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    J.Chem.T echnol.Biotechnol. 1998,73, 414420

    Catalyst Prepared byElectroless MethodCu/SiO2Ching-Yeh Shiau*& J. C. Tsai

    Department of Chemical Engineering, National Taiwan University of Science and Technology, Taipei,Taiwan

    (Received 26 January 1998; accepted 5 August 1998)

    Abstract: catalysts prepared by an electroless deposition method wereCu/SiO2

    investigated and compared with those by an impregnation method. Copper con-tents varied from 5% to 15% and was used as support. All catalysts wereSiO

    2characterized by BET, DSC, SEM and TPR and tested by ann-butanol dehydro-genation reaction for activities and stabilities. BET analysis showed that thecatalysts prepared by the two methods present larger average pore size and lesssurface area than those of the fresh indicating that smaller pores may getSiO

    2,

    blocked during the course of preparation. This blockage is more severe in theimpregnation method. SEM photos showed that the electroless method producessmaller copper crystals than the impregnated method. The reaction activity wasfound to be in the order of the calcined electroless copper catalyst [ the freshelectroless copper catalyst[ impregnated copper catalyst. 1998 Society of(Chemical Industry

    J.Chem.T echnol.Biotechnol.73, 414420 (1998)

    Key words: copper catalyst; electroless plating; impregnation; n-butanolSiO2

    ;dehydrogenation

    INTRODUCTION

    Copper-based catalysts are widely used in many indus-

    trial reactions, especially for dehydrogenation reactions.

    Church and Joshi1and Franckaerts and Froment2indi-cated that a CuCoCr catalyst had good activity for

    ethanol dehydrogenation. Pepe et al.3 studied the dehy-drogenation of isopropanol and found that the reaction

    rate increased linearly with the exposed copper surface

    area of the supported catalysts. Doca and Segal4h7usedCr-, Mn-, Fe- and Ni-promoted copper catalysts to

    investigate the kinetics of low aliphatic alcoholic

    dehydrogenation in the temperature range of(C2C

    4)

    200280C by a chromatographic pulse technique. They

    found that the fresh copper catalyst was very active, but

    its activity decreased rapidly with pulse number. If the

    promoters Cr and Mn were added into the catalysts, the

    activity of the catalysts remained fairly constant for a

    * To whom correspondence should be addressed.Contract/grant sponsor : National Science Council of the

    Republic of China; Contract/grant number: NSC84-2214-E011-005.

    longer time due to the formation of a Cu-oxide junc-

    tion. Prasad et al.8 and Tu et al.9 studied the role ofchromia in a copper catalyst for the dehydrogenation of

    ethanol; the addition of chromia improved dispersion of

    copper on the support and helped to prevent the cata-

    lyst from sintering. Sivarajet al.10 found that CuZnOAl catalysts prepared by a depositionprecipitation

    method had high selectivity for the dehydrogenation of

    cyclohexanol to cyclohexanone. Lin et al .11 used a

    CuZnO catalyst to investigate the oxidative dehydro-genation of cyclohexanol to cyclohexanone. Sivaraj et

    al.12 examined the selectivity dependence on the acidityof supported copper catalysts prepared using the urea

    hydrolysis procedure in the hydrogenation of cyclo-

    hexanol. Shiau and Liaw13 found that a CuBa catalystwas potentially attractive for the dehydrogenation ofn-

    butanol to butyraldehyde. Shiau and Chen14 also foundthat a CuCr catalyst was quite eective for the ethanol

    dehydrogenation reaction. Grift et al .15 studied theeect of preparation procedure on the reduction behav-

    ior of silica-supported copper catalysts. They found that

    the dispersion of copper strongly depended on the prep-

    aration methods and the conditions used.

    4141998 Society of Chemical Industry. J.Chem.T echnol.Biotechnol. 0268-2575/98/$17.50. Printed in Great Britain(

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    Cu/SiO2

    catalyst prepared by electroless method 415

    Traditionally, copper catalysts are prepared by either

    impregnation methods or precipitation methods.

