US4048098A
Expired / Lapsed
US
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Catalyst for purification of exhaust gases and processes for its production and use
Assignee: Evonik Operations GmbH
•
Filing: 1974-02-04
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Granted: 1977-09-13
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Expires: 1994-02-04
Abstract
Abstract A carrier catalyst comprises as the catalytically active component an intermetallic system of at least three metals, wherein at least one of said three metals is selected from the group consisting of (a) ruthenium, rhodium, palladium and platinum, and wherein at least one of said three metals is a base metal selected from the group consisting of (b) aluminum, titanium, chromium, manganese, cobalt and nickel, and further wherein said group (a) metals and said group (b) metals are in an atomic ratio of about 1:4 to 1:1, provided that, when said system contains platinum, rhodium and at least one of said base metals, the atomic ratio is 1:4 to 1:2.4. The catalyst can also contain aluminum.
Inventors
- 👤 Edgar Koberstein
- 👤 Eduard Lakatos
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 04:38
CPC Classifications
B; B01; B01D; B01D53/00; B01D53/34; B01D53/92; B01D53/94; B01D53/9445; B01D53/945; B01J; B01J23/00; B01J23/38; B01J23/40; B01J23/54; B01J23/56; B01J23/64; B01J23/652; B01J23/70; B01J23/89; Y; Y02; Y02A; Y02A50/00; Y02A50/20; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 56
Claim 1
Independent Claim
153 words
A carrier catalyst comprising an intermetallic system of at least three metals as catalytically active component, said catalyst comprising the product obtained by contacting a catalyst carrier with an aqueous solution comprising a halide of at least one metal selected from the group consisting of (a) rhodium, palladium and platinum, and a halide of at least one base metal selected from the group consisting of (b) aluminum, titanium, chromium, manganese, cobalt and nickel; drying the resulting impregnated carrier; and reducing the halides at a temperature of about 450°-1000° C in a stream of hydrogen; wherein said group (a) metals and said group (b) metals are in an atomic ratio of group (a) metals to group (b) metals of about 1 : 4 to 1 : 1; provided that, when said system contains platinum, rhodium and at least one of said base metals, said atomic ratio is 1 : 4 to 1 : 2.4.
Claim 2
Dependent Claim
153 words
A carrier catalyst comprising an intermetallic system of at least three metals as catalytically active component, said catalyst comprising the product obtained by contacting a catalyst carrier with an aqueous solution comprising a halide of at least one metal selected from the group consisting of (a) rhodium, palladium and platinum, and a halide of at least one base metal selected from the group consisting of (b) aluminum, titanium, chromium, manganese, cobalt and nickel; drying the resulting impregnated carrier; and reducing the halides at a temperature of about 450°-1000° C in a stream of hydrogen; wherein said group (a) metals and said group (b) metals are in an atomic ratio of group (a) metals to group (b) metals of about 1 : 4 to 1 : 1; provided that, when said system contains platinum, rhodium and at least one of said base metals, said atomic ratio is 1 : 4 to 1 : 2.4.
Claim 3
Dependent Claim
16 words
Catalyst according to claim 1 in which at least one of said halides is a chloride.
Claim 4
Dependent Claim
61 words
Catalyst according to claim 1 in which said active component is prepared by treating a catalyst carrier with an aqueous impregnating solution containing halides of said metals other than an aluminum halide, drying the resulting impregnated carrier, treating the dried carrier with an aqueous suspension of aluminum powder, drying the treated carrier, and reducing the halides in a stream of hydrogen.
Claim 5
Dependent Claim
15 words
Catalyst according to claim 1 in which the active component comprises rhodium, platinum and aluminum.
Claim 6
Dependent Claim
14 words
Catalyst according to claim 1 in which the carrier is a catalysis promoting oxide.
Claim 7
Dependent Claim
24 words
Catalyst according to claim 5 in which the catalysis promoting carrier is a film on a shock resistant, slightly porous, predominantly crystalline ceramic support.
Claim 8
Dependent Claim
49 words
Catalyst according to claim 6 in which the catalysis promoting carrier is applied to the ceramic support by contacting the support with an aqueous dispersion of the carrier, of a hydroxide of the carrier, or of a hydrated oxide precursor of the carrier, and subsequently calcining the resulting structure.
Claim 9
Dependent Claim
22 words
Catalyst according to claim 7 in which the dispersion contains a salt of the metal component of the catalysis promoting carrier material.
Claim 10
Dependent Claim
39 words
Catalyst according to claim 1 in which the carrier is a catalysis promoting metal oxide comprising gamma-Al 2 O 3 having a specific surface of at least about 100 m 2 /g, and containing calcium, strontium or barium ions.
