In situ electrochemical regeneration of deactivated coated foam catalysts in a Robinson–Mahoney basket reactor: Example of Pd/C for nitrobenzene hydrogenation

The adsorption of nitrobenzene over an alumina-supported palladium catalyst: an infrared spectroscopic study

As part of an on-going programme of development of an aniline synthesis catalyst suitable for operation at elevated temperatures, the geometry of the adsorption complex for nitrobenzene on a 5 wt% Pd/Al2O3 catalyst is investigated by infrared (IR) spectroscopy. Via an appreciation of the reduced site symmetry resulting from adsorption, application of the metal surface selection rule, and observation of in-plane modes only, the adsorption complex (Pd-nitrobenzene) at 28 °C is assigned as occurring vertically or tilted with respect to the metal surface, adopting Csσv(yz) symmetry. Moreover, adsorption occurs via a single Pd-O bond. Single molecule DFT calculations and simulated IR spectra assist vibrational assignments but indicate a parallel adsorption geometry to be energetically favourable. The contradiction between calculated and observed structures is attributed to the DFT calculations corresponding to an isolated molecule adsorption complex, while IR spectra relate to multi molecule adsorption that is encountered during sustained catalytic turnover. Residual hydrogen from the catalyst reduction stage leads to aniline formation on the Pd surface at low nitrobenzene coverages but, on increasing nitrobenzene exposure, the aniline is forced on to the alumina support. A reaction scheme is proposed whereby the nitrobenzene adsorption geometry is inherently linked to the high aniline selectivity observed for Pd/Al2O3 catalysts.

Toward High Selectivity Aniline Synthesis Catalysis at Elevated Temperatures

In connection with an initiative to enhance heat recovery from the large-scale operation of a heterogeneously catalyzed nitrobenzene hydrogenation process to produce aniline, it is necessary to operate the process at elevated temperatures (>100 °C), a condition that can compromise aniline selectivity. Alumina-supported palladium catalysts are selected as candidate materials that can provide sustained aniline yields at elevated temperatures. Two Pd/Al₂O₃ catalysts are examined that possess comparable mean Pd particle sizes (∼5 nm) for different Pd loading: 5 wt % Pd/Al₂O₃ and 0.3 wt % Pd/Al₂O₃. The higher Pd loading sample represents a reference catalyst for which the Pd crystallite morphology has previously been established. The lower Pd loading technical catalyst more closely corresponds to industrial specifications. The morphology of the Pd crystallites of the 0.3 wt % Pd/Al₂O₃ sample is explored by means of temperature-programmed infrared spectroscopy of chemisorbed CO. Reaction testing over the range of 60–180 °C shows effectively complete nitrobenzene conversion for both catalysts but with distinction in their selectivity profiles. The low loading catalyst is favored as it maximizes aniline selectivity and avoids the formation of overhydrogenated products. A plot of aniline yield as a function of WHSV for the 0.3 wt % Pd/Al₂O₃ catalyst at 100 °C yields a “volcano” like curve, indicating aniline selectivity to be sensitive to residence time. These observations are brought together to provide an indication of an aniline synthesis catalyst specification suited to a unit operation equipped for enhanced heat transfer.

Structured Ni–B amorphous alloy catalysts on Ni foam for a gas–liquid–solid microreactor

In this work, structured Ni–B amorphous alloy catalysts on Ni foam (termed as Ni–B/Ni foam catalysts) were proposed for nitrobenzene catalytic hydrogenation by a facile and effective electroless plating technique.

A New Concept of Stirred Multiphase Reactor Using a Stationary Catalytic Foam

Developing new stirred gas–liquid–solid reactors with high mass transfer capabilities is still a challenge. In this publication, we present a new concept of multiphase reactor using a stationary catalytic foam and a gas-inducing impeller. The gas–liquid (GL) and liquid–solid (LS) mass transfer rates in this reactor were compared to a stirred reactor with basket filled with beads. Batch absorption of hydrogen and measurement of α-methylstyrene hydrogenation rate on Pd/Al2O3 catalyst were used to evaluate kGLaGL coefficients and kLS coefficients, respectively. With similar LS transfer rates to the basket-reactor and much higher GL transfer rates, the new reactor reveals a very promising tool for intrinsic kinetics investigations.