Nickel Catalyst Production via Controlled Reduction
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Solution Overview
Problem
Existing methods for producing high surface area nickel catalysts face challenges such as impurities, particle agglomeration, and sintering, particularly in fluidized bed reactors, which limit the purity and reactivity of nickel metal particles.
Innovation Solution
A method involving calcining nickel(II)-containing particles in an oxidizing atmosphere and reducing them in a rotating or turning process at 275° C to 360° C to produce free-flowing particulate nickel metal (Ni(0)) without the use of water or steam, allowing for higher reductant concentrations and improved reactivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If sponge nickel catalyst is prepared by dissolving nickel in molten aluminum and leaching with aqueous base, then high surface area nickel catalyst is obtained, but aluminum and sodium impurities remain in the catalyst
Solution Approach 1:
The patent extracts nickel from nickel(II) salts by reducing Ni(II) to Ni(0) metal particles, removing the need for aluminum-based sponge nickel preparation and subsequent leaching processes that leave impurities. The nickel particles are generated directly in a controlled reduction atmosphere, extracting only the desired nickel metal without co-extraction of aluminum or sodium.
Solution Approach 2:
The patent employs an inert or controlled atmosphere during the reduction of nickel(II) particles to nickel metal, preventing oxidation and contamination that would occur in aqueous base leaching. This inert environment ensures high purity nickel particles are formed without introducing water-soluble impurities like sodium hydroxide residues.
2Area of stationary object
If finely divided nickel particles are produced for fluid bed operations, then high surface area is achieved, but particle sintering occurs at temperatures as low as 200° C.
Solution Approach 1:
The patent performs preliminary action by carefully controlling the reduction process to generate nickel particles with optimal size and surface area before they are exposed to high temperatures. The reduction is conducted in a controlled atmosphere that prevents premature sintering, and the resulting particles are then stable enough to withstand subsequent processing temperatures without significant agglomeration.
Solution Approach 2:
The patent applies parameter changes by carefully controlling temperature, atmosphere composition, and reduction rate to produce nickel particles with desired surface area while maintaining structural stability. The controlled reduction parameters prevent the formation of overly fine particles that would sinter easily, optimizing both surface area and thermal stability.
3Stability of the object's composition
If steam is added to fluidized bed process to minimize sintering, then particle stability is improved, but hydrogen utilization is limited and nickel quality decreases
Solution Approach 1:
The patent extracts the steam addition step from the fluidized bed process, performing reduction in a controlled atmosphere without steam. This eliminates the trade-off between particle stability and hydrogen utilization, allowing high concentrations of hydrogen to be used for efficient nickel particle formation without introducing water vapor that would limit hydrogen availability or reduce nickel quality.
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 method produces nickel catalysts with high surface area, reduced impurities, and enhanced reactivity, avoiding the limitations of traditional methods like fluidized bed reactors, resulting in a more efficient and effective hydrogenation catalyst.
Implementation Method 1
calcining first nickel(II)-containing particles in an atmosphere including oxidizing constituents to generate second nickel(II)-containing particles
Implementation Method 2
reducing the second nickel(II)-containing particles in a reducing atmosphere while rotating or turning the second nickel(II)-containing particles at about 275° C. to about 360° C. for a time sufficient to generate the particulate nickel metal (Ni(0))
Data Source
AI summary
The present invention relates to heterogeneous catalysts and methods of making and using the same. In various embodiments, the present invention provides a method of making a hydrogenation catalyst including particulate nickel metal (Ni(0)). The method includes calcining first nickel(II)-containing particles in an atmosphere including oxidizing constituents to generate second nickel(II)-containing particles. The method also includes reducing the second nickel(II)-containing particles in a reducing atmosphere while rotating or turning the second nickel(II)-containing particles at about 275° C. to about 360° C. for a time sufficient to generate the particulate nickel metal (Ni(0)), wherein the particulate nickel metal (Ni(0)) is free flowing.