Role of precursor alloy phases and intermediate oxides in the preparation of Raney and Urushibara iron

⁵⁷Fe Mössbauer spectroscopy and scanning electron microscopy measurements of precursor phases formed during catalyst preparation and of the catalysts, themselves, demonstrate that the preparation of Raney iron from iron aluminum alloys involves the formation of Fe(OH)₂ and Fe₃O₄ as intermediate phases. The metallic Fe is formed from subsequent reduction of Fe₃O₄ by hydrogen generated by the oxidation of aluminum metal by hydroxide ions. Precursors to Urushibara iron U?Fe (III) are found to consist of Fe?Zn alloys when Zn is used as a reductant and of epitaxial deposits of Fe on aluminum when Al is the reductant. The material resulting from the reduction of the iron salt by aluminum is not a hydrogenation catalyst; the absence of catalytic activity is related to the absence of any alloying of the iron and aluminum. A consideration of the preparation of Raney iron, Urushibara iron, ammonia synthesis and Fischer-Tropsch catalysts leads to the conclusions that catalytic activity is highly correlated to the existence of intermediate mixed-crystals phases and the presence of intimate mixtures of at least two phases in the final catalyst.