Ordered cobalt-aluminum and iron-aluminum intermetallic compounds as hydrogenation catalysts

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This patent describes the use of ordered cobalt-aluminum (Co-Al) and iron-aluminum (Fe-Al) intermetallic compounds as highly selective and stable catalysts for hydrogenation reactions, particularly for selectively hydrogenating unsaturated hydrocarbon compounds such as acetylene to ethylene, even in the presence of a large excess of ethylene. Unlike conventional catalysts (like palladium-based ones), these intermetallic compounds offer improved selectivity, stability, and significantly lower catalyst costs.

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• Selective hydrogenation of acetylene to ethylene during ethylene production for polyethylene manufacturing.
• Removal of acetylenic and other unsaturated impurities from hydrocarbon streams in petrochemical plants.
• Hydrogenation of unsaturated hydrocarbons such as alkadienes, alkynes, cycloalkadienes, and aromatics in chemical manufacturing.
• Use in supported or monolithic catalyst forms in commercial hydrogenation reactors.
• Production of high-purity ethylene with minimal over-hydrogenation to ethane.

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• High selectivity: Preferential hydrogenation of target compounds (e.g., acetylene to ethylene) with minimal over-hydrogenation of ethylene.
• Excellent long-term stability: Maintains catalytic activity and selectivity over extended use, even under industrial conditions.
• Cost-effective: Made from cheaper base metals (iron, cobalt, aluminum) compared to conventional precious metal catalysts such as palladium or platinum.
• Reduced catalyst deactivation: Less prone to poisoning and carbon/hydrocarbon deposits, reducing regeneration and replacement frequency.
• Structural robustness: Stable up to high temperatures (600°C), allowing for flexible operating conditions.
• Scalable synthesis: Readily produced from common metals using established techniques (e.g., arc melting, Czochralski growth) and adaptable to various reactor setups.

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Patent Abstract

The present invention relates to a process for the hydrogenation, in particular the selective hydrogenation of unsaturated hydrocarbon compounds, such as the selective hydrogenation of acetylene to ethylene, using a hydrogenation catalyst comprising an ordered intermetallic compound, namely an ordered cobalt-aluminum or iron-aluminum intermetallic compound. According to another aspect, the present invention relates to a catalyst comprising a support and at least one specific ordered cobalt-aluminum and/or iron-aluminum intermetallic compound supported thereon, as well as to the use of specific ordered intermetallic cobalt-aluminum and iron-aluminum intermetallic compounds as catalysts. The ordered cobalt-aluminum and iron-aluminum intermetallic compounds proved to be highly selective and long-term stable catalysts, e.g. in the selective hydrogenation of acetylene to ethylene in a large excess of ethylene.