    Recently, electroless deposition method has been

    adopted in the preparation of copper catalysts. Chang

    and Saleque16h19 used this method to prepare a coppercatalyst on for the dehydrogenation reactionsAl

    2O3

    and found that the catalysts prepared by the electrolessmethod were better than those prepared by the conven-

    tional methods. Shiau and Tsai20 also found similarresults for the dehydrogenation reaction of n-butanol

    when using catalysts prepared by the electro-Cu/Al2

    O3

    less method. In this study, the electroless deposition

    method was used to prepare copper catalysts for the

    dehydrogenation of n-butanol. was used asSiO2

    support. All the catalysts prepared by the electroless

    method were compared with the catalysts prepared by

    the impregnation method.

    EXPERIMENTAL

    Catalyst preparation

    Electroless method

    The electroless method is an oxidationreduction

    chemical deposition reaction, which can deposit certain

    metals on a substrate without an external electrical

    source. In this study was used as substrate. BeforeSiO2

    electroless deposition, was rstly treated withSiO2

    dilute acid solution to remove any fats and oils. The

    clean was then treated with palladium chlorideSiO

    2solution for activation. At this stage, palladium servedas seeds for catalytic nucleating centers. The activated

    was nally contacted with copper solution forSiO2

    copper plating. In the copper solution, formaldehyde

    was added as reducing agent for the oxidation

    reduction reaction. The plating bath was maintained at

    70C and the pH was varied from 11 to 13. The plated

    was then ltered and washed with distilled water,SiO2

    then dried at 110C for 24 h. The copper content was

    controlled by the plating solution concentration as well

    as the plating time. The plated copper catalysts can be

    directly used as the plated copper is present as copper

    atoms instead of copper oxide. However, some freshelectroless copper catalysts were also calcined at 450C

    for 3 h to study the calcination eect.

    Impregnation method

    Catalysts were prepared by putting support into aSiO2

    copper nitrate solution container for 30 min impregna-

    tion. The container was then placed in an isothermal

    water bath to vaporize most of water. The bath tem-

    perature was maintained at 70C. The soaked paste was

    then dried at 110C and calcined, if necessary, at 450C

    for 3 h.

    Six catalysts were prepared, namely, I05, I10, I15,

    E05, E10 and E15 in which I denotes impregnation

    method, E denotes electroless method and the numbers

    represent the copper content in the catalyst as a per-

    centage. The copper content was determined by atomic

    absorption spectrometry. The catalysts were character-

    ized by BET, DSC, SEM and TPR analyses.

    n-Butanol reaction

    The catalyst activity data were obtained by carrying out

    the dehydrogenation reaction ofn-butanol in a contin-

    uous ow type reactor with a xed catalyst bed under

    atmospheric pressure. The reactor was made of a Pyrex

    tube with 136 mm inner diameter, equipped with a

    thermocouple well along the central axis. A known

    amount of catalyst was loaded in the reactor. Pure n-

    butanol was fed into the reactor by a metering pump.

    The reaction temperature was set at 270C. All connect-

    ing gas lines and valves were wrapped with heating tape

    to prevent possible condensation. The compositions ofinlet and outlet streams were determined chromato-

    graphically using a column loaded with Porapak Q.

    The experiments were conducted under conditions free

    of external mass transfer and internal diusion resist-

    ances.

    RESULTS AND DISCUSSION

    Catalyst characterization

    Table 1 shows the specic surface areas and the meanpore sizes for the six types of catalysts measured by the

    BET method. Fresh was also included for refer-SiO2

    ence. As can be seen from this table, all the catalysts

    have less surface area and larger mean pore size than

    the fresh and the catalysts prepared by the elec-SiO2

    ,

    troless method exhibit a larger surface area and smaller

    mean pore size than all the impregnated catalysts.

    Moreover, the surface area increases and the mean pore

    size decreases with increasing copper loading for the

    electroless catalysts, but vice versa for the impregnated

    catalysts. All this information indicates that the impreg-

    nation method will block some small pores and this

    TABLE 1

    BET Surface Analysis

    Catalyst Surface area Pore size

    (m2 g~1) (A )

    SiO2 2988 2113

    I05 2552 2430

    I10 2415 2562

    I15 2347 2664

    E05 2644 2385

    E10 2712 2324

    E15 2785 2253

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    416 C.-Y. Shiau, J. C . T sai

    Fig. 1. Pore distribution for impregnated catalysts.

