Nickel, catalyst carbonate

Appreciable quantities are also obtained as a by-product in the manufacture of hydrogen from naphtha-gaseous hydrocarbons. In this process the gaseous hydrocarbon and superheated steam under a pressure of about 10 atmospheres and at a temperature of 1000 K are passed over a nickel-chromium catalyst. Carbon monoxide and hydrogen are produced ... 

This reaction is an undesirable side reaction in the manufacture of hydrogen but utilised as a means of removing traces of carbon monoxide left at the end of the second stage reaction. The gases are passed over a nickel catalyst at 450 K when traces of carbon monoxide form methane. (Methane does not poison the catalyst in the Haber process -carbon monoxide Joes.)... 

When levuhnic acid (CH3CCH2CH2CO2H) was hydrogenated at high pressure over a nickel catalyst at 220°C a single product C5Hg02 was isolated in 94% yield This compound lacks hydroxyl absorption in its IR spectrum and does not immediately liberate carbon dioxide on being shaken with sodium bicarbonate What is a reasonable structure for the compound" ... 

Reppe s work also resulted in the high pressure route which was estabUshed by BASF at Ludwigshafen in 1956. In this process, acetylene, carbon monoxide, water, and a nickel catalyst react at about 200°C and 13.9 MPa (2016 psi) to give acryUc acid. Safety problems caused by handling of acetylene are alleviated by the use of tetrahydrofuran as an inert solvent. In this process, the catalyst is a mixture of nickel bromide with a cupric bromide promotor. The hquid reactor effluent is degassed and extracted. The acryUc acid is obtained by distillation of the extract and subsequendy esterified to the desked acryhc ester. The BASF process gives acryhc acid, whereas the Rohm and Haas process provides the esters dkecdy. 

Fischer-Tropsch Process. The Hterature on the hydrogenation of carbon monoxide dates back to 1902 when the synthesis of methane from synthesis gas over a nickel catalyst was reported (17). In 1923, F. Fischer and H. Tropsch reported the formation of a mixture of organic compounds they called synthol by reaction of synthesis gas over alkalized iron turnings at 10—15 MPa (99—150 atm) and 400—450°C (18). This mixture contained mostly oxygenated compounds, but also contained a small amount of alkanes and alkenes. Further study of the reaction at 0.7 MPa (6.9 atm) revealed that low pressure favored olefinic and paraffinic hydrocarbons and minimized oxygenates, but at this pressure the reaction rate was very low. Because of their pioneering work on catalytic hydrocarbon synthesis, this class of reactions became known as the Fischer-Tropsch (FT) synthesis. 

Methane. The largest use of methane is for synthesis gas, a mixture of hydrogen and carbon monoxide. Synthesis gas, in turn, is the primary feed for the production of ammonia (qv) and methanol (qv). Synthesis gas is produced by steam reforming of methane over a nickel catalyst. 

Thermodynamically, the formation of methane is favored at low temperatures. The equilibrium constant is 10 at 300 K and is 10 ° at 1000 K (113). High temperatures and catalysts ate needed to achieve appreciable rates of carbon gasification, however. This reaction was studied in the range 820—1020 K, and it was found that nickel catalysts speed the reaction by three to four orders of magnitude (114). The Hterature for the carbon-hydrogen reaction has been surveyed (115). 

Naphtha desulfurization is conducted in the vapor phase as described for natural gas. Raw naphtha is preheated and vaporized in a separate furnace. If the sulfur content of the naphtha is very high, after Co—Mo hydrotreating, the naphtha is condensed, H2S is stripped out, and the residual H2S is adsorbed on ZnO. The primary reformer operates at conditions similar to those used with natural gas feed. The nickel catalyst, however, requires a promoter such as potassium in order to avoid carbon deposition at the practical levels of steam-to-carbon ratios of 3.5—5.0. Deposition of carbon from hydrocarbons cracking on the particles of the catalyst reduces the activity of the catalyst for the reforming and results in local uneven heating of the reformer tubes because the firing heat is not removed by the reforming reaction. 

