Raney alloy methanation catalyst

Abstract

A methanation process utilizing an improved catalyst for the conversion of CO, CO 2 and mixtures thereof to CH 4 is disclosed. The catalyst comprises a monolithic mesh type structure of a nickel alloy having an integral Beta phase Raney coating on its outer surfaces. When used, substantially higher reactant flow rates and lower operating temperatures are possible as compared to conventional fluidized bed granular catalysts.

What is claimed is: .[.1. A monolithic catalyst comprised of a metallic substrate with an integral Raney metal exterior surface, said surface being predominantly derived from an adherent Ni x  M 1-x  Al 3  Beta structured crystalline precursory layer, where said layer is integral with and derived from said substrate, M is a catalytic enhancer selected from the group consisting of molybdenum, titanium, tantalum, ruthenium or mixtures thereof and where x, the weight fraction of nickel in the combined weight of Ni and M, is within the range of from about 0.80 to about 0.95..]. .[.2. The catalyst of claim 1 wherein said catalyst enhancer is molybdenum..]. .[.3. The catalyst of claim 1 wherein said catalyst enhancer is ruthenium..]. .[.4. The catalyst of claim 1 wherein said catalyst enhancer is tantalum..]. .[.5. The catalyst of claim 1 wherein said catalyst enhancer is titanium..]. .[.6. The catalyst of claim 2 wherein x is between about 0.82 and about 0.90..]. .[.7. The catalyst of claim 3 wherein x is between about 0.90 and about 0.95..]. .[.8. The catalyst of claim 1 wherein said substrate is a perforated metal..]. .[.9. The catalyst of claim 8 wherein said substrate is expanded mesh..]. .[.10. The catalyst of claim 9 wherein said substrate is a metallic screen..]. 
     
        .Iadd.11.  A monolithic catalyst comprised of a metallic substrate with an integral Raney metal exterior surface, said surface being predominantly derived from an adherent Ni x  M 1-x  Al 3  Beta structured crystalline precursory layer, where said layer is integral with and derived from said substrate, M is a catalytic enhancer selected from the group consisting of ruthenium and mixtures thereof with molybdenum, titanium, and tantalum, and where x, the weight fraction of nickel in the combined weight of Ni and M, is within the range of from about 0.80 to about 0.95..Iaddend. .Iadd.12. The catalyst of claim 11 wherein said catalyst enhancer is ruthenium..Iaddend. .Iadd.13. The catalyst of claim 12 wherein x is between about 0.90 and 0.95..Iaddend. .Iadd.14. The catalyst of claim 11 wherein said substrate is a perforated metal..Iaddend. .Iadd.15. The catalyst of claim 11 wherein said substrate is expanded mesh..Iaddend. .Iadd.16. The catalyst of claim 11 wherein said substrate is a metallic screen..Iaddend. .Iadd.17. A monolithic catalyst comprised of a metallic substrate with an integral Raney metal exterior surface, said surface being predominantly derived from an adherent Ni x  M 1-x  Al 3  Beta structured crystalline precursory layer, where said layer is integral with and derived from said substrate, M is a catalytic enhancer selected from the group consisting of titanium and mixtures thereof with molybdenum, tantalum, and ruthenium, and where x, the weight fraction of nickel in the combined weight of Ni and M, is within the range of from about 0.80 to about 0.95..Iaddend. .Iadd.18. The catalyst of claim 17 wherein said catalyst enhancer is titanium..Iaddend. .Iadd.19. The catalyst of claim 18 wherein x is between about 0.90 and about 0.95..Iaddend. .Iadd.20. The catalyst of claim 17 wherein said substrate is a perforated metal..Iaddend. .Iadd.21. The catalyst of claim 17 wherein said substrate is expanded mesh..Iaddend. .Iadd.22. The catalyst of claim 17 wherein said substrate is a metallic screen..Iaddend. .Iadd.23. A monolithic catalyst comprised of a metallic substrate with an integral Raney metal exterior surface, said surface being predominantly derived from an adherent Ni x  M 1-x  Al 3  Beta structured crystalline precursory layer, where said layer is integral with and derived from said substrate, M is a catalytic enhancer selected from the group consisting of tantalum and mixtures thereof with molybdenum, titanium, and ruthenium, and where x, the weight fraction of nickel in the combined weight of Ni and M, is within the range of from about 0.80 to about 0.95..Iaddend. .Iadd.24. The catalyst of claim 23 wherein said catalyst enhancer is tantalum..Iaddend. .Iadd.25. The catalyst of claim 24 
     
     
        wherein x is between a out 0.85 and about 0.90..Iaddend. .Iadd.26.  The catalyst of claim 23 wherein said substrate is a perforated metal..Iaddend. .Iadd.27. The catalyst of claim 23 wherein said substrate is expanded mesh..Iaddend. .Iadd.28. The catalyst of claim 23 wherein said substrate is a metallic screen..Iaddend.