EP0130835A2 — High temperature stable catalyst, process for pre…

Claim 1

Independent Claim 102 words

A high temperature stable catalyst, which comprises a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g, where said composite oxide is substantially a mixture of L-β-alumina and its precursor that is convertible to L-β-alumina when heated to an elevated temperature above 1000°C within 2 hours or substantially the precursor.

Claim 2

Dependent Claim 102 words

A high temperature stable catalyst, which comprises a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g, where said composite oxide is substantially a mixture of L-β-alumina and its precursor that is convertible to L-β-alumina when heated to an elevated temperature above 1000°C within 2 hours or substantially the precursor.

Claim 3

Dependent Claim 35 words

A high temperature stable catalyst acccrding to claim 1, wherein the composite oxide has a composition of 1 to 20 molar % of the oxide of lanthanum, neodymium and praseodymium and the balance being alumina.

Claim 4

Dependent Claim 121 words

A high temperature stable catalyst, which comprises a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g, where said composite oxide contains less than 1% by weight of chromium, strontium and cerium, has a composition of 1 to 20 molar % of the oxide of lanthanum, neodymium and praseodymium and the balance being alumina, the composite oxide being substantially a mixture of L-β-alumina and its precursor or the precursor.

Claim 5

Dependent Claim 121 words

A high temperature stable catalyst, which comprises a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g, where said composite oxide contains less than 1% by weight of chromium, strontium and cerium, has a composition of 1 to 20 molar % of the oxide of lanthanum, neodymium and praseodymium and the balance being alumina, the composite oxide being substantially a mixture of L-β-alumina and its precursor or the precursor.

Claim 6

Dependent Claim 155 words

A high temperature stable catalyst, which comprises a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g and having a structural form other than a-, γ-, θ-, η-, K -, χ-, p- and δ-forms, where said composite oxide contains less than 1% by weight of chromium, strontium and cerium, and is a mixture of L-β-alumina and its precursor that is convertible to L-β-alumina when heated to an elevated temperature above 1000°C within 2 hours, or the precursor, wherein the composite oxide has a composition of 1 to 20 molar % of the oxide of lanthanum, neodymium and praseodymium and the balance being alumina.

Claim 7

Dependent Claim 155 words

A high temperature stable catalyst, which comprises a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g and having a structural form other than a-, γ-, θ-, η-, K -, χ-, p- and δ-forms, where said composite oxide contains less than 1% by weight of chromium, strontium and cerium, and is a mixture of L-β-alumina and its precursor that is convertible to L-β-alumina when heated to an elevated temperature above 1000°C within 2 hours, or the precursor, wherein the composite oxide has a composition of 1 to 20 molar % of the oxide of lanthanum, neodymium and praseodymium and the balance being alumina.

Claim 8

Dependent Claim 132 words

A high temperature stable catalyst, which comprises a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g, where said composite oxide contains less than 1% by weiqht of chromium, strontium and cerium, and is substantially L-β-alumina and its precursor that is convertible to L-β-alumina when heated to an elevated temperature-above 1000°C within 2 hours, wherein the composite oxide has a composition of 1 to 20 molar % of the oxide of lanthanum, neodymium and praseodymium and the balance being alumina.

Claim 9

Dependent Claim 132 words

A high temperature stable catalyst, which comprises a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g, where said composite oxide contains less than 1% by weiqht of chromium, strontium and cerium, and is substantially L-β-alumina and its precursor that is convertible to L-β-alumina when heated to an elevated temperature-above 1000°C within 2 hours, wherein the composite oxide has a composition of 1 to 20 molar % of the oxide of lanthanum, neodymium and praseodymium and the balance being alumina.

Claim 10

Dependent Claim 39 words

A high temperature stable catalyst according to any one of claims 1 to wherein the composite oxide has a composition of 3 to 10 molar % of the oxide of lanthanum, neodymium and praseodymium and the balance being alumina.

Claim 11

Dependent Claim 30 words

A high temperature stable catalyst according to any one of claims 1 to 7 wherein the composite oxide has a specific surface area of 20 to 100 m 2 /g.

Claim 12

Dependent Claim 26 words

8 . A high temperature stable catalyst according to any one of clams 1 to 7 wherein the shape of the support is a honeycomb structure.

Claim 13

Dependent Claim 26 words

8 . A high temperature stable catalyst according to any one of clams 1 to 7 wherein the shape of the support is a honeycomb structure.

Claim 14

Dependent Claim 32 words

A high temperature stable catalyst according to any one of clams 1 to 8 wherein the support comprises the part for supporting the active component and a substrate for carrying the support.

Claim 15

Dependent Claim 32 words

A high temperature stable catalyst according to any one of clams 1 to 8 wherein the support comprises the part for supporting the active component and a substrate for carrying the support.

Claim 16

Dependent Claim 25 words

A high temperature stable catalyst according to claim 9,, wherein the substrate is a member selected from a metallic plate, metallic mesh, and foamed metal.

