Ammonia synthesis catalyst and ammonia synthesis method
10017395 ยท 2018-07-10
Assignee
Inventors
- Hiroshi Kageyama (Kyoto, JP)
- Yoji Kobayashi (Kyoto, JP)
- Naoya Masuda (Kyoto, JP)
- Hideo Hosono (Tokyo, JP)
Cpc classification
B01J37/086
PERFORMING OPERATIONS; TRANSPORTING
B01J2523/00
PERFORMING OPERATIONS; TRANSPORTING
B01J37/0236
PERFORMING OPERATIONS; TRANSPORTING
Y02P20/52
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B01J23/58
PERFORMING OPERATIONS; TRANSPORTING
B01J2523/00
PERFORMING OPERATIONS; TRANSPORTING
B01J23/78
PERFORMING OPERATIONS; TRANSPORTING
International classification
B01J23/00
PERFORMING OPERATIONS; TRANSPORTING
B01J23/58
PERFORMING OPERATIONS; TRANSPORTING
B01J37/02
PERFORMING OPERATIONS; TRANSPORTING
B01J23/78
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The ammonia synthesis catalyst of the present invention, comprises: a powder of a perovskite oxyhydride having hydride (H.sup.) incorporated therein as a support; and a metal or a metal compound exhibiting a catalytic activity for ammonia synthesis, supported on the support, and the perovskite oxyhydride is represented by ATiO.sub.3-xH.sub.x (wherein A represents Ca, Sr, or Ba, and 0.1x0.6).
Claims
1. An ammonia synthesis catalyst, comprising: a powder of a perovskite oxyhydride having hydride (H.sup.) incorporated therein as a support; and a metal or a metal compound exhibiting a catalytic activity for ammonia synthesis, supported on the support.
2. The ammonia synthesis catalyst according to claim 1, wherein the perovskite oxyhydride is represented by ATiO.sub.3-xH.sub.x (wherein A represents Ca, Sr, or Ba, and 0.1x0.6).
3. The ammonia synthesis catalyst according to claim 1, wherein the perovskite oxyhydride further contains nitrogen.
4. The ammonia synthesis catalyst according to claim 3, wherein the perovskite oxyhydride is represented by ATi(O.sub.3-zH.sub.xN.sub.y) (wherein A represents Ca, Sr, or Ba, and 0.1x0.6, 0<y0.3, zx+y, and zxy represents the amount of oxygen defects).
5. The ammonia synthesis catalyst according to claim 1, wherein the metal exhibiting a catalytic activity is supported on the surface of the powder in the form of metal nanoparticles.
6. The ammonia synthesis catalyst according to claim 1, wherein the metal compound exhibiting a catalytic activity is mixed with the powder and supported thereon.
7. The ammonia synthesis catalyst according to claim 5, wherein the metal exhibiting a catalytic activity or the metal of the metal compound exhibiting a catalytic activity is Ru and the supported amount in terms of Ru metal with respect to the support is from 0.1 to 5 wt %.
8. A method for producing an ammonia synthesis catalyst, comprising: a first step of preparing a powder of a perovskite oxyhydride having hydride (H.sup.) incorporated therein by keeping a powder of a perovskite titanium-containing oxide as a starting material together with a powder of an alkali metal hydride or an alkaline earth metal hydride selected from LiH, CaH.sub.2, SrH.sub.2, and BaH.sub.2 in a temperature range of 300 C. or higher and lower than the melting point of the hydride in a vacuum or in an inert gas atmosphere, thereby substituting some of the oxide ions in the oxide with hydride ions; a second step of preparing a catalyst precursor by dispersing the perovskite oxyhydride powder obtained in the first step in a solvent solution of a compound of a metal having an ammonia synthesis activity, followed by evaporating the solvent; and a third step of preparing a catalyst having a metal compound exhibiting a catalytic activity supported on the powder by drying the catalyst precursor obtained in the second step.
