A novel nickel catalyst derived from layered double hydroxides (LDHs) supported on fluid catalytic cracking catalyst residue (FC3R) for rosin hydrogenation

•A novel layered nickel catalyst using spent FCC catalyst as support was prepared.•Spent FCC catalyst was used as Al3+ source for the synthesis of NiAl-layered precursor.•The confinement effect in the LDHs main layer lead to small nickel particles and high Ni dispersion.•The catalyst was more active and stable than the catalyst prepared by impregnation method.•The conversion of abietic-type resin acid reached 99.02% under relatively mild condition (5 MPa, 190 °C).

A novel Ni-based catalyst (LP-Ni/FC3R) derived from a layered double hydroxides (LDHs) precursor was synthesized in situ and applied to rosin hydrogenation. Fluid catalytic cracking catalyst residue (FC3R) was used as a support material and sole Al3+ source. The effects of nickel loading, H2 pressure, temperature, and reaction time on catalytic performance were extensively investigated in a 2 m3 stainless steel autoclave. Maximum conversion of abietic-type resin acids reached 99.29% under relatively mild conditions with a nickel content of 8 wt.% and reaction time of 100 min. For comparison, a nickel catalyst (IM-Ni/FC3R) was prepared via incipient wetness impregnation. The textural, structural, and morphological properties of the two catalyst precursors were characterized by XRD, SEM, XPS, FT-IR, and H2-TPR/TPD. Results showed that Ni2+Al3+-containing LDHs (NiAl-LDHs) in the novel catalyst grow in situ at the surface and in the pores of FC3R. Compared with IM-Ni/FC3R, LP-Ni/FC3R shows a smaller crystallite size, higher Ni dispersion, and stronger interactions between Ni species and the FC3R support. LP-Ni/FC3R exhibited higher activity and better stability, which may be mainly ascribed to its unique NiAl-LDHs structures.

Graphical abstractA Ni-based catalyst derived from LDHs precursor supported over FC3R is proved to be a highly efficient heterogeneous, reusable catalyst for hydrogenation of rosin under relatively mild conditions.Figure optionsDownload full-size imageDownload as PowerPoint slide