Nickel Oxalate. This salt, NiC204, mol wt 146.7, is produced as a greenish white crystalline dihydrate [6018-94-6]. It decomposes by heating at 320°C under vacuum into Ni metal and carbon dioxide. Nickel oxalate is used for the production of nickel catalysts and magnetic materials. 

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. 

Reaction with hydrogen at 220°C in the presence of reduced nickel catalyst results in total decomposition to hydrogen chloride and carbon. An explosive reaction occurs with butylUthium in petroleum ether solution (4). Tetrachloroethylene also reacts explosively with metallic potassium at its melting point, however it does not react with sodium (5). 

The first demonstration of catalytic conversion of synthesis gas to hydrocarbons was accompHshed ia 1902 usiag a nickel catalyst (42). The fundamental research and process development on the catalytic reduction of carbon monoxide was carried out by Fischer, Tropsch, and Pichler (43). Whereas the chemistry of the Fischer-Tropsch synthesis is complex, generalized stoichiometric relationships are often used to represent the fundamental aspects ... 

Fischer-Tropsch Synthesis The best-known technology for producing hydrocarbons from synthesis gas is the Fischer-Tropsch synthesis. This technology was first demonstrated in Germany in 1902 by Sabatier and Senderens when they hydrogenated carbon monoxide (CO) to methane, using a nickel catalyst. In 1926 Fischer and Tropsch were awarded a patent for the discovery of a catalytic technique to convert synthesis gas to liquid hydrocarbons similar to petroleum. 

Baker, R.T.K, Chemistry and physics of carbon, Marcel Dekker, New York, 14, 1978, Trimm, D.L., The formation and removal of coke from nickel catalyst, Catal. Rev. Sci. Eng., 1977, 16, 155 189. 

Effect of Catalyst The catalysts used in hydrotreating are molybdena on alumina, cobalt molybdate on alumina, nickel molybdate on alumina or nickel tungstate. Which catalyst is used depends on the particular application. Cobalt molybdate catalyst is generally used when sulfur removal is the primary interest. The nickel catalysts find application in the treating of cracked stocks for olefin or aromatic saturation. One preferred application for molybdena catalyst is sweetening, (removal of mercaptans). The molybdena on alumina catalyst is also preferred for reducing the carbon residue of heating oils. 

Replacement of halides with deuterium gas in the presence of a surface catalyst is a less useful reaction, due mainly to the poor isotopic purity of the products. This reaction has been used, however, for the insertion of a deuterium atom at C-7 in various esters of 3j -hydroxy-A -steroids, since it gives less side products resulting from double bond migration. Thus, treatment of the 7a- or 7j5-bromo derivatives (206) with deuterium gas in the presence of 5% palladium-on-calcium carbonate, or Raney nickel catalyst, followed by alkaline hydrolysis, gives the corresponding 3j3-hydroxy-7( -di derivatives (207), the isotope content of which varies from 0.64 to 1.18 atoms of deuterium per mole. The isotope composition and the stereochemistry of the deuterium have not been rigorously established. 

The operation of a large synthetic ammonia plant based on natural gas involves a delicately balanced sequence of reactions. The gas is first desulfurized to remove compounds which will poison the metal catalysts, then compressed to 30 atm and reacted with steam over a nickel catalyst at 750°C in the primary steam reformer to produce H2 and oxides of carbon ... 

Sufficient data are not yet available to allow evaluation of the relative merits of palladium-on-carbon and degassed Raney nickel catalysts. Comparable yields of 2,2 -biquinolines have been obtained by both methods under suitable conditions but the percentage conversions with degassed Raney nickel have been found to be much lower, reflecting the extent of side reactions with this catalyst. However, work in this laboratory has shown that the reaction of quinoline with palladium-on-carbon is not free from complications for example, at least three products in addition to 2,2 -biquinoline have been detected by paper chromatography. 

The chapter by Hausberger et al. deals with catalyst development, and the performance of several new high-nickel catalysts in bench-scale and large pilot tests with high carbon oxide concentrations. Kinetics of the reaction over these catalysts are developed. 

The chapter by Haynes et al. describes the pilot work using Raney nickel catalysts with gas recycle for reactor temperature control. Gas recycle provides dilution of the carbon oxides in the feed gas to the methanator, hence simulating methanation of dilute CO-containing gases which under adiabatic conditions gives a permissible temperature rise. This and the next two papers basically treat this approach, the hallmark of first-generation methanation processes. 