9. The method for producing an ammonia synthesis catalyst according to claim 8, wherein the method further comprises, after the third step, a fourth step of preparing a catalyst having metal nanoparticles supported on the surface of the powder by heating and reducing the metal compound in a reducing atmosphere or thermally decomposing the metal compound in a vacuum.
10. The method for producing an ammonia synthesis catalyst according to claim 8, wherein the method comprises, after the first step and before the second step, a step of incorporating nitrogen in the perovskite oxyhydride by treating the powder of the perovskite oxyhydride in the presence of a nitrogen supply source substance.
11. The method for producing an ammonia synthesis catalyst according to claim 8, wherein the method comprises, after the third step or the fourth step, a step of incorporating nitrogen in the perovskite oxyhydride by treating the catalyst in the presence of a nitrogen supply source substance.
12. An ammonia synthesis method, which is a method for synthesizing ammonia by reacting hydrogen and nitrogen using a gas containing hydrogen and nitrogen as raw materials, wherein the catalyst according to claim 1 is packed in a catalytic packed bed in a synthesis reactor, and nitrogen and hydrogen as the raw materials are reacted on the catalyst under conditions of a reaction temperature of 300 C. to 450 C. and a reaction pressure of 10 kPa or more and less than 20 MPa.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
DESCRIPTION OF EMBODIMENTS
(8) The ammonia synthesis catalyst of the present invention is constituted by a support composed of a powder of a perovskite oxyhydride having hydride (H.sup.) incorporated therein and a metal or a metal compound exhibiting a catalytic activity for ammonia synthesis supported on the support.
(9) <Composition and Structure of Titanium-Containing Perovskite Oxyhydride>
(10) A titanium-containing perovskite oxyhydride in which some of the oxide ions contained in a titanium-containing perovskite oxide are substituted with hydride ions (H.sup.). A Ti-containing perovskite oxide can incorporate hydride ions (H.sup.) in a low concentration to a high concentration under specific heat treatment conditions, and can be represented by the formula: ATiO.sub.3-xH.sub.x (wherein A represents Ca, Sr, or Ba, and 0.1x0.6). When the value of x is less than 0.1, the effect of improving the catalytic activity by hydride ions is not sufficient, and when it exceeds 0.6, the crystallinity deteriorates and impurities emerge, and therefore, such values are not desirable. As the content of hydrogen represented by x increases within this range, the catalytic activity for ammonia synthesis increases. A more preferred range of the value of x is from 0.3 to 0.6.
(11) The Ti-containing perovskite oxyhydride maintains a perovskite structure composed of octahedra which share vertices as shown in
(12) The catalyst of the present invention can be produced by the following steps.
(13) <First Step: Preparation of Ti-Containing Perovskite Oxyhydride>
(14) The titanium-containing perovskite oxyhydride can be prepared as a powder of a perovskite oxyhydride by keeping a powder of a perovskite titanium-containing oxide as a starting material together with a powder of an alkali metal hydride or an alkaline earth metal hydride selected from lithium hydride (LiH), calcium hydride (CaH.sub.2), strontium hydride (SrH.sub.2), and barium hydride (BaH.sub.2) in a temperature range of 300 C. or higher and lower than the melting point of the hydride, desirably 300 C. or higher and 600 C. or lower in a vacuum or in an inert gas atmosphere, followed by cooling to room temperature thereby substituting some of the oxide ions in the oxide with hydride ions. The temperature-increasing rate to the temperature at which the powders are kept and the temperature-decreasing rate to room temperature are not limited. The time required for keeping the powders may be about one hour or more and up to about 1 week though depending on the temperature.
