B shows the distribution of alcohol products from each reaction as a distribution based on the number ofcarbon atoms in the alcohol.
Referring to FIGS. 19A and 19B, the graphs show the distribution of products resulting from a reaction of two alcohols (ethanol and 1-butanol at about a 1:1 molar ratio) and a reaction of three alcohols (ethanol, methanol and 1-butanol at abouta 1:6:1 respective molar ratio). Both reactions are performed at about 500.degree. C. over hydroxyapatite, resulting in a conversion rate of the ethanol of about 100%. The graph depicted in FIG. 19A shows the distribution of all products from eachreaction as a distribution based on the number of carbon atoms in the product. The graph depicted in FIG. 19B shows the distribution of aldehyde and olefin products from each reaction as a distribution based on the number of carbon atoms in the aldehydeor olefin.
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