Supported Nickel Catalyst Precursor for Petrochemical Resin Hydrogenation
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Solution Overview
Problem
Current hydrogenation catalysts for petrochemical resins have limitations in catalytic activity, particularly in terms of thermal and oxidative stability, which affects the performance of aromatic polymers produced from C9 fractions during distillation of naphtha cracking.
Innovation Solution
A supported nickel catalyst precursor comprising Ni, Si, and Al, with specific porosity characteristics, is developed through a process involving the preparation of aqueous solutions with bases, nickel, aluminum, and silicon compounds, followed by precipitation and calcination, resulting in a catalyst with enhanced mesoporosity and BET surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional nickel catalysts are used for hydrogenation of petrochemical resins, then the catalyst provides basic catalytic activity, but the catalytic activity and reaction rate are insufficient
Solution Approach 1:
The patent applies porous materials by carefully controlling the pore structure of the catalyst support (SiO2-Al2O3) to achieve optimal porosity and surface area. The support is designed with specific pore size distributions and volumes to enhance mass transfer of reactants to active sites while maintaining structural stability under thermal and oxidative conditions, thereby improving both catalytic activity and reliability
Solution Approach 2:
The patent uses composite materials by combining nickel metal particles with a SiO2-Al2O3 mixed oxide support system. This composite structure leverages the high catalytic activity of nickel while the mixed oxide support provides thermal stability, mechanical strength, and controlled porosity, achieving synergistic effects that improve both productivity and reliability
2Productivity
If the catalyst support porosity is increased to improve mass transfer, then the catalytic activity increases, but the mechanical strength and stability of the catalyst structure decreases
Solution Approach 1:
The patent applies parameter changes by optimizing key parameters including the SiO2/Al2O3 ratio in the support, pore size distribution (with specific focus on mesopores), surface area, and nickel loading. These parameters are carefully adjusted to achieve the optimal balance between mass transfer (productivity) and mechanical strength, with the mixed oxide support providing structural integrity even at higher porosity levels
3Reliability
If the hydrogenation reaction is performed to remove double bonds, then the thermal and oxidative stability of petrochemical resins is improved, but the reaction requires highly active catalysts that are difficult to prepare
Solution Approach 1:
The patent applies preliminary action by pre-forming the optimized SiO2-Al2O3 mixed oxide support structure before nickel deposition. The support is prepared with controlled porosity, surface area, and chemical composition in advance, and then nickel is impregnated onto this pre-optimized support. This sequential approach simplifies the overall catalyst preparation process while ensuring the final catalyst has the required high activity for efficient hydrogenation
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 catalyst exhibits significantly improved activity in hydrogenation reactions, as evidenced by increased reaction rate constants and hydrogen adsorption capacity, leading to enhanced stability and performance of petrochemical resins.
Implementation Method 1
The invention relates to a supported nickel catalyst precursor comprising Ni, Si, Al, and O, preferably obtainable and/or obtained according to the process of any one of the embodiments disclosed herein
Implementation Method 2
followed by precipitation and calcination, resulting in a catalyst with enhanced mesoporosity and BET surface area
Implementation Method 3
The catalyst exhibits significantly improved activity in hydrogenation reactions, as evidenced by increased reaction rate constants and hydrogen adsorption capacity
Implementation Method 4
a use thereof in a hydrogenation reaction of aromatic compounds
Data Source
AI summary
The present invention relates to a supported nickel catalyst precursor comprising Ni, Si, Al, and O, wherein the catalyst precursor displays a specific total intrusion volume determined via Hg intrusion. Further, the present invention relates to a process for preparing said catalyst precursor. Yet further, the present invention relates to a supported nickel catalyst prepared from the said catalyst precursor. In addition thereto, the present invention relates to a use thereof in a hydrogenation reaction of aromatic compounds.