(15) The Ti-containing perovskite oxide as the starting material can be represented by the general formula: ATiO.sub.3 (wherein A represents Ca, Sr, or Ba). The Ti-containing perovskite oxide as the starting material, particularly the production method or form thereof is not limited. A perovskite oxide is produced by various methods such as a solid state reaction, an oxalic acid method, a citric acid method, a hydrothermal method, and a sol-gel method, however, as the catalyst, a catalyst having a larger specific surface area is desirable, and a catalyst having a specific surface area of 30 m.sup.2/g or more and a particle size distribution of about 5 to 500 nm is desirable.
(16) The obtained Ti-containing perovskite oxide containing hydride ions has both hydride ion conductivity and electronic conductivity, and also has reactivity with outside hydrogen gas at a low temperature of about 450 C. or lower, and therefore, when the contained hydrogen is reacted and substituted with deuterium, ATiO.sub.3-xD.sub.x (wherein A=Ca, Sr, or Ba, 0.1x0.6, and D represents deuterium) can be formed, which can also be used as a support. When hydrogen is substituted with deuterium, the composition has a high hydride concentration.
(17) Further, the method may include, after the first step, a step of incorporating nitrogen in the perovskite oxyhydride by treating the obtained Ti-containing perovskite oxyhydride in the presence of a nitrogen supply source substance such as ammonia gas, nitrogen gas, or a nitrogen compound. For example, when the Ti-containing perovskite oxyhydride is heated to a low temperature of 400 to 600 C. in an ammonia gas or N.sub.2/H.sub.2 mixed gas stream, BaTi(O,N,H).sub.3, which is a nitride, is formed through a H/N exchange process. In this manner, when a material obtained by introducing nitride ions into the Ti-containing perovskite oxyhydride in advance is used as a support, stabilization of ATiO.sub.3-xH.sub.x during an ammonia synthesis reaction is brought about. The Ti-containing perovskite oxyhydride having nitride ions introduced therein is represented by the formula: ATi(O.sub.3-zH.sub.xN.sub.y) (wherein 0.1x0.6, 0<y0.3, zx+y, and zxy represents the amount of oxygen defects).
(18) It is presumed that also in the case where the Ti-containing perovskite oxyhydride is used as a catalyst under ammonia synthesis conditions, BaTi(O,N,H).sub.3 is formed in the same manner so as to contribute to the stabilization of the catalyst.
(19) <Second Step: Preparation of Catalyst Precursor>
(20) The supporting of a metal on a perovskite oxyhydride support is performed by an impregnation method. As the metal compound to be used as the starting material, a compound such as a chloride is used. In particular, it is preferred to use a carbonyl compound or complex which can maintain the specific properties of the perovskite oxyhydride and is easily decomposed. For example, in the case where Ru is used as the metal exhibiting a catalytic activity, examples of a ruthenium compound include ruthenium chloride, ruthenium carbonyl, ruthenium acetylacetonate, ruthenium potassium cyanate, potassium ruthenate, ruthenium oxide, and ruthenium nitrate. Any of these metal compounds is dissolved in a polar organic solvent such as acetone or tetrahydrofuran or water, whereby a solvent solution is formed. The perovskite oxyhydride powder is dispersed in this solvent solution, followed by evaporating the solvent, whereby a catalyst precursor is prepared.
(21) <Third Step: Supporting of Metal Compound>
(22) Further, the catalyst precursor obtained in the second step is dried, whereby a catalyst having a metal compound exhibiting a catalytic activity supported on the powder is prepared. Before the catalyst is used in an ammonia synthesis reaction, a hydrogen reduction treatment is generally performed, and therefore, a step of reducing the metal compound in the subsequent step may be omitted.
(23) <Fourth Step: Supporting of Metal Particles>
(24) After the third step, further, the metal compound is heated and reduced in a reducing atmosphere or thermally decomposed in a vacuum, whereby metal nanoparticles are supported on the surface of the powder. In the case where metal nanoparticles are formed on the surface of the powder by hydrogen reduction of the metal compound, the hydrogen reduction temperature is from 100 C. to 700 C., preferably from 300 C. to 600 C., and the hydrogen reduction time is generally preferably from 1 to 5 hours.
