Catalyst preparation and deactivation issues for nitrobenzene hydrogenation in a microstructured falling film reactor

Hydrogenation of nitrobenzene to aniline in ethanol was performed continuously in a microstructured falling film reactor at 60 °C, 1–4 bar hydrogen pressure and residence time 9–17 s. Palladium catalyst was deposited as films or particles via sputtering, UV-decomposition of palladium acetate, incipient wetness or impregnation. Deactivation was observed and was particularly pronounced for the sputtered and UV-decomposed catalysts. Catalysts prepared through incipient wetness or impregnation were more stable and activity could be recovered by oxidation at 130 °C. The main causes of deactivation were determined to be deposition of organic compounds and palladium loss.