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EP-4082663-B1 - MOLDED CATALYST, PRODUCTION METHOD FOR SAME, AND METHOD FOR PRODUCING CYCLIC KETONE USING SAME

EP4082663B1EP 4082663 B1EP4082663 B1EP 4082663B1EP-4082663-B1

Inventors

  • PARK, JI WON
  • ROW, KYOUNGHO
  • PARK, JIN WOO

Dates

Publication Date
20260506
Application Date
20210408

Claims (7)

  1. A method for producing a catalyst molded body, the method comprising: (a) producing a mixed powder comprising a catalyst powder and a binder; (b) producing a slurry by mixing a first aqueous solution with the mixed powder; and (c) obtaining a catalyst molded body by molding and heat-treating the slurry, wherein the catalyst powder is a mixture of magnesium oxide and aluminum oxide, wherein the binder comprises a calcium oxide in an amount of 1 to 20 parts by weight based on 100 parts by weight of the catalyst molded body.
  2. The method of claim 1, wherein the catalyst powder has a molar ratio (Mg/Al) of magnesium and aluminum of 1.0 to 5.0.
  3. The method of claim 1, wherein the first aqueous solution comprises alkali hydroxide in an amount of 0.1 to 1 part by weight based on 100 parts by weight of the catalyst molded body.
  4. A catalyst molded body produced according to any one of claims 1 to 3.
  5. A method for producing cyclic ketone, the method comprising: (i) preparing a reactant comprising non-cyclic ketone; and (ii) reacting the reactant with the catalyst molded body according to claim 4 in a reactor.
  6. The method of claim 5, wherein Step (ii) is performed by a batch-type or continuous-type process.
  7. The method of claim 5, after Step (ii), further comprising: (iii) isolating cyclic ketone from the product in Step (ii).

Description

[Technical Field] Provided are a catalyst, a production method thereof and a method for producing cyclic ketone using the same. [Background Art] Non-cyclic ketones such as acetone are in an overproduced state, and a technology for producing a high value-added material using the same has been developed. Among acetone derivatives, isophorone (IPH) is used as an intermediate, a solvent, and the like for various chemical products. Although various methods for producing isophorone in the related art have been introduced, a batch process using a homogeneous catalyst, which corresponds to the most common method, has a problem in that the process is complicated because an aldol condensation reaction is performed by mixing acetone and the catalyst, and then isophorone is produced by neutralization, filtration and distillation. Further, since the temperature is adjusted for each batch and waste is generated by the neutralized salt of the catalyst, a process cost is high. Although a technique for omitting the neutralization process using a solid heterogeneous catalyst that can be recovered has been attempted, this also has a problem in that it is difficult to recover the catalyst as particles become too small because a filtration process for recovering is essential, process conditions at each batch need to be controlled, and the mechanical strength of the catalyst is insufficient. Although applying a continuous process using a fixed-bed reactor enables isophorone to be continuously produced and the process to be simplified, catalysts in the related art have insufficient stability and mechanical strength, so as a reaction proceeds, the service life of the catalyst is drastically reduced, thereby making it difficult to produce a product. US 5 153 156 A discloses catalysts made from anionic clay materials, including a process of making catalyst pellets suitable to be used efficiently for diffusion sensitive reactions such as aldol condensation of acetone. KELKAR C.P ET AL: "Efficient Hydrotalcite-based catalyst for acetone condensation to [alpha]-isophorone-scale up aspects and process development" (XP093110572) relates to the commercial development of a catalyst derived from magnesium-aluminum hydrotalcite precursor with a unique sheet-like morphology with a goal of maximizing α-isophorone production. [Disclosure] [Technical Problem] An aspect of the present specification has been made in an effort to solve the above-described problems in the related art, and an object thereof is to provide a catalyst molded body having excellent mechanical strength and catalyst stability and a small amount of by-products produced, and a production method thereof. Another object thereof is to produce cyclic ketone by a simplified process using the above-described catalyst molded body, thereby reducing the amount of energy used in an isolation and purification process, extending an operation time, and improving the yield. [Technical Solution] According to an aspect of the present specification, provided is a method for producing a catalyst molded body, the method including: (a) producing a mixed powder including a catalyst powder and a binder; (b) producing a slurry by mixing a first aqueous solution with the mixed powder; and (c) obtaining a catalyst molded body by molding and heat-treating the slurry, wherein the catalyst powder is a mixture of magnesium oxide and aluminum oxide,wherein the binder comprises a calcium oxide in an amount of 1 to 20 parts by weight based on 100 parts by weight of the catalyst molded body. In an exemplary embodiment, the catalyst powder may have a molar ratio (Mg/Al) of magnesium and aluminum of 1.0 to 5.0. In an exemplary embodiment, the binder may include an organic binder in an amount of 0.1 to 4.5 parts by weight based on 100 parts by weight of the catalyst molded body. In an exemplary embodiment, the first aqueous solution may include alkali hydroxide in an amount of 0.1 to 1 part by weight based on 100 parts by weight of the catalyst molded body. Another aspect of the present specification provides a catalyst molded body produced by the above-described method for producing a catalyst molded body. Still another aspect of the present specification provides a method for producing cyclic ketone, the method including: (i) preparing a reactant including non-cyclic ketone; and (ii) reacting the reactant with the above-described catalyst molded body in a reactor. In an exemplary embodiment, Step (ii) may be performed by a batch-type or continuous-type process. In an exemplary embodiment, the method may further include: (iii) isolating cyclic ketone from the product in Step (ii) after Step (ii). [Advantageous Effects] According to an aspect of the present specification, it is possible to produce a catalyst molded body having excellent mechanical strength and catalyst stability and a small amount of by-products produced. According to another aspect, cyclic ketone can be produced by a simplified process using t