JP2016510687A - 二酸化炭素の存在下において炭化水素を改質するためのニッケルヘキサアルミネート含有触媒 - Google Patents
二酸化炭素の存在下において炭化水素を改質するためのニッケルヘキサアルミネート含有触媒 Download PDFInfo
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- JP2016510687A JP2016510687A JP2015560691A JP2015560691A JP2016510687A JP 2016510687 A JP2016510687 A JP 2016510687A JP 2015560691 A JP2015560691 A JP 2015560691A JP 2015560691 A JP2015560691 A JP 2015560691A JP 2016510687 A JP2016510687 A JP 2016510687A
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- hexaaluminate
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- 239000003054 catalyst Substances 0.000 title claims abstract description 195
- 229910052759 nickel Inorganic materials 0.000 title claims abstract description 132
- 238000002407 reforming Methods 0.000 title claims abstract description 74
- 229930195733 hydrocarbon Natural products 0.000 title claims abstract description 35
- 150000002430 hydrocarbons Chemical class 0.000 title claims abstract description 35
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 title claims abstract description 34
- 239000001569 carbon dioxide Substances 0.000 title claims abstract description 17
- 229910002092 carbon dioxide Inorganic materials 0.000 title claims abstract description 17
- 239000002245 particle Substances 0.000 claims abstract description 74
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 42
- 150000001768 cations Chemical class 0.000 claims abstract description 30
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 29
- 239000011229 interlayer Substances 0.000 claims abstract description 29
- 239000000203 mixture Substances 0.000 claims abstract description 29
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- 229910052712 strontium Inorganic materials 0.000 claims abstract description 25
- 239000002184 metal Substances 0.000 claims abstract description 22
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 19
- 238000004519 manufacturing process Methods 0.000 claims abstract description 16
- 150000003839 salts Chemical class 0.000 claims abstract description 11
- RKTYLMNFRDHKIL-UHFFFAOYSA-N copper;5,10,15,20-tetraphenylporphyrin-22,24-diide Chemical compound [Cu+2].C1=CC(C(=C2C=CC([N-]2)=C(C=2C=CC=CC=2)C=2C=CC(N=2)=C(C=2C=CC=CC=2)C2=CC=C3[N-]2)C=2C=CC=CC=2)=NC1=C3C1=CC=CC=C1 RKTYLMNFRDHKIL-UHFFFAOYSA-N 0.000 claims abstract description 8
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- 238000006243 chemical reaction Methods 0.000 claims description 12
