Carbon formation catalyst

Carbon produced by these latter reactions is formed in the catalyst pores, making it much more difficult to remove, and potentially causing physical breakage. Operating steam to carbon ratios are chosen above the minimum required in order to make carbon formation by these reactions thermodynamically impossible (3). Steam is another potential source of contaminants. Chemicals from the boiler feedwater or the cooling system are poisons to the reformer catalyst, so steam quality must be carefully monitored. 

Dry reduced nickel catalyst protected by fat is the most common catalyst for the hydrogenation of fatty acids. The composition of this type of catalyst is about 25% nickel, 25% inert carrier, and 50% soHd fat. Manufacturers of this catalyst include Calsicat (Mallinckrodt), Harshaw (Engelhard), United Catalysts (Sud Chemie), and Unichema. Other catalysts that stiH have some place in fatty acid hydrogenation are so-called wet reduced nickel catalysts (formate catalysts), Raney nickel catalysts, and precious metal catalysts, primarily palladium on carbon. The spent nickel catalysts are usually sent to a broker who seUs them for recovery of nickel value. Spent palladium catalysts are usually returned to the catalyst suppHer for credit of palladium value. 

Steam reforming is the reaction of steam with hydrocarbons to make town gas or hydrogen. The first stage is at 700 to 830°C (1,292 to 1,532°F) and 15-40 atm (221 to 588 psih A representative catalyst composition contains 13 percent Ni supported on Ot-alumina with 0.3 percent potassium oxide to minimize carbon formation. The catalyst is poisoned by sulfur. A subsequent shift reaction converts CO to CO9 and more H2, at 190 to 260°C (374 to 500°F) with copper metal on a support of zinc oxide which protects the catalyst from poisoning by traces of sulfur. 

Rapoport s findings have been confirmed in the authors laboratory where the actions of carbon-supported catalysts (5% metal) derived from ruthenium, rhodium, palladium, osmium, iridium, and platinum, on pyridine, have been examined. At atmospheric pressure, at the boiling point of pyridine, and at a pyridine-to-catalyst ratio of 8 1, only palladium was active in bringing about the formation of 2,2 -bipyridine. It w as also found that different preparations of palladium-on-carbon varied widely in efficiency (yield 0.05-0.39 gm of 2,2 -bipyridine per gram of catalyst), but the factors responsible for this variation are not knowm. Palladium-on-alumina was found to be inferior to the carbon-supported preparations and gave only traces of bipyridine,... 

Rhodium-on-carbon has also been found to bring about the formation of 2,2 -biquinoline from quinoline, the yield and the percentage conversion being similar to that obtained with palladium-on-carbon. On the other hand, rhodium-on-carbon failed to produce 2,2 -bipyridine from pyridine, and it has not yet been tried with other bases. Experiments with carbon-supported catalysts prepared from ruthenium, osmium, iridium, and platinum have shown that none of these metals is capable of bringing about the formation of 2,2 -biquinoline from quinoline under the conditions used with palladium and rhodium. ... 

Lu has demonstrated that cyclic carbonate formation can dominate over polymer formation at much lower C02 pressures when the (salen)Co-OTs catalyst 24 and... 

Two other components, methanol and benzene, were included in this study. Methanol is important in processes using Rectisol Systems for C02 removal prior to methanation. Benzene was considered in order to determine the effect of aromatics on catalyst activity and potential carbon formation. 

There is no separate shift conversion system and no recycle of product gas for temperature control (see Figure 1). Rather, this system is designed to operate adiabatically at elevated temperatures with sufficient steam addition to cause the shift reaction to occur over a nickel catalyst while avoiding carbon formation. The refractory lined reactors contain fixed catalyst beds and are of conventional design. The reactors can be of the minimum diameter for a given plant capacity since the process gas passes through once only with no recycle. Less steam is used than is conventional for shift conversion alone, and the catalyst is of standard ring size (% X %= in). 

Various design and operating problems have been experienced by most developers of methanation systems. Specifically, carbon formation and catalyst sintering are two of the more common problems in methanation processes. Carbon formation refers to the potential production of carbon from carbon oxides and methane by the following reactions. 

G. A. White We have done some experimental work on impregnating catalyst with potash, and, in fact, potash has been used in related fields to inhibit carbon formation primarily from hydrocarbons. We find that the mechanism of carbon formation from hydrocarbons is quite different from that from syngas. So an agent that is effective in reducing the formation of carbon from one source can be quite different with that from another source. You have to be a little bit specific in terms of the feed material from which you are trying to prevent carbon formation. 

