Heterogeneous selective hydrogenation of maleic anhydride with uniform microparticle size nickel supported catalyst coupled crystallization separation process

A series of highly dispersed nanoscale nickel-based catalysts were prepared by utilizing a co-precipitation method with the addition of surfactants. These catalysts were used for the synthesis of succinic anhydride through the selective hydrogenation of maleic anhydride (MA). Acetic acid was introduced as a novel solvent to facilitate a gas-liquid-solid three-phase reaction. This approach enables rapid separation of the product, succinic anhydride, from the solvent through cooling crystallization. The catalysts' structure and mechanism were thoroughly characterized using XRD, FT-IR, SEM, BET, XPS, NH3-TPD, and H2-TPR methods. Various surfactants, including PVA and PEG, were tested and optimized to enhance the selectivity of hydrogenation. A multifactor response surface analysis explored the effects of reaction temperature, reaction time, solvent ratio, and catalyst dosage on catalytic activity. Optimal conditions were determined, and hydrogenation kinetics were analyzed. The design and simulation of a new process integrating hydrogenation reaction with rapid crystallization separation were performed using the Aspen Plus software package.