Methanation Nickel carbonyl formation

Nickel catalysts were used in most of the methanation catalytic studies they have a rather wide range of operating temperatures, approximately 260°-538°C. Operation of the catalytic reactors at 482°-538°C will ultimately result in carbon deposition and rapid deactivation of the catalysts (10). Reactions below 260°C will usually result in formation of nickel carbonyl and also in rapid deactivation of the catalysts. The best operating range for most fixed-bed nickel catalysts is 288°-482 °C. Several schemes have been proposed to limit the maximum temperature in adiabatic catalytic reactors to 482°C, and IGT has developed a cold-gas recycle process that utilizes a series of fixed-bed adiabatic catalytic reactors to maintain this temperature control. 

Nickel, cobalt, and iron catalysts are cmnmonly used for the Fischer-Tropsch s thesis. Nickel catalysts have been prepared by precipitation from a nitrate solution with potassium carbonate in the presence of thoria and kieselguhr in the proportions lOONiilSThOzilOO kieselguhr. It is not desirable to employ nickel catalysts at low temperatures and elevated pressures because the formation of nickel carbonyl is excessive. In the temperature range of 170-220°C at. low pressures, both liquid and gaseous products are obtained. As the temperature is increased to 300-350°C and the pressure increased to 300-400 psi, nickel catalysts produce only methane. Thus, these catal nsts can be used for making a gas from coal comparable in heating value to natural gas. 

Another reason of the surface enrichments or loss is the formation of volatile compounds of a certain component of catalysts with reactants. For example, nickel can react with carbon monoxide in reactants to form the volatile and thermally unstable nickel carbonyl, which escapes gradually from the catalyst surface. The activated carbon supported ruthenium-based catalysts also loses obviously part of itself due to the volatilization of ruthenium oxides or the occurrence of methanation reactions of the activated carbon. 

Sabatier was first attracted to the use of nickel as a catalyst when he saw details of the newly introduced Mond process, in which nickel metal was purified by the formation and decomposition of nickel carbonyl. The fact that nickel combined with gaseous carbon monoxide suggested thM other unsatuiated molecules might react in a similar way. Sabatier later described the methanation... 

Within the reaction parameters used, the nickel catalyst is highly selective towards carbonylation. With the exception of trace a-mounts of methane formed, no other hydrogenation product is found. This is in contrast with cobalt whose carbonylation catalytic activity is enhanced by hydrogen but generally associated with aldehyde formation and homologation. 

In addition to the successful reductive carbonylation systems utilizing the rhodium or palladium catalysts described above, a nonnoble metal system has been developed (27). When methyl acetate or dimethyl ether was treated with carbon monoxide and hydrogen in the presence of an iodide compound, a trivalent phosphorous or nitrogen promoter, and a nickel-molybdenum or nickel-tungsten catalyst, EDA was formed. The catalytst is generated in the reaction mixture by addition of appropriate metallic complexes, such as 5 1 combination of bis(triphenylphosphine)-nickel dicarbonyl to molybdenum carbonyl. These same catalyst systems have proven effective as a rhodium replacement in methyl acetate carbonylations (28). Though the rates of EDA formation are slower than with the noble metals, the major advantage is the relative inexpense of catalytic materials. Chemistry virtually identical to noble-metal catalysis probably occurs since reaction profiles are very similar by products include acetic anhydride, acetaldehyde, and methane, with ethanol in trace quantities. 

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