(25) The supported amount of the metal exhibiting a catalytic activity or the metal of the metal compound exhibiting a catalytic activity in terms of the metal with respect to the support is from 0.1 to 20 wt %. When the supported amount is less than 0.1 wt %, the catalytic activity is low, and when the supported amount exceeds 20 wt %, even if the supported amount is increased, improvement of the ammonia synthesis activity is not observed. The most preferred metal as the metal exhibiting a catalytic activity is ruthenium, however, since ruthenium is an expensive metal, in the case of ruthenium, the supported amount is preferably from 0.1 to 5 wt %.
(26) The method may include, after the third step or the fourth step, a step of incorporating nitrogen in the perovskite oxyhydride by treating the catalyst in the presence of a nitrogen supply source substance. Also in this case, in the same manner as in the case of introducing nitride ions into the perovskite oxyhydride in advance after the first step and before the second step, the Ti-containing perovskite oxyhydride may be heated to a low temperature of 400 to 600 C. in an ammonia gas or N.sub.2/H.sub.2 mixed gas stream.
(27) Incidentally, it is also possible to perform the hydride formation after supporting metal particles exhibiting a catalytic activity on the perovskite oxide in advance, however, in such a case, the metal particles are likely to be sintered to decrease the catalytic activity, and therefore, it is necessary to suppress sintering as much as possible.
(28) <Synthesis of Ammonia>
(29) The ammonia synthesis method of the present invention is a method in which in order to react hydrogen and nitrogen using a gas containing hydrogen and nitrogen as raw materials, the catalyst powder is packed in a catalytic packed bed in a synthesis reactor, and the raw material gas is reacted on the catalyst powder bed, whereby ammonia is synthesized. A representative form of the reaction is a method in which a mixed gas of nitrogen and hydrogen is directly reacted under heated and pressurized conditions, and ammonia produced by the reaction of N.sub.2+3H.sub.2.fwdarw.2NH.sub.3 is cooled or absorbed in water in the same manner as the conventional Haber-Bosch method. Nitrogen gas and hydrogen gas are supplied so as to come in contact with the catalyst powder bed placed in the reactor. It is preferred that before supplying nitrogen gas and hydrogen gas, the surface of the catalyst is subjected to a reduction treatment with hydrogen gas or a mixed gas of hydrogen and nitrogen so that the oxide and the like attached to the surface of the supported catalyst are removed.
(30) It is preferred that the ammonia synthesis reaction is performed in an atmosphere which is as water-free as possible, that is, in a dry nitrogen and hydrogen atmosphere which is an atmosphere at a water vapor partial pressure of about 0.1 kPa or less.
(31) Subsequently, by heating the catalyst in a mixed gas atmosphere of nitrogen and hydrogen as the raw materials, ammonia is synthesized. It is preferred to perform the synthesis under conditions that the molar ratio of nitrogen to hydrogen is about 1/10 to 1/1. The reaction temperature is set to room temperature or higher and lower than 500 C. The reaction temperature is more preferably from about 300 to 350 C. A lower reaction temperature is favorable for the equilibrium to produce ammonia, and the above-mentioned range is preferred for obtaining a sufficient ammonia production rate and also making the equilibrium favorable to produce ammonia.
(32) The reaction pressure of the mixed gas of nitrogen and hydrogen when the synthesis reaction is performed is not particularly limited, but is preferably from 10 kPa to 20 MPa, more preferably from 10 kPa to 5 MPa. In consideration of practical use, it is preferred that reaction can be applicable in atmospheric pressure to a pressurized condition. Therefore, from a practical viewpoint, the reaction pressure is more preferably from about 100 kPa to 1.5 MPa.
(33) For the reaction device, any of a batch-type reaction container, a closed circulation-type reaction device, and a flow-type reaction device may be used, however, from a practical viewpoint, a flow-type reaction device is most preferred.