    blockage will become more severe with increasing

    copper loading, but the blockage phenomenon in the

    electroless method is much less. These blockage pheno-

    mena can also be seen from the pore distribution

    curves, as shown in Figs 1 and 2. Figure 1 is the pore

    distribution for the impregnation method and Fig. 2 for

    the electroless method. It is clearly seen from Fig. 1 that

    the specic pore volume was sharply decreased when

    loading copper metal onto the support by the impreg-

    nation method and the curves are slightly right-shiftingwhen the copper loading increases, indicating that more

    smaller pores are blocked when increasing copper load-

    ings. In contrast, the curves for the electroless method,

    as shown in Fig. 2, are slightly left-shifting when the

    Fig. 2. Pore distribution for electroless catalysts.

    copper loading increases. This is due to the fact that

    copper was more uniformly plated on the wall of the

    pores by the electroless method. Expect for those ne

    pores which became blocked, the pore size of the non-

    blocked pores therefore becomes smaller when copper

    loading increases.

    Apart from the BET surface area, the copper particlesize also plays an important role in the catalysts activ-

    ity. Figures 3 and 4 are the SEM photos of the I15 cata-

    lyst and the fresh E15 catalyst, respectively. It is seen

    from these two gures that the electroless method pro-

    duces quite small ball-like copper catalysts whereas the

    impregnated methods forms much larger needle-like

    ones. Thus, the crystal type is quite dierent in the two

    preparation methods and the copper crystal size pre-

    pared by the electroless method is much smaller than

    that prepared by the impregnation method. Figure 5 is

    the SEM photo of calcined E15 catalyst. Comparing

    Figs 3 and 5 shows that even the calcined E15 catalystgives smaller crystals than the I15 catalyst.

    Figure 6 and 7 are the TPR proles of the six cata-

    lysts. The TPR experiments were conducted in a xed

    bed reactor from room temperature to 500C at a con-

    Fig. 3. SEM photo of I15 catalyst.

    Fig. 4. SEM photo of E15 catalyst.

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    Cu/SiO2

    catalyst prepared by electroless method 417

    Fig. 5. SEM photo of E15 catalyst with calcination.

    stant rate of 10C min~1. A mixture stream of H2

    /Ar

    (25%/75%) was introduced at 30 cm3 min~1 to reduce

    the calcined catalyst sample. The effluent stream wasanalyzed for hydrogen by a thermal conductivity detec-

    tor after removal of moisture by a molecular sieve trap.

    For both preparation methods; the TPR of each cata-

    lyst exhibited only one peak. This peak is attributed to

    the reaction:

    CuO]H2]Cu]H

    2O

    Both gures show that larger copper loadings have

    larger hydrogen consumption. However, comparing the

    two gures indicates that the reduction pattern is slight-

    ly dierent for the two types of catalysts. Firstly, the

    peak maxima of the impregnated catalysts are about

    50C higher than those of the electroless catalysts. Sec-

    Fig. 6. TPR spectra for impregnated catalysts.

    Fig. 7. TPR spectra for electroless catalysts.

    ondly, the TPR curves of the electroless catalysts are

    much sharper and narrower than those of the impreg-

    nated catalysts. Thirdly, as can be seen from Fig. 6,

    there are no real peak maxima for the I05 and I10 cata-

    lysts. These three points imply that the interaction

    between copper and the support for the two prep-

    aration methods are dierent and the electroless cata-

    lysts are easier to get reduction.The DSC analysis traces, recorded in the temperature

    range of room temperature up to 450C at a rate of

    10C min~1 for the impregnated and the electrolesscatalysts are given in Figs 8 and 9 respectively. In Fig.

    8, an endothermic peak was observed around 100C,

    indicating the dehydration of the impregnated catalysts.

    Starting from 230C to about 290C, a larger endo-

    thermic peak was observed. This peak represents the

    decomposition of copper salts and some kind of

    bonding formed between copper and support. Higher

    copper loadings give larger peaks. Above 300C, no

    peaks were observed, indicating that the impregnatedcatalysts are quite stable from 300 to 450C. For the

    electroless catalysts, as shown in Fig. 9, a similar endo-

    thermic peak was observed around 100C followed by a

    wide exothermic peak. The endothermic peak is the

    vaporization of water inside the catalyst and the exo-

    thermic peak represents the phase change of fresh elec-

    troless copper to copper oxides. Again, higher copper

    loadings present larger peaks. No endothermic peak at

    around 250C was observed for the electroless catalysts,

    indicating that the interaction between copper and

    support for the electroless catalysts may be dierent

    from that for the impregnation catalysts. This point

    seems quite similar to the TPR result.