This paper surveys the field of methanation from fundamentals through commercial application. Thermodynamic data are used to predict the effects of temperature, pressure, number of equilibrium reaction stages, and feed composition on methane yield. Mechanisms and proposed kinetic equations are reviewed. These equations cannot prove any one mechanism however, they give insight on relative catalyst activity and rate-controlling steps. Derivation of kinetic equations from the temperature profile in an adiabatic flow system is illustrated. Various catalysts and their preparation are discussed. Nickel seems best nickel catalysts apparently have active sites with AF 3 kcal which accounts for observed poisoning by sulfur and steam. Carbon laydown is thermodynamically possible in a methanator, but it can be avoided kinetically by proper catalyst selection. Proposed commercial methanation systems are reviewed. 

Nickel. As a methanation catalyst, nickel is presently preeminent. It is relatively cheap, it is very active, and it is the most selective to methane of all the metals. Its main drawback is that it is easily poisoned by sulfur, a fault common to all the known active methanation catalysts. The nickel content of commercial nickel catalysts is 25-77 wt %. Nickel is dispersed on a high-surface-area, refractory support such as alumina or kieselguhr. Some supports inhibit the formation of carbon by Reaction 4. Chromia-supported nickel has been studied by Czechoslovakian and Russian investigators. 

Catalyst Poisons. Hausberger, Atwood, and Knight (33) reported that nickel catalysts are extremely sensitive to sulfides and chlorides. If all materials which adversely affect the performance of a catalyst were classified as poisons, then carbon laydown and, under extreme conditions, water vapor would be included as nickel methanation catalyst poisons. 

These experiments were performed over a nickel catalyst, and it is speculated that the anomolous free energy of the deposited carbon may be attributable to the formation of a carbide or a solid solution. 

The methanation process commonly operates at pressures up to 30 atm, and, with the nickel catalyst which is almost universally used for the process, the inlet temperature is about 300°C ( 570°F). Almost complete conversion of the oxides of carbon occurs giving a product synthesis gas containing less than 5 ppm CO + C02. The temperature rise for the exothermic methanation reactions is typically 35 °C (63°F). 

Table III. Iron and Carbon Content of Raney Nickel Catalyst Grids after Experiment HGR-10...

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. 

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). 

Catalysts in an oxidized state showed high activity in the oxidation of carbon monoxide [nickel catalysts (146) ] and hydrogen [molybdenum catalysts (146a)]. 

At present, most commercial hydrogen is obtained as a by-product of petroleum refining in a sequence of two catalyzed reactions. The first is a re-forming reaction, in which a hydrocarbon and steam are converted into carbon monoxide and hydrogen over a nickel catalyst ... 

A hydrocarbon is 90% carbon by mass and 10% hydrogen by mass and has a molar mass of 40 g-mol It decolorizes bromine water, and 1.46 g of the hydrocarbon reacts with 1.60 L of hydrogen (measured at STP) in the presence of a nickel catalyst. Write the molecular formula of the hydrocarbon and the structural formulas of two possible isomers. 

A new comparison of the copper and nickel catalysts (Fig. 12) on the arylation of alcohols, using potassium carbonate as base, shows once again the superiority of the nickel catalyst (70 % against 40 % for the copper catalyst). 

This reaction is similar to 13-1 and, like that one, generally requires activated substrates. With unactivated substrates, side reactions predominate, though aryl methyl ethers have been prepared from unactivated chlorides by treatment with MeO in HMPA. This reaction gives better yields than 13-1 and is used more often. A good solvent is liquid ammonia. The compound NaOMe reacted with o- and p-fluoronitrobenzenes 10 times faster in NH3 at — 70°C than in MeOH. Phase-transfer catalysis has also been used. The reaction of 4-iodotoluene and 3,4-dimethylphenol, in the presence of a copper catalyst and cesium carbonate, gave the diaryl ether (Ar—O—Ar ). Alcohols were coupled with aryl halides in the presence of palladium catalysts to give the Ar—O—R ether. Nickel catalysts have also been used. ... 

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