(34) <Function of Catalyst of the Present Invention>
(35) The function of the catalyst of the present invention will be described below, however, this is an assumption and does not limit the scope of the present invention. The reason why the catalyst of the present invention exhibits excellent properties is considered to be the hydride ions in the support have a specific function which affects the nitrogen molecules and the hydrogen molecules of the raw materials. That is, a heterogeneous catalyst is generally constituted by supporting metal catalyst particles on a carbon or metal oxide support. In an oxidation reaction by a catalyst, a metal oxide directly participates in the reaction in some cases, however, in various hydrogenation reactions, the metal oxide itself is inactive as a support, and has played a relatively indirect role such as merely supporting metal particles.
(36) However, it is presumed that the Ti-containing perovskite oxyhydride directly dissociates a gas molecule such as a hydrogen molecule at around 300 to 450 C. and preferentially adsorbs the dissociated molecule on the support, and also participates in a reaction of directly dissociating a nitrogen molecule by a conversion reaction between a hydride ion and a nitrogen molecule. It is considered that by doing this, poisoning due to accumulation of hydrogen on the metal particles is prevented. This is completely different from the conventional catalyst support, and is considered to be due to an unknown attribution of the perovskite oxyhydride having hydride (H.sup.) incorporated therein under the ammonia synthesis conditions.
(37) Hereinafter, the present invention will be described in more detail based on Examples.
Example 1
1. Synthesis of Oxyhydride
(38) 0.3 g of a commercially available BaTiO.sub.3 powder having a particle diameter distributed in a range from 100 nm to 200 nm was mixed with 3 equivalents of a CaH.sub.2 powder in a glove box, and the resulting mixed powder was pressed into a tablet using a hand press. Thereafter, the tablet was vacuum-sealed in a glass tube having an internal volume of about 15 cm.sup.3, and a hydrogenation reaction was performed by keeping the tablet therein at 500 to 600 C. for 168 hours (one week), whereby a BaTiO.sub.2.5H.sub.0.5 powder in which some of the oxide ions were substituted with hydride ions was synthesized.
2. Supporting of Ru
(39) The synthesized BaTiO.sub.2.5H.sub.0.5 powder was mixed in a THF solution of Ru.sub.3(CO).sub.12 and stirred for 3 hours. Thereafter, the solvent was evaporated at 40 C. in a reduced pressure state, whereby a catalyst precursor was prepared. Subsequently, this precursor was dried, and then vacuum-sealed again in the glass tube, followed by heating to 390 C. for 3 hours to thermally decompose a carbonyl compound, whereby a Ru/BaTiO.sub.2.5H.sub.0.5 powder having Ru metal particles supported thereon was obtained. The supported amount of ruthenium in the obtained Ru/BaTiO.sub.2.5H.sub.0.5 powder was 1.0 wt % in terms of Ru.
3. Form of Ru-Supported Catalyst
(40) In
Example 2
1. Synthesis of Oxyhydride
(41) A BaTiO.sub.2.4D.sub.0.6 powder having a high hydride concentration was synthesized under the same conditions as those in Example 1 except that a CaD.sub.2 (D represents deuterium) powder was used in place of the CaH.sub.2 powder in Example 1. The CaD.sub.2 powder was prepared as follows. A chunks of Ca was reacted with D.sub.2 at 600 C. for 30 minutes, and the resulting material was crushed in a nitrogen atmosphere, and the crushed material was reacted with D.sub.2 again. This procedure was repeated 3 times, whereby a pure powder was prepared.
2. Supporting of Ru
(42) Ru was supported on this powder in the same manner as in Example 1.
Example 3
1. Synthesis of Oxyhydride
(43) A BaTiO.sub.2.5H.sub.0.5 powder was synthesized under the same conditions as those in Example 1.