Claim 17

Dependent Claim 35 words

11 . A high temperature stable catalyst according to any one cf claims 1 to 10, wherein the surface of the support is coated with the composite oxide on which said active component is supported.

Claim 18

Dependent Claim 59 words

A high temperature stable catalyst according to any one of claims 1 to 11, wherein the active component is a member selected from the group consisting of Group VIII elements of the Periodic Table, manganese, chromium, zirconium, rare earth elements, tin, zinc, copper, magnesium, barium, strontium, vanadium, tungsten, molybdenum, titanium, gallium, indium, lead, bismuth, antimony, chromium, silver, and calcium.

Claim 19

Dependent Claim 121 words

A process for preparing a high temperature stable catalyst, which comprises the steps of: effecting coprecipitation of an aluminum salt and a salt of lanthanum, praseodymium and/or neodymium from an aqueous solution of the salts by adding an alkali to the solution; separating the resulting precipitate; shaping the precipitate; and heating to a temperature higher than 1000°C the shaped precipitate to convert it into a composite oxide of aluminium and lanthanum, neodymium and/or praseodymium, whereby said composite oxide has a specific surface area of at least 10 m 2 /g and is substantially a mixture of L-β-alumina and its precursor that is convertible to L-β-alumina when heated to an elevated temperature above 1000°C preferably within 2 hours or substantially the precursor.

Claim 20

Dependent Claim 121 words

A process for preparing a high temperature stable catalyst, which comprises the steps of: effecting coprecipitation of an aluminum salt and a salt of lanthanum, praseodymium and/or neodymium from an aqueous solution of the salts by adding an alkali to the solution; separating the resulting precipitate; shaping the precipitate; and heating to a temperature higher than 1000°C the shaped precipitate to convert it into a composite oxide of aluminium and lanthanum, neodymium and/or praseodymium, whereby said composite oxide has a specific surface area of at least 10 m 2 /g and is substantially a mixture of L-β-alumina and its precursor that is convertible to L-β-alumina when heated to an elevated temperature above 1000°C preferably within 2 hours or substantially the precursor.

Claim 21

Dependent Claim 125 words

A process for conducting a catalytic chemical reaction, which comprises contacting a reactive component with a catalyst comprising a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g, where said composite oxide contains less than 1% by weight of chromium, strontium and cerium, and is substantially a mixture of L-B-alumina and its precursor that is convertible to L-β-alumina when heat to an elevated temperature above 1000°C within 2 hours or substantially the precursor.

Claim 22

Dependent Claim 125 words

A process for conducting a catalytic chemical reaction, which comprises contacting a reactive component with a catalyst comprising a support and a catalytically active component supported on said support, wherein at least the part of said support that predominantly supports said active component comprises a composite oxide of aluminium and at least one member selected from the group of lanthanum, neodymium, praseodymium and mixtures thereof, said composite oxide having a specific surface area of at least 10 m 2 /g, where said composite oxide contains less than 1% by weight of chromium, strontium and cerium, and is substantially a mixture of L-B-alumina and its precursor that is convertible to L-β-alumina when heat to an elevated temperature above 1000°C within 2 hours or substantially the precursor.

Claim 23

Dependent Claim 38 words

A process for conducting a catalytic chemical reaction according to claim 14 wherein the composite oxide has a composition of 1 to 20 molar % of the oxide of lanthanum, neodymium and/or praseodymium and the balance being alumina.

Claim 24

Dependent Claim 38 words

A process for conducting a catalytic chemical reaction according to claim 15, wherein the compcsite oxide has a composition of 3 to 10 molar % of the oxide of lanthanum, neodymium and/or praseodymium and the balance being alumina.

Claim 25

Dependent Claim 33 words

A process for conducting a catalytic chemical reaction according to any one of claims 14 to 16 wherein the composite oxide has a specific 2 surface area of 20 to 100 m /g.

Claim 26

Dependent Claim 30 words

A process for conducting a catalytic chemical reaction according to any one of claims 14 to 17 wherein the catalyst is according to any one of claims 1 to 12.

Claim 27

Dependent Claim 53 words

A process for conducting a catalytic chemical reaction according to any one of clains 14 to 18, wherein the active component is at least one member selected from the group consisting of Group VIII elements of the Periodic Table, manganese, chromium, zirconium, rare earth elements, tin, zinc, copper, magnesium, barium, strontium and calcium.

Claim 28

Dependent Claim 53 words

A process for conducting a catalytic chemical reaction according to any one of clains 14 to 18, wherein the active component is at least one member selected from the group consisting of Group VIII elements of the Periodic Table, manganese, chromium, zirconium, rare earth elements, tin, zinc, copper, magnesium, barium, strontium and calcium.

Claim 29

Dependent Claim 32 words

. A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein the catalyst is contacted with a fluid fuel and oxidant for catalytic combustion.

Claim 30

Dependent Claim 35 words

A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein said catalyst is contacted with at least one of hydrogen, carbon monoxide, alcohols, hydrocarbons and mixtures thereof.