- 238000002441 X-ray diffraction Methods 0.000 claims description 10
- VXAUWWUXCIMFIM-UHFFFAOYSA-M aluminum;oxygen(2-);hydroxide Chemical compound [OH-].[O-2].[Al+3] VXAUWWUXCIMFIM-UHFFFAOYSA-M 0.000 claims description 10
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- 238000012360 testing method Methods 0.000 description 8
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- ATRRKUHOCOJYRX-UHFFFAOYSA-N Ammonium bicarbonate Chemical compound [NH4+].OC([O-])=O ATRRKUHOCOJYRX-UHFFFAOYSA-N 0.000 description 2
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- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 2
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- AOPCKOPZYFFEDA-UHFFFAOYSA-N nickel(2+);dinitrate;hexahydrate Chemical compound O.O.O.O.O.O.[Ni+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O AOPCKOPZYFFEDA-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/83—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with rare earths or actinides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/02—Boron or aluminium; Oxides or hydroxides thereof
- B01J21/04—Alumina
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/002—Mixed oxides other than spinels, e.g. perovskite
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Abstract
Description
製造工程が以下の工程:
(i)ナノ粒子状アルミニウムオキシドヒドロキシド源と、La、Sr及びBaからなる群からの元素を含む金属塩及びニッケル塩をも接触させる工程であって、
ニッケル含有量が3mol%以下、好ましくは2.5mol%以下、及び、より好ましくは2mol%以下であり、
アルミニウムに対する層間カチオンのモル比が、1:6〜11、好ましくは1:7〜10及び、特に好ましくは1:8〜10である工程と、
(ii)出発成分を均質に混合する工程と、
(iii)少なくとも乾燥させ、塩を分解し、及び/又は混合物を成形する工程と、
(iV)900℃以上の温度で焼成する工程と、還元工程と、を含む
炭化水素及びCO2改質用の本発明の触媒の製造方法も提供する。
本発明の触媒を製造するための工程で使用される。
本発明はまた、CO2の存在の下での炭化水素、好ましくはメタンの改質方法を提供する。
(a.1)炭化水素、好ましくはメタン、及びCO2を含む改質ガスと、本発明の開示によるニッケルヘキサアルミネート含有触媒を接触させる工程と、
(a.2)改質ガスと接触している触媒を、800℃を超える温度で、及び、より好ましくは850℃を超える温度で加熱する工程と、
(a.3)反応を行う一方で、5バールを超える処理圧力で、好ましくは10バールを超える処理圧力で、及び、より好ましくは15バールを超える処理圧力で反応器を運転させる工程と、
(a.4)改質ガスを、500〜20000hr−1の範囲、好ましくは1500〜10000hr−1の範囲、及び、より好ましくは2000〜5000hr−1の範囲のGHSVで該触媒と接触させる工程と、
を含むことを特徴とするCO2の存在下における炭化水素、好ましくはメタンの改質方法。
表1には、実施例の方法によって製造された一連の16の試料の概要と、それらの組成と特徴のデータを示す。化学組成のために報告された数値は、Al、Ni、及びLa、Sr、Baからなる群からの少なくとも一個の他の元素のモル比に基づく。試料の番号付けにおいて、その中に存在する元素に応じて、それぞれの試料に文字L、S又はBが加えられる。試料L1〜L4は、1600℃の温度で焼成され、他の全ての試料(すなわち、L5〜L8、S1〜S4及びB1〜B4)は1200℃の温度で焼成された。
還元状態の試料S4、B3及びB2を、透過型電子顕微鏡によってより詳しく特性評価をした。試料に還元処理工程を施した後に、試料にTEMによる特性評価を行った。この特性評価の結果を図1〜3に示し、以下に論じた。
顕微鏡写真は、そのような粒子の数が、酸化物ヘキサアルミネート中のニッケルの割合が増加するにつれて増加し、大きなニッケル粒子は、ヘキサアルミネートプレートレット上で、もっぱら強くざらざらした状態で成長しないということを示す。特に、そのような大きなニッケル粒子は、Ni0.25のニッケル含有量又は1.92mol%の上で発生する。
