Manufacture of Raney Type Catalysts via Spray Deposition

摘要

Raney nickel catalyst is usually pre-pared by alloying nickel and alu-rninium, crushing the ingot to pow-cler and then leaching out the alu-minium with alkali to expose the [ nickel as a finely divided porous solid. The highly active material is then widely used as a slurry based catalyst for hydrogenation and reductive alkylation type reactions. This paper describes a spray deposition process developed at CERAM which pro-duces active nickel catalyst support-ed on a metal foil. This supported catalyst can be coiled orformed into a variety of different shapes suitable for use in efficient loop reaction ves-sels. A number of processing para-meters have been investigated in-cluding Substrate material, foil speed and thickness, melt and gas flow rate and coating thickness with full analy-sis of their effect on the physical properties of the final supported catalyst produced. It was found that in particular, the thickness of the sub-strate and the coating together with the melt flow rate, were keys to the performance of the supported catalyst. The optimised material had great flexibility with good overall coating activity, with an excellent bond between the coating and the Substrate. CERAM is the first to make these thin coatings and have applied for the patent on the process.