Doped Ni/Al Catalyst for Nitro-Compound Hydrogenation
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Solution Overview
Problem
Existing activated Ni catalysts used for hydrogenation of nitro-compounds face issues with the formation of nickel aluminates, such as takovite, which lead to safety hazards, productivity drops, and catalyst deactivation due to leachable aluminum content, despite efforts to reduce aluminum levels through alloy composition and activation processes.
Innovation Solution
Doping the Ni/Al alloy with elements like Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Pt, Cu, Ag, and Bi before or after activation, with average particle sizes below 25 μm, to minimize takovite formation by reducing aluminum leachability and enhancing catalyst stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum content in Ni catalyst is reduced to prevent nickel aluminate formation, then safety hazards and productivity drops are minimized, but catalyst activity and stability deteriorate
Solution Approach 1:
The patent changes the chemical composition parameters by introducing doping elements (Fe, Cr, Mn, Co, Ni, Cu, Zn, Mo, Pd, Pt) in controlled amounts (0.1-5.0 wt%) to modify the catalyst's properties. This allows maintaining lower aluminum content (3-15 wt%) while preserving catalytic activity through the synergistic effects of the doping elements on the Ni-Al alloy structure
Solution Approach 2:
The patent creates a composite catalyst system by combining Ni-Al alloy with multiple doping elements that form a complex multi-component material. This composite structure prevents nickel aluminate formation while maintaining catalytic activity, as the doping elements modify the surface properties and electronic structure of the catalyst
2Object-generated harmful factors
If aluminum content in Ni catalyst is reduced, then takovite formation is minimized, but catalyst stability deteriorates
Solution Approach 1:
The patent modifies the compositional parameters by adding doping elements that alter the thermodynamic stability of the catalyst system. These elements (particularly Fe, Cr, and Mo) form stable oxides and modify the surface chemistry, preventing takovite formation while enhancing overall catalyst stability even at reduced aluminum levels
3Object-generated harmful factors
If aluminum content in Ni catalyst is reduced, then nickel aluminate formation is minimized, but leachable aluminum content increases
Solution Approach 1:
The patent changes the chemical environment by introducing doping elements that alter the leaching behavior of aluminum. Elements like Fe and Cr form protective surface layers and modify the electrochemical potential, reducing aluminum solubility and leachability while preventing nickel aluminate formation in the reaction medium
4Reliability
If doping elements are added to Ni/Al alloy, then takovite formation is reduced and catalyst stability is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent optimizes the doping element concentrations within specific ranges (0.1-5.0 wt% for most elements) to achieve the desired effect without excessive complexity. This controlled parameter adjustment maintains manageable alloy composition while effectively reducing takovite formation and improving stability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The approach significantly reduces takovite formation, improves catalyst stability, and maintains high activity, allowing for efficient hydrogenation of nitro-compounds while minimizing the risks associated with nickel aluminates, even at lower aluminum content levels.
Implementation Method 1
Doping the Ni/Al alloy with elements like Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Pt, Cu, Ag, and Bi before or after activation
Implementation Method 2
The activated catalyst powder is pyrophoric and stored under water or organic solvents or is embedded in organic compounds (e.g., distearylamine) which are solid at room temperature
Implementation Method 3
its use for the hydrogenation of nitro-compounds
Data Source
AI summary
Nitro-compounds are hydrogenated with an activated Ni catalyst that has an average particle size (APS) less than 25 μm and is doped with one or more elements from the list of Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Pt, Cu, Ag, Au and Bi via its/their addition to the alloy before activation and/or doped with one or more elements from the list of Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Ni, Cu, Ag, Au and Bi by their adsorption onto the surface of the activated catalyst. This invention also includes the hydrogenation of nitro-compounds with an activated Ni catalyst that has and APS less than 20 μm and is doped with one or more elements from the list of Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Tr, Pt, Pd, Mo, Cu, Ag, Au and Bi via its/their addition to the alloy before activation and/or doped with one or more elements from the list of Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Ni, Cu, Pd, Pt, Mo, Ag, Au and Bi by their adsorption onto the surface of the activated catalyst.