触媒の特性評価のために、活性組成物を循環型反応器内で試験した。試験をした試料を、シリコンカーバイドで希釈し、それぞれの場合、20mgの試料を、それぞれの場合、80mgのシリコンカーバイド中に混合した。その研究を、粒径が500〜750μmの範囲の試料を使用して行った。その研究で使用されるシリコンカーバイドは、試験される触媒試料として同一の粒径、すなわち、500〜750μmの範囲の粒径のフラクション
を有する。触媒試料とシリコンカーバイドのそれぞれの試験混合物を、6mmの内径を有する反応器管に入れた。1mmの壁厚を有し、アルミニウムオキシドセラミックからなる反応器管を、8mmの内径を有する鋼鉄製反応器の中に挿入した。反応器管と鋼鉄製反応器の寸法が合っているので、ガスは、セラミック製反応器の壁と鋼鉄製反応器の壁の間を移動することはできなかった。
実施例で調査された全ての触媒試料の物理的特性評価を、XRD分析、窒素収着測定、バルク密度測定によって行った。XRD分析を、CuK−α源(40kV及び40mAで0.154nmの波長を有する)を使用し、Bruker/AXS製のD8アドバンスシリーズ2を使用して行った。測定を測定範囲:5〜80°(2シータ)、4.8秒/ステップで0.02°ステップで行った。リートベルト分析は反射強度の評価に基づいている。表1に示すBETデータ及びリートベルト分析データは非還元状態の試料に関する。
Claims (15)
- β’’−アルミネート及び/又はマグネトプランバイトの状態のヘキサアルミネートを含有する酸化物担体材料並びに金属ニッケル粒子を含有する炭化水素及びCO2の改質触媒であって、
該触媒中の前記金属ニッケル粒子の大部分が正方晶型であり、
前記金属ニッケル粒子が、成長した粒子として前記酸化物担体材料の表面上に細かく分布され、
前記金属ニッケル粒子の平均粒径が、50nm以下、好ましくは40nm以下、及び、特に好ましくは30nm以下であることを特徴とする改質触媒。 - 前記触媒の酸化物相が、前記ヘキサアルミネートを、少なくとも65〜95質量%、好ましくは70〜90質量%、及び、結晶酸化物の二次相を、5〜35質量%、好ましくは10〜30質量%含み、
前記ヘキサアルミネートを含む相が、Ba、Sr及びLaからなる群からの少なくとも1個の層間カチオンを含み、
アルミニウムに対する前記層間カチオンのモル比が、1:6〜11、好ましくは1:7〜10、及び、特に好ましくは、1:8〜10の範囲であり、
前記結晶酸化物の二次相が、少なくともLaAlO3、SrAl2O4及び/又はBaAl2O4を含み、
前記触媒のBET表面積が、5m2/g以上、好ましくは10m2/g以上であることを特徴とする請求項1に記載の炭化水素及びCO2の改質触媒。 - 前記触媒の前記ニッケルの含有量が、3mol%以下、好ましくは2.5mol%以下、及び、より好ましくは、2mol%以下であり、
前記ニッケル粒子の主な部分が、前記ヘキサアルミネート相の表面に存在することを特徴とする請求項1又は請求項2に記載の炭化水素及びCO2の改質触媒。 - 非還元状態における請求項1〜3の何れか1項に記載の炭化水素及びCO2の改質触媒製造用の前駆体触媒であって、
該前駆体触媒が、ニッケル−バリウムヘキサアルミネートを、少なくとも65〜95質量%、好ましくは70〜90質量%含み、
前記改質触媒中の前記ヘキサアルミネートが、35.72 2θ[°]で[114]反射を有するβ’’−アルミネートの状態で存在し、
前記改質触媒が、前記結晶酸化物の二次相を5〜35質量%、好ましくは10〜30質量%含み、
前記改質触媒の前記ニッケル含有量が、3mol%以下、好ましくは2.5mol%以下、及び、より好ましくは2mol%以下であり、
前記改質触媒のAlに対するBaのモル比が、1:6〜11、好ましくは1:7〜10及び、特に好ましくは1:8〜10であり、
前記結晶酸化物の二次相が、少なくともBaAl2O4を含み、
前記触媒のBET表面積が、5m2/g以上、より好ましくは10m2/g以上であることを特徴とする前駆体触媒。 - 非還元状態で存在する請求項1〜3の何れか1項に記載の炭化水素及びCO2の改質触媒製造用の前駆体触媒であって、
該前駆体触媒が、マグネトプランバイトの状態のニッケル−ストロンチウムヘキサアルミネートを、少なくとも65〜95質量%、好ましくは70〜90質量%、及び、前記結晶酸化物の二次相を、5〜35質量%、好ましくは10〜30質量%含み、
前記改質触媒の前記ニッケル含有量が、3mol%以下、好ましくは2.5mol%以下、及び、より好ましくは2mol%以下であり、
前記改質触媒のAlに対するSrのモル比が、1:6〜11、好ましくは1:7〜10、及び、特に好ましくは1:8〜10の範囲であり、
前記結晶酸化物の二次相が、少なくともSrAl2O4を含み、
前記改質触媒のBET表面積が、5m2/g以上、好ましくは10m2/g以上であることを特徴とする前駆体触媒。 - 非還元状態で存在する請求項1〜3の何れか1項に記載の炭化水素及びCO2の改質触媒製造用の前駆体触媒であって、
該前駆体触媒が、ニッケルヘキサアルミネートを、少なくとも65〜95質量%、好ましくは70〜90質量%、及び前記結晶酸化物の二次相を、5〜35質量%、好ましくは10〜30質量%含み、
前記改質触媒が、合成のためのナノ粒子状アルミニウムオキシドヒドロキシド源を使用して製造されることができ、
前記改質触媒の前記ニッケル含有量が、3mol%以下、好ましくは2.5mol%以下、及び、より好ましくは2mol%以下であり、
