The document discusses activated alloy catalyst KALCAT, which is a fine particle of nickel seated on aluminum suspended in water. It describes the manufacturing process, activation and structure, mechanism of reaction, essential properties, applications, testing methods, handling tips, factors affecting performance, safety tips, and advantages of KALCAT.
The document discusses activated alloy catalyst KALCAT, which is a fine particle of nickel seated on aluminum suspended in water. It describes the manufacturing process, activation and structure, mechanism of reaction, essential properties, applications, testing methods, handling tips, factors affecting performance, safety tips, and advantages of KALCAT.
The document discusses activated alloy catalyst KALCAT, which is a fine particle of nickel seated on aluminum suspended in water. It describes the manufacturing process, activation and structure, mechanism of reaction, essential properties, applications, testing methods, handling tips, factors affecting performance, safety tips, and advantages of KALCAT.
The document discusses activated alloy catalyst KALCAT, which is a fine particle of nickel seated on aluminum suspended in water. It describes the manufacturing process, activation and structure, mechanism of reaction, essential properties, applications, testing methods, handling tips, factors affecting performance, safety tips, and advantages of KALCAT.
1924 by Dr.Murray Raney (1885-1966) Activated Alloy Catalyst are fine particles of Nickel seated on Aluminum, suspended in water. This catalyst is porous with occluded hydrogen in its pores, which imparts activity.
Manufacturing Process
K A L C A T
Ni
Al
Furnace
Alloy
Crusher
Pulverizer
Alloy Powder NaOH Washing Vessel
QC
Catalyst Suspension
Catalyst Ready for
Dispatch
Activation Vessel
Activation & Structure
K A L C A T
Activation Reaction 2Al + 2NaOH + 6H2O 2Na[Al(OH)4] + 3H2 Leaching of Aluminium by Alkali, makes alloy particles porous and imparts activity to the catalyst. Structure of the Catalyst Catalyst particle consists of Ni seated on Al. Al works as support & preserves pore structure of the catalyst. Particle is porous & H2 is occluded in it. Average particle size is 20 - 25 microns.
Mechanism of reaction
K A L C A T
Replacement of occluded H2 by External H2 (this is very
important to keep the catalyst active). Diffusion of reactants to the Catalyst Surface. Adsorption, reaction with elemental H & de-sorption of product. Mechanism External H2
Nascent [H]
Essential Catalyst Properties
K A L C A T
Activity: Rate at which the catalyst hydrogenates
the feedstock to product. E.g Percentage change in reactant (conversion) Selectivity: Ability of the catalyst to give the desired product, out of all possible products, e.g. product as percentage of reactant (yield) Shelf Life: Time for which the catalyst keeps a sufficient level of activity and/or selectivity.
Applications KALCAT 1961
KALCAT 2921
KALCAT 4061
Ni% 85-89
Ni% 87-91
Ni% 85-89
With min dehalogenatio, Oximes to Amines
-NO2 to NH2 in neat
condition
-CN to -CH2-NH2
Lisinopril, Mebevarine,
PNC to Pcumidiene
Venlafaxine, Atorvastatin
-N02 to NH2
KALCAT 9031 Ni% 85-89
Dehydrogenation
Carbazole
Applications KALCAT 3801
KALCAT 3063
Ring Hydrogenation, Debenzylation
-NO2 to NH2, >C=O to >CH-OH
Pyridine to Piperidine
Styrene Oxide
KALCAT 6104
-CN to -NH2, >C=O to >CH-OH
Sorbitol
K A L C A T
Testing Methods Weighing of Catalyst Hydrogen Absorption Test Hydrogenation test
Weighing of catalyst
K A L C A T
Wcat = 1. 22 (Wsl Vsl)
5 4 Vsl
Supernatant water
2 1 Settled Catalyst
Wsl (weight of catalyst + weight of water)
Very important step: to measure accurate dosage of catalyst.
Derived from densities to metals and Archimedes principle. Videos for AAC presentation\Lab weighment.mpg Videos for AAC presentation\RNC weighment.mpg
Hydrogen Absorption Test
K A L C A T
H2 Rubber Tubing
500 450 400 350 300
Conical flask (250 ml)
250
Magnet
200 150 100 50
Rubber Tubing
Magnetic stirrer
Gives primary idea about the catalyst activity.
This test confirms the desired levels of catalyst activity. Useful in establishing recycles with the catalyst. Videos for AAC presentation\NB Activity.mpg
Hydrogenation (Autoclave) Test
K A L C A T
This test confirms the quality of catalyst as well as the
raw material Each grade is tested at MCPL different molecules for different grades. Always maintain Std Catalyst & Std RM. Highly recommended to perform this test at customers end on their own molecule USER TEST.
Handling Tips
K A L C A T
Weigh the Catalyst by DRY basis formula.
Restrict excessive washings to avoid loss of activity. Gentle handling to avoid catalyst attrition Charge catalyst by Gravity (not by suction) & retain the catalyst activity. Keep stirrer OFF till you start reduction. Maintain Specific temp (e.g. 400C) of reaction mass during catalyst charging. Always make sure that the solution for hydrogenation is homogeneous
Factors affecting catalyst performance
K A L C A T
Poisoning: Gelatinous Al(OH)3 present in catalyst,
free ions of Sulphate, Nitrates, Carbonates, Acids & high
concentrations of Alkali, oxidation & removal of occluded H2 during the handling & dosing of catalyst.
Technical Errors Poor gas distribuon. Poor mixing of reactants. Leakage in gas supply
Breakage or Erosion of catalyst particles
(Attrition)
Safety Tips
K A L C A T
Do not allow catalyst to dry.
Always store under water. Always use safety Apparels. Avoid skin contact. Keep drums upright & store in a cool & shaded place with good air ventilation. Spent catalyst should ALSO be carefully stored under water. Commit your blunders on a small scale and make your profits on large scale
Reprocessing A Myth
K A L C A T
Catalyst is an Alloy Particle
During reaction ATTRITION occurs Oxidation of Catalyst. Coating of Organic Material. Catalyst Particle can not be reconstructed to its original state. Technically AAC cannot be reprocessed * * *
Spent Ni catalyst
K A L C A T
We offer BUY BACK at very attractive price
Nickel extracted from the Spent in salt form Assurance on total re-cycle of the nickel Environmentally sound processes Approved & Certified by CPCB & MPCB for Processing and recycling of Hazardous Waste.
KALCAT - Advantages
K A L C A T
Product adhering to International quality
standards. Specific Grades designed based on application. We use Virgin Nickel metal - the secret of consistent quality Value added services Catalysts Screening Service Process OpFmizaFon Process Trouble ShooFng Tailored Catalysts Technical Training Seminars Ni recovery from spent catalysts
We offer complete Cycle
We sell & We buy back
Technical Services
K A L C A T
At MONARCH, we always work with our
customers as strategic partners, right from R&D to scaling up. We have a well equipped laboratory with all the essential elements related to hydrogenation. Bank of application studies, 5 autoclaves with efficient filteration systems, Gas Chromatography, HPLC, TLC and wet lab. We accept projects of hydrogenation where selection of catalyst, optimization studies for better cost economics are carried out.
Our Offer
K A L C A T
We are confident that we can offer you an improved
solution to your catalyst needs. Be at par with Global standards and maintain consistency in quality. Efficient deliveries Derive the best results with our Excellent technical support. Catalyst development at our research centre for new and emerging applications
