Process for the reactivation of nickel-alumina catalysts

Abstract

A process for the reactivation, or rejuvenation of a nickel-alumina catalyst employed in the production of a gas comprised of an admixture of hydrogen and carbon monoxide, or synthesis gas, by the conversion, in a reactor, or reaction zone, of light hydrocarbons in a fluidized bed of the catalyst at elevated temperature, in the presence of steam and oxygen. Catalyst reactivation is accomplished by withdrawing a portion of the catalyst from the fluidized bed of the reactor and treating the catalyst in an oxidation zone at temperature sufficient to oxidize and convert the nickel component of the catalyst to nickel aluminate and disperse said nickel aluminate within the alumina support, and then recycling the treated catalyst to the reactor, or reaction zone, to reactivate and increase the activity of the catalyst. The catalyst, on reduction in the reactor, or reaction zone, is provided an additional boost in activity by washing, treating or contacting the catalyst from the elevated temperature oxidation zone with an acid sufficient to remove trace impurities without removing any substantial amount of the nickel aluminate, and without forming a residue on the catalyst surface. The normal tendency of the catalyst to agglomerate at reaction conditions is also reduced by the acid treatment.