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    418 C.-Y. Shiau, J. C . T sai

    Fig. 8. DSC spectra for impregnated catalysts.

    Catalyst activities

    Dehydrogenation of n-butanol is used as the test reac-

    tion for the catalysts activity. The catalysts loading was

    04 g and time factor was 47 g-cat h gmole~1. Experi-mental results show that all the catalysts dehydrogenate

    n-butanol into n-butyraldehyde and hydrogen. Only a

    Fig. 9. DSC spectra for electroless catalysts.

    Fig. 10. Reaction activity of 5% Cu catalysts.

    trace amount of heavy compounds was detected.

    Figures 1012 show the catalysts stabilities and activ-

    ities for the n-butanol dehydrogenation reaction. The

    calcined electroless copper catalysts are also included.

    Comparing these three gures reveals three interesting

    points. Firstly, higher copper loadings have better reac-

    tion activities and the electroless copper catalysts

    Fig. 11. Reaction activity of 10% Cu catalysts.

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    Cu/SiO2

    catalyst prepared by electroless method 419

    Fig. 12. Reaction activity of 15% Cu catalysts.

    present better performance for all copper loadings. Sec-

    ondly, all the impregnated catalysts are deactivated sig-

    nicantly, especially the I05 catalyst. In contrast, both

    E10 and E15 are quite stable during an 8 h reaction

    course. Thirdly, the calcined electroless copper catalysts

    show much better reaction activities than the fresh elec-

    troless copper catalysts. The higher activities of the cal-

    TABLE 2

    Carbon Content after Reaction

    Catalyst Carbon content (wt%)

    I05 632

    I10 545

    I15 498

    E05 242

    E10 114

    E15 081

    TABLE 3

    Surface Area Change after Reaction

    Catalyst BET surface area (m2 g~1)

    Fresh Used % change

    I05 2552 2222 [ 129I10 2415 2244 [ 71I15 2347 2274 [ 31E05 2644 2581 [ 24E10 2712 2685 [ 10

    E15 2785 2734 [ 18

    cined electroless copper catalysts may be attributed to

    the interaction between copper and support during cal-

    cination.

    Catalyst deactivation

    Coking and sintering problems which cause catalyst

    deactivation were also investigated in this study. For

    the coking problem, we used elemental analysis to

    determine the weight % of carbon present in the cata-

    lyst after an 8 h reaction at 270C, and for the sintering

    problem we used the BET method to determine the

    surface area change. Table 2 shows the result of elemen-

    tal analysis which indicates that all the catalysts have

    carbon deposition after undergoing the dehydroge-

    nation reaction. The weight percentage of carbon on the

    copper surface ranges from 081% to 632%. Table 2

    also shows that after the dehydrogenation reaction thecatalysts prepared by the electroless method have much

    less carbon deposition than the impregnated catalysts.

    The amount of carbon deposition for the electroless

    catalysts is much less than 40% of that for impregnated

    ones. Table 3 compares the BET surface area between

    the fresh and used catalysts. The fourth column in the

    table is the percentage change of the surface area after

    reaction. As can be seen from this result, the impreg-

    nated catalysts have a signicant sintering phenomenon

    while the degree of sintering is slight for the electroless

    catalysts. The percentage decrease in surface area for

    the electroless catalysts is about one-fth of that for the

    impregnated catalysts. Tables 2 and 3 clearly indicatewhy the electroless catalysts show better stability and

    activity than the impregnated catalysts do, as aforemen-

    tioned in the reaction performance results.

    CONCLUSIONS

    (1) All the characterization results show that the elec-

    troless deposition method provides more uniform

    copper distribution than the impregnation method.

    (2) Although the calcined electroless copper catalysts

    have larger copper particles, they exhibit better reac-tion activities than the fresh electroless catalysts.

    (3) The reaction activities are in the order of the cal-

    cined electroless copper catalyst[ the fresh electro-

    less copper catalyst[ the impregnated copper

    catalysts.

    ACKNOWLEDGEMENT

    This work was supported by the National Science

    Council of the Republic of China (NSC84-2214-E011-

    005).

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    420 C.-Y. Shiau, J. C . T sai

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