Methanation catalyst and process for preparing the catalyst

Claim 1

A catalyst for methanation reactions consisting essentially of nickel and a porous material containing alumina and zirconia, the components being evenly distributed amongst each other, wherein the content of nickel is from 15 to 40% by weight, calculated as nickel oxide, of the total catalyst and zirconia and alumina are present in a ratio of from 0.05 to 2.0 parts by weight of zirconia per part by weight of alumina and which catalyst has been prepared by the sequential steps of (a) preparing an aqueous solution of a nickel salt and containing, in at least partly dissolved state, aluminum and zirconium compounds thermally decomposable to the oxides, (b) precipitating substantially all metal ions from said aqueous solution by the addition of a base, (c) isolating and drying the precipitated metal compounds mixed with any undissolved compounds present in the system formed in step (b), (d) converting the thus-formed mixture of compounds into a mixture of the corresponding oxides by calcination at temperatures between 300° and 500° C., (e) working up the thus-formed oxides mixture into particles of any desired shape and size, (f) subjecting and shaped particles to a firing temperature of between 800° and 1100° C. for two to ten hours and (g) subsequently at least partially reducing the nickel oxide present in the fired particles into metallic nickel.

Claim 5

A method for preparing a methanation catalyst, said catalyst consisting essentially of nickel and a porous material containing alumina and zirconia, the components being evenly distributed amongst each other, wherein the content of nickel is from 15 to 40% by weight, calculated as nickel oxide, of the total catalyst and zirconia and alumina are present in a ratio of from 0.05 to 2.0 parts by weight of zirconia per part by weight of alumina; consisting essentially of the following sequential steps: (a)preparing an aqueous solution of nickel salt and containing, in at least partly dissolved state, aluminum and zirconium compounds thermally decomposable to the oxides, (b) precipitating substantially all metal ions from said aqueous solution by the addition of a base, (c) isolating and drying the precipitated metal compounds mixed with any undissolved compounds present in the system formed in step (b), (d) converting the thus-formed mixture of compounds into a mixture of the corresponding oxides by calcination at temperatures between 300° and 500° C., (e) working up the thus-formed oxides mixture into particles of any desired shape and size, (f) subjecting the shaped particles to a firing temperature of between 800° and 1100° C. for two to ten hours and (g) subsequently at least partially reducing the nickel oxide present in the fired particles into metallic nickel.

Claim 6

A method for preparing a methanation catalyst, said catalyst consisting essentially of nickel and a porous material containing alumina and zirconia, the components being evenly distributed amongst each other, wherein the content of nickel is from 15 to 40% by weight, calculated as nickel oxide, of the total catalyst and zirconia and alumina are present in a ratio of from 0.05 to 2.0 parts by weight of zirconia per part by weight of alumina; consisting essentially of the following sequential steps: (a)preparing an aqueous solution of nickel salt and containing, in at least partly dissolved state, aluminum and zirconium compounds thermally decomposable to the oxides, (b) precipitating substantially all metal ions from said aqueous solution by the addition of a base, (c) isolating and drying the precipitated metal compounds mixed with any undissolved compounds present in the system formed in step (b), (d) converting the thus-formed mixture of compounds into a mixture of the corresponding oxides by calcination at temperatures between 300° and 500° C., (e) working up the thus-formed oxides mixture into particles of any desired shape and size, (f) subjecting the shaped particles to a firing temperature of between 800° and 1100° C. for two to ten hours and (g) subsequently at least partially reducing the nickel oxide present in the fired particles into metallic nickel.