A method for making a supported raney nickel catalyst by casting molten aluminum heated to about 850 deg c around a nickel substrate in a mold heated to about 1,050 deg c, retaining the metals in the mold at 1,050 deg c for about 30 s, allowing the mold to cool to ambient temperature, removing the casting from the mold and activating it by leaching with hot sodium hydroxide. Thus, a sheet of ni 25.4 X 152 x 1.27 Mm was placed in the center of a graphite mold having an internal cavity 3.55 Mm thick. The ni sheet was centered in the cavity by small graphite tabs. The mold, with the contained ni sheet, was then heated to 1,050 deg c in an electric furnace for approximately 10 min. Molten aluminum at 850 deg c was then poured in to fill the mold, and the temperature was maintained at 1,050 deg c for 30 s. The mold then was allowed to cool in air, the mold being coated with aluminum paint to prevent oxidation. Raney nickel layers 1.27 Mm thick on both sides of the ni substrate were produced. After leaching with sodium hydroxide solution, the sample was tested for methanation activity and found to give 99 pct conversion of 25 pct co-75 pct h2 (60 cm3/min total flow) to methane at 320 deg c. Additional elements may be added by either alloying them with the aluminum or with the nickel.
U.S. Pat. 4,043,946, Aug. 23, 1977; Chem. Abstr. Not Found