Iron-ammonia catalysts poisons

Other substances decrease or annihilate, even in traces, the catalytic properties of iron. Such catalyst poisons had already been known as a nuisance in the catalytic oxidation of sulfur dioxide. With the ammonia catalysis several elements, particularly sulfur proved to be harmful, even in amounts of 4oo of one per cent. Chlorine, phosphorus and arsenic showed a similar behavior (30), just as certain metals, such as lead, tin and zinc. 

From a study of the mechanism of the poisoning action of water vapors mill oxygen on iron ammonia catalysts 21 and by making certain assumptions, Almquistsu has been able to calculate that in pure iron catalysts about one atom in two thousand is active toward ammonia synthesis, whereas in iron catalysts promoted by alumina about one atom in two hundred is active. This shows the remarkable added activity obtainable by the use of promoters. That the effect is complicated beyond any simple explanation is evidenced further by some of the results of Almquist and Black, These workers have shown that whereas an iron-alumina catalyst shows greater activity toward ammonia synthesis at atmospheric pressure than an iron catalyst containing both alumina and potassium oxide, the hitter catalyst is 50 per cent more active when the pressure is raised to 1(X) atmospheres. 

We can readily understand these setbacks today if we consider the high sensitivity of iron as an ammonia catalyst toward numerous catalyst poisons. In those early years, this fact was unknown to us. Specifically, no one suspected the harm which is done to the catalyst by substances such as sulfur and sulfur compounds. Even Haber had never discussed a catalyst poisoning by impurities, because he had been able, apparently to avoid the presence of catalyst poisons in his small scale experiments. 

Molybdenum In its pure form, without additions, it is the most efficient catalyst of all the easily obtainable and reducible substances, and it is less easily poisoned than iron. It catalyzes in another way than iron, insofar as it forms analytically easily detectable amounts of metal nitrides (about 9% nitrogen content) during its catalytic action, whereas iron does not form, under synthesis conditions, analytically detectable quantities of a nitride. In this respect, molybdenum resembles tungsten, manganese and uranium which all form nitrides during their operation, as ammonia catalysts. Molybdenum is clearly promoted by nickel, cobalt and iron, but not by oxides such as alumina. Alkali metals can act favorably on molybdenum, but oxides of the alkali metals are harmful. Efficiency, as pure molybdenum, 1.5%, promoted up to 4% ammonia. 

Hydrogen sulfide causes a permanent poisoning of iron catalysts. Methane does not poison ammonia catalysts under normal synthesis conditions. Equilibrium data (Browning, De Witt, and Emmett, 77 Browning and Emmett, 78) should be mentioned in this connection. 

With regard to the sulfur bound on the catalyst surface, differences exist between the various types of ammonia catalysts, especially between those that contain alkali and alkaline earth metals and those that are free of them. Nonpromoted iron and catalysts activated only with alumina chemisorb S2N2 and thiophene. When treated with concentrations that lie below the equilibrium for the FeS bond, a maximum of 0.5 mg of sulfur per m2 of inner surface or free iron surface is found this corresponds to monomolecular coverage [382], [383], The monolayer is also preserved on reduction with hydrogen at 620 °C, whereas FeS formed by treatment above 300 °C with high H2S concentrations is reducible as far as the monolayer. For total poisoning, 0.16-0.25 mg S/m2 is sufficient. Like oxygen, sulfur promotes recrystallization of the primary iron particle. 

J. H. de Boer (Staatsmijnen, Netherlands) Dr. C. Bokhovenstudied the poisoning action of on an iron catalyst for ammonia catalyst in the Staatsmijnen laboratories. He found that the radioactive C passed through very quickly (in the form of CH4) while the poisoning action (by the oxygen) was still in the catalyst bed. 

In 1920s, the studies on the catalysts for ammonia sjmthesis were performed sporadically in BASF, instead, the company mainly focused on the organic synthesis under high pressm-es and the new fields in heterogeneous catalysis. Dm-ing the development of ammonia synthesis catalysts, researchers provided valuable information about the dm-ability, thermal stability, sensitivity to poisons, and in particular to the concept of promoter. Mittasch smnmarized the roles of various additives as shown in Fig. 1.9. The hypothesis of successful catalyst is multi-component system proposed by Mittasch was confirmed to be very successful. Iron-chromium catalysts for water gas shift reaction, zinc hromium catalystfor methanol synthesis, bismuth iron catalysts for ammonia oxidation and iron/zinc/alkali catalysts for coal hydrogenation were successively developed in BASF laboratories. 

The active catalyst for the ammonia synthesis is alpha iron with small amounts of oxidic additives.. .. The quality of the final catalyst is crucially influenced by the activation process which is the reduction of magnetite to metallic iron. It is important to minimise the concentration of the reaction product water which is a catalyst poison. ... 

Remaining trace quantities of CO (which would poison the iron catalyst during ammonia synthesis) are converted back to CH4 by passing the damp gas from the scmbbers over a Ni methanation catalyst at 325° CO -t- 3H2, CRt -t- H2O. This reaction is the reverse of that occurring in the primary steam reformer. The synthesis gas now emerging has the approximate composition H2 74.3%, N2 24.7%, CH4 0.8%, Ar 0.3%, CO 1 -2ppm. It is compressed in three stages from 25 atm to 200 atm and then passed over a promoted iron catalyst at 380-450°C ... 

The goal of Haber s research was to find a catalyst to synthesize ammonia at a reasonable rate without going to very high temperatures. These days two different catalysts are used. One consists of a mixture of iron, potassium oxide. K20, and aluminum oxide. Al203. The other, which uses finely divided ruthenium, Ru. metal on a graphite surface, is less susceptible to poisoning by impurities. Reaction takes place at 450°C and a pressure of 200 to 600 atm. The ammonia... 

While chlorine is a poison for the ammonia synthesis over iron, it serves as a promoter in the epoxidation of ethylene over silver catalysts, where it increases the selectivity to ethylene oxide at the cost of the undesired total combustion to C02. In this case an interesting correlation was observed between the AgCl27Cl ratio from SIMS, which reflects the extent to which silver is chlorinated, and the selectivity towards ethylene oxide [16]. In both examples, the molecular clusters reveal which elements are in contact in the surface region of the catalyst. 

The character of the chemisorption of nitrogen can be also judged from the results of studies of ammonia synthesis kinetics at the reversible poisoning of the catalyst with water vapor (102,103). If a gas mixture contains water vapor, an adsorption-chemical equilibrium of adsorbed oxygen, hydrogen gas, and water vapor sets in on the iron catalyst. 

One strong point of SIMS is its ability to detect elements that are present in trace amounts, and as such the technique is highly suited to the detection of poisons on a catalyst caused by contaminants in the reactor feed. Chlorine, for example, poisons the iron catalyst used in ammonia synthesis because it suppresses the dissociation of nitrogen molecules. Plog et al. [18] used SIMS to show that chlorine impurities may coordinate to potassium promoters, as evidenced by a KCI2- signal, or to iron, visible by an FeCh- peak. The SIMS intensity ratio... 

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