Claim 31

Dependent Claim 34 words

A process for conducting a catalytic chemical reaction according to claim 21 wherein said hydrocarbon is methane and said catalytically active component is at least one of the Group VIII elements of Periodic Table.

Claim 32

Dependent Claim 82 words

A process for conducting a catalytic chemical reaction according to any one of claims 14 to 18 wherein the catalyst is contacted with an exhaust gas from an internal combustion engine and oxygen to oxidize carbon monoxide and hydrocarbons in said exhaust gas and to reduce nitrogen oxides in said exhaust gas, wherein the catalytically active component is a member selected from the group consisting of the Group VIII elements, manganese, rare earth metal, chromium, vanadium, tin, zirconium, magnesium, calcium and/or strontium.

Claim 33

Dependent Claim 48 words

A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein said catalyst is contacted with a stream of a mixture of hydrocarbons and steam at a temperature of 300 to 1200°C to form a gas comprising hydrogen and carbon monoxide.

Claim 34

Dependent Claim 30 words

A process for conducting a catalytic chemical reaction according to claim 19 or claim 23 wherein said active component is at least one Group VIII element of the Periodic Table.

Claim 35

Dependent Claim 45 words

A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein said catalyst is contacted with an exhaust gas containing nitrogen oxide and also with ammonia at a temperature of 150°C to 1000°C to reduce the nitrogen oxide.

Claim 36

Dependent Claim 30 words

A process for conducting a catalytic chemical reaction according to claim 26, wherein said active component is at least one of tungsten, vanadium, titanium, tin, cerium, iron, nickel and cobalt.

Claim 37

Dependent Claim 38 words

28 . A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein said catalyst is contacted with hydrocarbons at a temperature ranging from 500°C to 1000°C to effect the dehydrogenation.

Claim 38

Dependent Claim 26 words

A process for conducting a catalytic chemical reaction according to claim 21, wherein said catalyst is contacted with methanol at a temperature of 800°C to 1000°C.

Claim 39

Dependent Claim 71 words

A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein the active component is a member selected from the group consisting of molybdenum, tungsten, nickel and cobalt, and the catalyst is contacted with hydrocarbon oil containing a sulfur compound at 250°C to 500°C under 1 to 100 kg/cm 2 in the presence of hydrogen so as tt i effect desulfurization of the oil.

Claim 40

Dependent Claim 78 words

, A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein the active component is at least one member selected from the group consisting of Group VIII elements, manganese, titanium, zinc, copper, rare earth metal elements, tungsten, chromium, vanadium, and zirconium, and the catalyst is contacted with a gas containing an odorous organic compound and oxygen at a temperature of 100 to 1500°C so as to remove the odorous compound.

Claim 41

Dependent Claim 88 words

A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein the active component is at least one member selected from the group consisting of Group VIII elements titanium, zirconium, vanadium, molybdenum, tungsten, manganese, copper, zinc, gallium, indium, tin, lead, bismuth and antimony, and the catalyst is contacted with heavy oil, asphalt or coal in the presence of hydrogen at a temperature of 350 to 800°C under a pressure of 1 to 500 kg/cm 2 so as to produce light oil.

Claim 42

Dependent Claim 69 words

A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein the active component is at least one member selected from the group consisting of Group VIII elements, manganese, chromium, zirconium, rare earth elements, tin, zinc, copper, silver, magnesium, barium, strontium and calcium, and the catalyst is contacted with a gas containing an organic substance at a temperature of 1500°C or below.

Claim 43

Dependent Claim 42 words

A process for conducting a catalytic chemical reaction according to claim 21 wherein the catalyst is contacted with a gas containing carbon monoxide and hydrogen at a temperature of 1000°C or below under a pressure of 1 to 200 kg/cm 2 .

Claim 44

Dependent Claim 43 words

A process for conducting a catalytic chemical reaction according to claim 21 wherein the catalyst is contacted with carbon monoxide and hydrogen at a temperature of 600°C or below under a pressure of 1 to 200 kg/cm 2 so as to produce methanol.

Claim 45

Dependent Claim 36 words

A process for conducting a catalytic chemical reacting according to claim 21 , wherein the catalyst is contacted with a hydrocarbon at a temperature of 700°C or below so as to effect isomerization of the hydrocarbon.

Claim 46

Dependent Claim 37 words

37- A process for conducting a catalytic chemical reaction according to claim 21 , wherein the catalyst is contacted with gaseous hydrocarbons at a temperature of 1000°C or below so as to effect cracking of the hydrocarbons.

Claim 47

Dependent Claim 51 words

38 . A process for conducting a catalytic chemical reaction according to any one of claims 14 to 19 wherein the catalyst is contacted with an organic compound and/or nitrogen in the presence of hydrogen at a temperature of 800°C or below under a pressure of 500 kg/cm 2 or below.

High temperature stable catalyst, process for preparing same and process for conducting chemical reaction using same

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