In
connection with an initiative to enhance heat recovery from
the large-scale operation of a heterogeneously catalyzed nitrobenzene
hydrogenation process to produce aniline, it is necessary to operate
the process at elevated temperatures (>100 °C), a condition
that
can compromise aniline selectivity. Alumina-supported palladium catalysts
are selected as candidate materials that can provide sustained aniline
yields at elevated temperatures. Two Pd/Al
2
O
3
catalysts are examined that possess comparable mean Pd particle
sizes (∼5 nm) for different Pd loading: 5 wt % Pd/Al
2
O
3
and 0.3 wt % Pd/Al
2
O
3
. The higher
Pd loading sample represents a reference catalyst for which the Pd
crystallite morphology has previously been established. The lower
Pd loading technical catalyst more closely corresponds to industrial
specifications. The morphology of the Pd crystallites of the 0.3 wt
% Pd/Al
2
O
3
sample is explored by means of temperature-programmed
infrared spectroscopy of chemisorbed CO. Reaction testing over the
range of 60–180 °C shows effectively complete nitrobenzene
conversion for both catalysts but with distinction in their selectivity
profiles. The low loading catalyst is favored as it maximizes aniline
selectivity and avoids the formation of overhydrogenated products.
A plot of aniline yield as a function of WHSV for the 0.3 wt % Pd/Al
2
O
3
catalyst at 100 °C yields a “volcano”
like curve, indicating aniline selectivity to be sensitive to residence
time. These observations are brought together to provide an indication
of an aniline synthesis catalyst specification suited to a unit operation
equipped for enhanced heat transfer.