Activated base metal catalysts
Nitro-compounds are hydrogenated with an activated Ni catalyst that has an average particle size (APS) less than 25 μm and is doped with one or more elements from the list of Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Pt, Cu, Ag, Au and Bi via its/their addition to the alloy before activation and/or doped with one or more elements from the list of Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Ni, Cu, Ag, Au and Bi by their adsorption onto the surface of the activated catalyst. This invention also includes the hydrogenation of nitro-compounds with an activated Ni catalyst that has and APS less than 20 μm and is doped with one or more elements from the list of Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Tr, Pt, Pd, Mo, Cu, Ag, Au and Bi via its/their addition to the alloy before activation and/or doped with one or more elements from the list of Mg, Ce, Ti, V, Nb, Cr, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Ni, Cu, Pd, Pt, Mo, Ag, Au and Bi by their adsorption onto the surface of the activated catalyst.
1. An activated catalyst comprising:
a) a Ni/Al alloy comprising Fe:
b) a doping element selected from the group consisting of Mo and Cu adsorbed onto the surface of said activated catalyst;
and wherein:
i) said activated catalyst is in the form of particles with an average particle size (APS) of less than 25 μm;
ii) each doping element in said activated catalyst is present at 0.01 wt % to 10 wt %; and
iii) Al is present in said activated catalyst at 0.05 wt% to 10 wt %.
2. The activated catalyst of claim 1 , wherein said Ni/Al alloy further comprises Cr or both Cr and Cu.
3. The activated catalyst of claim 1 , wherein said APS is less than 20 μm.
4. The activated catalyst of claim 1 , wherein the Ni/Al alloy is doped with Fe or a combination of Cr and Fe and has the doping element Mo adsorbed onto its surface.
5. The activated catalyst of claim 4 , wherein said APS is less than 20 μm.
6. The activated catalyst of claim 1 , wherein the Ni/Al alloy is doped with Fe or a combination of Cr and Fe and has the doping element Cu adsorbed onto its surface.
7. The activated catalyst of claim 6 , wherein said APS is less than 20 μm.
8. A method for the hydrogenation of a nitro-compound, comprising reacting said nitro-compound with hydrogen in the presence of the activated catalyst of claim 1 .
9. The method of claim 8 , wherein said nitro-compound is a nitrated aromatic.
10. The method of claim 9 , wherein the hydrogenation is carried out continuously.
11. The method of claim 8 wherein the APS of said activated catalyst is less than 20 μm.
12. The method of claim 8 , wherein the Ni/Al alloy of said activated catalyst is doped with Fe or a combination of Cr and Fe and has the doping element Mo adsorbed onto its surface.
13. The method of claim 12 , wherein said nitro-compound is a nitrated aromatic.
14. The method of claim 13 , wherein the hydrogenation is carried out continuously.
15. The method of claim 12 , wherein the APS of said activated catalyst is less than 20 μm.
16. The method of claim 15 , wherein said nitro-compound is a nitrated aromatic.
17. The method of claim 8 , wherein the Ni/Al alloy of said activated catalyst is doped with Fe or a combination of Cr and Fe and has the doping element Cu adsorbed onto its surface.
18. The method of claim 17 , wherein said nitro-compound is a nitrated aromatic.
19. The method of claim 18 , wherein the hydrogenation is carried out continuously.
20. The method of claim 17 , wherein the APS of said activated catalyst is less than 20 μm.
21. The method of claim 20 , wherein said nitro-compound is a nitrated aromatic.