The steam reforming catalyst is very robust but is threatened by carbon deposition. As indicated in Fig. 8.1, several reactions may lead to carbon (graphite), which accumulates on the catalyst. In general the probability of carbon formation increases with decreasing oxidation potential, i.e. lower steam content (which may be desirable for economic reasons). The electron micrograph in Fig. 8.4 dramatically illustrates how carbon formation may disintegrate a catalyst and cause plugging of a reactor bed. 

Figure 8.4. Transmission electron microscope picture of carbon formation and filament growth on a Si02-supported Ni catalyst after exposure to a CH4 + H2 gas mixture at 1 bar...

It is important to note that the selectivity of sulfur-passivated catalysts towards steam reforming is greatly enhanced because carbon formation is effectively suppressed. The decrease in activity can to largely be compensated for by selecting inherently more active catalysts and by operating at higher temperatures. Unfortun-... 

The activity and stability of catalysts for methane-carbon dioxide reforming depend subtly upon the support and the active metal. Methane decomposes to carbon and hydrogen, forming carbon on the oxide support and the metal. Carbon on the metal is reactive and can be oxidized to CO by oxygen from dissociatively adsorbed COj. For noble metals this reaction is fast, leading to low coke accumulation on the metal particles The rate of carbon formation on the support is proportional to the concentration of Lewis acid sites. This carbon is non reactive and may cover the Pt particles causing catalyst deactivation. Hence, the combination of Pt with a support low in acid sites, such as ZrO, is well suited for long term stable operation. For non-noble metals such as Ni, the rate of CH4 dissociation exceeds the rate of oxidation drastically and carbon forms rapidly on the metal in the form of filaments. The rate of carbon filament formation is proportional to the particle size of Ni Below a critical Ni particle size (d<2 nm), formation of carbon slowed down dramatically Well dispersed Ni supported on ZrO is thus a viable alternative to the noble metal based materials. 

As the metal particle size decreases the filament diameter should also decrease. It has been shown that the surface energy of thirmer filaments is larger and hence the filaments are less stable (11,17-18). Also the proportion of the Ni(l 11) planes, which readily cause carbon formation, is lower in smaller Ni particles (19). Therefore, even though the reasons are diverse, in practice the carbon filament formation ceases with catalysts containing smaller Ni particles. Consequently, well dispersed Ni catalysts prepared by deposition precipitation of Ni (average metal particle size below 2-3 nm) were stable for 50 hours on stream and exhibited no filamentous coke [16]. 

The anchoring and the reduction methods of precious metal precursors influence the particle size, the dispersion and the chemical composition of the catalyst. The results of SEM and H2 chemisorption measurements are summarised in Table 3. The XPS measurements indicate that the catalysts have only metallic Pd phase on their surface. The reduction of catalyst precursor with sodium formate resulted in a catalyst with lower dispersion than the one prepared by hydrogen reduction. The mesoporous carbon supported catalysts were prepared without anchoring agent, this explains why they have much lower dispersion than the commercial catalyst which was prepared in the presence of a spacing and anchoring agent (15). 

Barnett et al. [AIChE J., 7 (211), 1961] have studied the catalytic dehydrogenation of cyclohexane to benzene over a platinum-on-alumina catalyst. A 4 to 1 mole ratio of hydrogen to cyclohexane was used to minimize carbon formation on the catalyst. Studies were made in an isothermal, continuous flow reactor. The results of one run on 0.32 cm diameter catalyst pellets are given below. 

On the surface of the Ni catalyst, carbon is normally produced in a whisker (or filamentous) form. According to Rostrup-Nielsen, carbon formation is avoided when the concentration of carbon dissolved in Ni crystal is smaller than that at the equilibrium. The steady-state activity is proportional to [C ], which can be expressed by the following equation ... 

Another important factor affecting carbon deposition is the catalyst surface basicity. In particular, it was demonstrated that carbon formation can be diminished or even suppressed when the metal is supported on a metal oxide carrier with a strong Lewis basicity [47]. This effect can be attributed to the fact that high Lewis basicity of the support enhances the C02 chemisorption on the catalyst surface resulting in the removal of carbon (by surface gasification reactions). According to Rostrup-Nielsen and Hansen [12], the amount of carbon deposited on the metal catalysts decreases in the following order ... 

The catalysts supports and promoters have a significant effect on the rate of carbon deposition. In particular, Zr02 has been widely used as a support for Pt because of the lower rate of carbon deposition compared to other supports [48]. The authors demonstrated the following order of the carbon formation rate ... 

Alstrup, I. and Tavares, T., Kinetics of carbon formation from CH4-H2 on silica-supported nickel and Ni-Cu catalysts, /. Catal., 139, 513,1993. 

FIGURE 4.1 Possible modes of carbon formation during FTS on cobalt catalysts. 

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