Method for preparing a generally spherical catalyst precursor material for a methanation reaction, spheres obtained by such a method, methanation method and device

A preparation method for preparing a generally spherical catalyst precursor material for a methanation reaction, comprising:

• a formation step for forming a generally spherical support comprising mesoporous alumina (Al2O3) or an alumina precursor and having a sphericity factor greater than 0.75, preferably greater than 0.80 and more preferably greater than 0.85:
• an incorporation step for incorporating a nickel precursor into the support comprising mesoporous alumina (Al2O3) or an alumina precursor by bringing a composition comprising the nickel precursor into contact with the support;
• a calcination step for calcining the support incorporating the nickel precursor to at least partially transform the nickel precursor into nickel oxide (NiO) and the alumina precursor into alumina, and subsequently form a solid having a generally spherical shape, the solid being referred to as a “sphere made of a catalyst precursor material for a methanation reaction”;
• and
• a step of mechanically treating the spherical support after the step of forming the support, to increase the sphericity factor of the spherical support.

A device for preparing a generally spherical catalyst precursor material for a methanation reaction, comprising:

• a means for forming a generally spherical support comprising mesoporous alumina (Al2O3) or an alumina precursor and having a sphericity factor greater than 0.75, preferably greater than 0.80 and more preferably greater than 0.85;
• a means for incorporating a nickel precursor into the support comprising mesoporous alumina (Al2O3) or an alumina precursor, by bringing a composition comprising the nickel precursor (Ni) into contact with the support;
• and
• a means for calcining the support incorporating the nickel precursor, configured to at least partially transform the nickel precursor into nickel oxide (NiO) and the alumina precursor into alumina, and configured to form a solid having a generally spherical shape, this solid being referred to as a “sphere made of a catalyst precursor material for a methanation reaction”,
• which device also comprises a means for mechanically treating the spherical support, after the formation of the support, to increase the sphericity factor of the spherical support.