Method for manufacturing catalysts with reduced attrition
The present invention discloses an inventive method for manufacturing a catalyst using alloy granules having a high-Ni content. The inventive method may include providing alloy granules comprising aluminum and nickel, and treating the alloy granules with an alkaline solution to form the catalyst. A content of the nickel in the alloy granules may be within a range of about 43 wt % to about 60 wt %. The alloy granules may have effective diameters within a range of about 1 mm to about 10 mm. The catalyst may have an attrition value of less than about 7.0%.
1. A catalyst formed by a method comprising providing alloy granules comprising aluminum and nickel, and treating the alloy granules with an alkaline solution comprising 1 wt % to 20 wt % sodium hydroxide to form the catalyst,
wherein a content of the nickel in the alloy granules is 53 wt % to 60 wt %,
wherein at least 40% of the aluminum from the alloy granules is leached upon treating with the alkaline solution,
wherein the catalyst exhibits an attrition value of less than 5.0%, and
wherein the catalyst comprises nickel and aluminum, and wherein a content of the nickel in the catalyst is about 57 wt % to about 75 wt %.
2. The catalyst of claim 1 , wherein the alloy granules have effective diameters within a range of about 1 mm to about 10 mm,
wherein effective diameter is a maximum size of square opening in a sieve mesh through which an irregular shaped granule may pass through, or the cross-sectional (circular) diameter of a cylindrical granule, or the diameter of a spherical granule.
3. A fixed bed sponge metal catalyst comprising the catalyst of claim 2 for a hydrogenation process.
4. A process for hydrogenation using the catalyst of claim 2 .
5. A process for producing 1,4 butanediol by hydrogenation using the catalyst of claim 2 .
6. A process for producing sorbitol by hydrogenation using the catalyst of claim 2 .
7. A fixed bed sponge metal catalyst comprising the catalyst of claim 1 for a hydrogenation process.
8. The catalyst of claim 1 , wherein the content of the nickel in the alloy granules is 53 wt %.
9. The catalyst of claim 1 , wherein the content of the nickel in the alloy granules is 53 wt % to 56 wt %.
10. The catalyst of claim 1 , wherein the alloy granules have effective diameters of about 2 mm to about 6 mm,
wherein effective diameter is a maximum size of square opening in a sieve mesh through which an irregular shaped granule may pass through, or the cross-sectional (circular) diameter of a cylindrical granule, or the diameter of a spherical granule.
11. The catalyst of claim 1 , wherein a concentration of the sodium hydroxide in the alkaline solution is 1 wt % to 15 wt %.
12. The catalyst of claim 1 , wherein a concentration of the sodium hydroxide in the alkaline solution is 1 wt % to 10 wt %.
13. The catalyst of claim 1 , wherein the alloy granules are treated with the alkaline solution at a temperature of about 20° C. to about 110° C.
14. The catalyst of claim 1 , further comprising promoting the catalyst using an additional process step chosen from:
a. treating the catalyst with a solution comprising a soluble salt of a metal selected from the group consisting of Mo, Cr, W, Cu, Fe, and mixtures of any two or more thereof, or
b. adding a component chosen from Mo, Cr, W, Cu, Fe, and mixtures of any two or more thereof in forming the alloy granules.
15. The catalyst of claim 1 , wherein a content of the nickel in the catalyst is about 60 wt % to about 70 wt %.
16. The catalyst of claim 1 , wherein the catalyst exhibits an attrition value of 3.0% or less.