2. Supporting of Co
(44) The synthesized BaTiO.sub.2.5H.sub.0.5 powder was mixed in a THF solution of Co(acetylacetonate).sub.3 and stirred for 3 hours. Thereafter, the solvent was evaporated at 40 C. in a reduced pressure state, whereby a catalyst precursor was prepared. This catalyst precursor was packed in a catalytic packed bed of an ammonia synthesis evaluation device, and then reduced for 2 hours in a hydrogen gas stream, whereby a Co/BaTiO.sub.2.5H.sub.0.5 catalyst was formed and used.
Example 4
1. Synthesis of Oxyhydride
(45) A BaTiO.sub.2.5H.sub.0.5 powder was synthesized under the same conditions as those in Example 1.
2. Supporting of Fe
(46) The synthesized BaTiO.sub.2.5H.sub.0.5 powder was mixed in a THF solution of Fe(acetylacetonate).sub.3 and stirred for 3 hours. Thereafter, the solvent was evaporated at 40 C. in a reduced pressure state, whereby a catalyst precursor was prepared. This catalyst precursor was packed in a catalytic packed bed of an ammonia synthesis evaluation device, and then reduced for 2 hours in a hydrogen gas stream, whereby an Fe/BaTiO.sub.2.5H.sub.0.5 catalyst was formed and used.
Comparative Example 1
(47) Ru was supported on the BaTiO.sub.3 powder, which was not subjected to the hydrogenation reaction, under the same conditions as those in Example 1, whereby a Ru/BaTiO.sub.3 catalyst was obtained.
Comparative Example 2
(48) A Ru/MgO catalyst was obtained by supporting Ru under the same conditions as those in Example 1 except that a MgO powder was used in place of the BaTiO.sub.3 powder in Comparative Example 1.
Comparative Example 3
(49) Ru/MgO obtained in Comparative Example 2 was impregnated with an ethanol solution of Cs.sub.2CO.sub.3, followed by thermal decomposition of Cs.sub.2CO.sub.3, whereby a RuCs/MgO (Ru/Cs=1) catalyst was obtained. The supported amount of RuCs in the catalyst was 1.0 wt %.
Example 5
Ammonia Synthesis
(50) Ammonia synthesis was performed using a fixed-bed flow-type device as shown in
(51) Thereafter, the temperature was once decreased to about 150 C. or lower, and then increased again, and when the temperature reached about 200 C., the valves 4, 5, and 7 were closed, and the valve 6 was opened to change the gas flow. Then, the flow rate was adjusted with a needle valve 8, and an Ar/N.sub.2/H.sub.2 mixed gas (Ar:N.sub.2:H.sub.2=10:22.5:67.5) was made to flow in the vertical reaction tube 1 (flow rate: 110 mL/min), and in order to make the conditions closer to industrial conditions, the pressure in the vertical reaction tube 1 was increased to 5.0 MPa (50 atm) by pressurization using a back pressure regulator 9, and the temperature was gradually increased to 400 C. The produced ammonia was qualitatively confirmed using a mass spectrometer 10, and trapped in water after passing through an oil bubbler (flow meter) 11, and then, quantitatively determined using an ammonia selection electrode 12 and discharged to the air.
(52) In
(53) <Comparison of Catalytic Activity>
(54) Also for the catalysts of Examples 2, 3, and 4, and Comparative Examples 1 to 3, evaluation was performed in the same manner as the evaluation of ammonia synthesis for the catalyst of Example 1 (H.sub.2/N.sub.2=3, flow rate: 110 mL/min). In
(55) In the graph of
INDUSTRIAL APPLICABILITY
(56) According to the catalyst of the present invention, a catalyst in which a catalytic activity has been significantly improved even if it is used at a low pressure in place of conventional high-pressure reaction conditions can be achieved by only adding a hydride formation step using a widely used Ti-containing perovskite oxide in place of a Ru catalyst using various supports, and therefore, ammonia can be highly efficiently synthesized using less energy in a method for industrially synthesizing ammonia using a gas containing hydrogen and nitrogen as raw materials.