# US 11,439,988 B2 · Method for manufacturing catalysts with reduced attrition

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 11,439,988 B2
- Document ID: US11439988B2
- Status: Granted
- Kind: B2
- Application number: 16/462,717
- Filed: 2017-11-20
- Published: 2019-12-05
- Granted: 2022-09-13
- Earliest claimed: 2016-11-22
- Assignees: W. R. Grace & Co.-Conn.
- Applicants: W. R. Grace & Co.-Conn.
- Inventors: Stephen R. Schmidt
- Web page: https://patentgrep.com/patent/US11439988B2

## CPC

- B01J 23/755: Nickel
- B01J 23/85: Chromium, molybdenum or tungsten
- B01J 23/883: and nickel
- B01J 25/00: Catalysts of the Raney type
- B01J 25/02: Raney nickel
- B01J 35/30: characterised by their physical properties
- B01J 35/38: Abrasion or attrition resistance
- B01J 35/40: characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77)
- B01J 37/06: Washing {(B01J37/0009, B01J37/0018 take precedence)}
- C07C 29/132: by reduction of an oxygen containing functional group
- C07C 29/172: {with the obtention of a fully saturated alcohol}
- C22B 23/0446: {with an ammoniacal liquor or with a hydroxide of an alkali or alkaline-earth metal}
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C22B: PRODUCTION AND REFINING OF METALS (electrolytic C25); PRETREATMENT OF RAW MATERIALS

## Abstract

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%.

## Claims

### Claim 1

A method for manufacturing a catalyst, 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 %.

### Claim 2 (depends on 1)

The method of claim 1, wherein the alloy granules have effective diameters within a range of about 1 mm to about 10 mm.

### Claim 3 (depends on 1)

The method of claim 1, wherein the content of the nickel in the alloy granules is 53 wt %.

### Claim 4 (depends on 1)

The method of claim 1, wherein the content of the nickel in the alloy granules is 53 wt % to 56 wt %.

### Claim 5 (depends on 1)

The method of claim 1, wherein the alloy granules have effective diameters of about 2 mm to about 6 mm.

### Claim 6 (depends on 1)

The method of claim 1, wherein a concentration of the sodium hydroxide in the alkaline solution is 1 wt % to 15 wt %.

### Claim 7 (depends on 1)

The method of claim 1, wherein a concentration of the sodium hydroxide in the alkaline solution is 1 wt % to 10 wt %.

### Claim 8 (depends on 1)

The method of claim 1, wherein the alloy granules are treated with the alkaline solution at a temperature of about 20° C. to about 110° C.

### Claim 9 (depends on 1)

The method 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.

### Claim 10 (depends on 1)

The method of claim 1, wherein a content of the nickel in the catalyst is about 60 wt % to about 70 wt %.

### Claim 11 (depends on 1)

The method of claim 1, wherein the catalyst exhibits an attrition value of 3.0% or less.

### Claim 12 (depends on 1)

The method of claim 1, wherein a concentration of the sodium hydroxide in the alkaline solution is from 6 wt % to 15 wt %.