該ニッケルヘキサアルミネートを含有する相が、Ba、Sr及びLaからなる群から少なくとも1個の層間カチオンを含み、
アルミニウムに対する前記層間カチオンのモル比が1:6〜11、好ましくは1:7〜10及び、特に好ましくは、1:8〜10の範囲であり、
前記結晶酸化物の二次相が、少なくともLaAlO3、SrAl2O4及びBaAl2O4を含み、
前記改質触媒のBET表面積が、5m2/g以上、好ましくは10m2/g以上であることを特徴とする前駆体触媒。 - 非還元状態における請求項1〜3の何れか1項に記載の炭化水素及びCO2の改質触媒製造用の前駆体触媒であって、
該前駆体触媒が、35.72 2θ[°]で[114]反射を有するβ’’−アルミネート及び/又はマグネトプランバイトの状態のニッケルヘキサアルミネートを、少なくとも65〜95質量%、好ましくは70〜90質量%、及び、前記結晶酸化物の二次相を、5〜35質量%、好ましくは10〜30質量%含み、
前記改質触媒が、合成のためのナノ粒子状アルミニウムオキシドヒドロキシド源を使用して製造されることができ、
前記改質触媒の前記ニッケル含有量が、3mol%以下、好ましくは2.5mol%以下、及び、より好ましくは2mol%以下であり、
前記ニッケルヘキサアルミネートを含有する相が、Ba及びSrからなる群からの少なくとも1個の層間カチオンを有し、
前記改質触媒のアルミニウムに対する前記層間カチオンのモル比が、1:6〜11の範囲、好ましくは1:7〜10、及び、特に好ましくは1:8〜10の範囲であり、
前記結晶酸化物の二次相が、少なくともSrAl2O4及び/又はBaAl2O4を含み、
前記改質触媒のBET表面積が、5m2/g以上、好ましくは10m2/g以上であることを特徴とする前駆体触媒。 - 前記改質触媒のX線回折パターンが、せいぜい少量のγ−、及び/又はσ−、及び/又はθ−、及び/又はα−アルミニウムオキシドを示し、
前記γ−アルミニウムオキシドの量が、10質量%未満、好ましくは5質量%未満、及び、特に好ましくは2質量%未満であることを特徴とする請求項1〜7の何れか1項に記載の炭化水素及びCO2の改質触媒。 - 請求項1〜3の何れか1項に記載の炭化水素及びCO2の改質触媒の製造方法であって、
前記改質触媒が、ニッケルヘキサアルミネート含有主相を、少なくとも65〜95質量%、好ましくは70〜90質量%、及び、結晶酸化物の二次相を、5〜35質量%、好ましくは10〜30質量%含み、
製造工程が以下の工程:
(i)ナノ粒子状アルミニウムオキシドヒドロキシド源と、La、Sr及びBaからなる群からの元素を含む金属塩及びニッケル塩をも接触させる工程であって、
ニッケル含有量が3mol%以下、好ましくは2.5mol%以下、及び、より好ましくは2mol%以下であり、
アルミニウムに対する層間カチオンのモル比が、1:6〜11、好ましくは1:7〜10及び、特に好ましくは1:8〜10である工程と、
(ii)出発成分を均質に混合する工程と、
(iii)少なくとも乾燥させ、塩を分解し、及び/又は混合物を成形する工程と、
(iV)900℃以上の温度で焼成する工程と、工程(iV)の後に続く、触媒を還元処理する工程と、を含むことを特徴とする製造方法。 - 金属塩が、硝酸塩の状態で使用され、
及び/又はアルミニウム源が、ナノ粒子状アルミニウムオキシドヒドロキシドの状態で使用され、
及び/又は水が、溶媒として使用されることを特徴とする請求項9に記載の炭化水素及びCO2の改質触媒の製造方法。 - 以下の工程:
(a.1)炭化水素、好ましくはメタン、及びCO2を含む改質ガスと、請求項1〜6の何れか1項に記載のニッケルヘキサアルミネート含有触媒又は、請求項7又は8に記載の方法によって製造される触媒とを接触させる工程と、
(a.2)前記改質ガスを前記触媒と接触させる際に、800℃を超える温度で、及び、より好ましくは850℃を超える温度で加熱する工程と、
(a.3)反応を行う間に、5バールを超える処理圧力で、好ましくは10バールを超える処理圧力で、及び、より好ましくは15バールを超える処理圧力で反応器を運転させる工程と、
(a.4)該改質ガスを、500〜20000hr−1の範囲、好ましくは1500〜10000hr−1の範囲、及び、より好ましくは2000〜5000hr−1の範囲のGHSVで該触媒と接触させる工程と、
を含むことを特徴とするCO2の存在下における炭化水素、好ましくはメタンの改質方法。 - 工程(a.1)で記述された前記改質ガスが、最大で70体積%、好ましくは最大で50体積%、及び、特に好ましくは最大で30体積%の水含有量を有することを特徴とする請求項11に記載の二酸化炭素の存在下における炭化水素、好ましくはメタンの改質方法。
- 前記触媒が、還元状態で使用され、又は還元工程が、触媒工程よりも先に行われることを特徴とする請求項11又は12の何れかに記載の二酸化炭素の存在下における炭化水素、好ましくはメタンの改質方法。
- 出発流体が、水蒸気を含み、
出発流体が、成分CH4/CO2/H2Oが、好ましくは、35/35/30から45/45/10の範囲で、25/25/50から50/50/0のガス体積比で存在する構成を有することを特徴とする請求項11〜13の何れか1項に記載の二酸化炭素の存在下における炭化水素、好ましくはメタンの改質方法。 - 工程で製造される合成ガスが、0.8〜2.0の範囲のH2/CO比を有し、
該合成ガスのH2/CO比が、好ましくは、0.9〜1.1の範囲であることを特徴とする請求項11〜14の何れか1項に記載の二酸化炭素の存在下における炭化水素、好ましくはメタンの改質方法。
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