Supported Raney Alloy Catalyst Embedded in Polymer
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Solution Overview
Problem
Raney nickel catalysts, despite their high catalytic activity, are challenging to use in fixed bed or fluidized bed reactions due to their powdery and inflammable nature, which limits their application and requires shaping to enhance their usability.
Innovation Solution
A supported catalyst is developed by embedding Raney alloy particles into an organic polymer material support, allowing for high active metal loading and utilization, with the catalyst being activated using a caustic aqueous solution to maintain activity and selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Raney nickel catalysts are used in powder form, then they have high catalytic activity, but they are inflammable and difficult to handle in fixed bed reactions
Solution Approach 1:
The patent embeds Raney alloy particles within an organic polymer material to form a supported catalyst. The polymer acts as a protective shell that contains the powdery Raney nickel, preventing it from being inflammable and difficult to handle, while still allowing catalytic reactions to proceed effectively. This resolves the contradiction by providing physical containment without sacrificing catalytic function.
2Ease of operation
If Raney nickel catalysts are shaped into fixed bed catalysts using conventional methods, then they become easier to handle, but the polymer may cover active sites or high-temperature calcination may sinter alloy particles
Solution Approach 1:
The patent employs a low-temperature shaping process using organic polymer materials that do not require high-temperature calcination. The polymer is processed at temperatures below those that would cause sintering of the alloy particles, and the polymer composition is selected to avoid covering active sites. This parameter change in processing temperature and material selection resolves the contradiction between ease of handling and maintenance of catalytic activity.
3Productivity
If high metal loading is achieved in supported catalysts, then productivity increases, but metal recovery becomes more difficult
Solution Approach 1:
The patent uses an organic polymer material as the support that can be easily discarded or processed after use, while the Raney alloy particles embedded within can be recovered through simple processing steps. The organic polymer does not form strong chemical bonds with the metal particles, allowing for easy separation and recovery of precious metals while maintaining high metal loading in the catalyst structure.
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 supported catalyst exhibits high activity and selectivity in reactions such as hydrogenation, dehydrogenation, and dehalogenation, with improved structural stability and ease of metal recovery, while avoiding the limitations of high-temperature calcination and polymer coverage issues.
Implementation Method 1
then dissolving the aluminum in the alloy with a strong caustic solution, leaving metallic nickel having a porous structure
Implementation Method 2
Raney alloy particles supported on the organic polymer material support, wherein substantially all of the Raney alloy particles are partially embedded into the organic polymer material support
Implementation Method 3
The activated, supported catalyst of the present invention in hydrogenation, dehydrogenation, amination, dehalogenation or desulfuration
Data Source
AI summary
A supported catalyst and preparation method thereof, the catalyst comprising an organic polymer material carrier and Raney alloy particles supported on the organic polymer material carrier, wherein substantially all of the Raney alloy particles are partially embedded in the organic polymer material carrier. The catalyst can be used in hydrogenation, dehydrogenation, amination, dehalogenation or desulfuration reactions.