Claim 11
Dependent Claim
43 words
Catalyst according to claim 7 in which the ceramic support has a surface area of at least about 0.3 m 2 /g, a macropore volume as determined by mercury porosimetry of at least about 20%, and macropores of at least about 10,000 A.
Claim 12
Dependent Claim
35 words
Catalyst according to claim 7 in which the ceramic support is contacted with an aqueous dispersion of gamma-aluminum oxide, its hydroxide or hydrated oxide precursor, said dispersion containing calcium nitrate, strontium nitrate or barium nitrate.
Claim 13
Dependent Claim
42 words
Catalyst according to claim 11 in which the dispersion contains about 0.05-0.5 mole/l of the hydroxide, or its hydrated oxide precursor, expressed as Al 2 O 3 , in suspension, and about 0.0075-1.5 of the calcium, strontium or barium salt in solution.
Claim 14
Dependent Claim
39 words
Catalyst according to claim 12 in which the ceramic support is contacted with an aqueous dispersion of gamma-aluminum oxide, its hydroxide or hydrated oxide precursor, said dispersion containing an aluminum salt and calcium nitrate, strontium nitrate or barium nitrate.
Claim 15
Dependent Claim
50 words
Catalyst according to claim 13 in which the dispersion comprises about 0.05-0.5 mole/l aluminum hydroxide or a hydrated oxide precursor, expressed as Al 2 O 3 , in suspension, and about 0.05-0.5 mole/l of the aluminum salt, and about 0.01-0.2 mole/l of the calcium, strontium or barium nitrate in solution.
Claim 16
Dependent Claim
31 words
Catalyst according to claim 14 in which the aluminum hydroxide is one which has been freshly precipitated and then aged for 1 to 6 hours at ambient temperature with intensive stirring.
Claim 17
Dependent Claim
36 words
Catalyst according to claim 13 in which the gamma-Al 2 O 3 , its hydroxide or hydrated oxide precursor contains about 0.5-5% by weight alkaline earth metal oxide based on the Al 2 O 3 .
Claim 18
Dependent Claim
37 words
Catalyst according to claim 1 in which said reduction is conducted for about 0.5 to about 3 hours and heating at about 100°-300° C for about 0.5 to about 3 hours to dry said resulting impregnated carrier.
Claim 19
Dependent Claim
22 words
Catalyst according to claim 17 in which said heating is conducted at about 150°-250° C for about 1 to about 1.5 hours.
Claim 20
Dependent Claim
23 words
Catalyst according to claim 1 in which said carrier material and said aqueous solution are contacted for about 5 to about 40 minutes.
Claim 21
Dependent Claim
16 words
Catalyst according to claim 4 in which said active component also contains cobalt, chromium or manganese.
Claim 22
Dependent Claim
15 words
Catalyst according to claim 1 in which the active component comprises palladium, platinum and aluminum.
Claim 23
Dependent Claim
16 words
Catalyst according to claim 21 in which the active component also contains cobalt, manganese or nickel.
Claim 24
Dependent Claim
16 words
Catalyst according to claim 1 in which the active component comprises rhodium, palladium, platinum and aluminum.
Claim 25
Dependent Claim
13 words
Catalyst according to claim 23 in which the active component also contains nickel.
Claim 26
Dependent Claim
15 words
Catalyst according to claim 1 in which the active component comprises palladium, titanium and manganese.
Claim 27
Dependent Claim
62 words
Catalyst according to claim 1 in which the carrier is selected from the group consisting of eta- or gamma-Al 2 O 3 , BeO, ZrO 2 , MgO, SiO 2 , barium silicate, boron silicate, silicon nitride, an aluminosilicate, barium titanate, and mixtures of any of these materials, said carrier having a specific surface of at least about 10 m 2 /g.
Claim 28
Dependent Claim
42 words
Catalyst according to claim 26 in which the carrier is selected from the group consisting of eta- or gramma-Al 2 O 3 , and mixtures of these materials, said carrier having a specific surface of at least about 10 m 2 /g.
Claim 29
Dependent Claim
42 words
Catalyst according to claim 10 in which the ceramic support is comprised of α-Al 2 O 3 , mullite, zirconium, zirconium mullite, cordierite, barium titanate, porcelain, thorium oxide, steatite, magnesium oxide, samarium oxide, gadolinium oxide, boron carbide, silicon nitride or silicon carbide.
Claim 30
Dependent Claim
17 words
Catalyst according to claim 28 in which the ceramic support is in a compact or fiber form.
Claim 31
Dependent Claim
24 words
Catalyst according to claim 28 in which the ceramic support is comprised of a monolithic skeletal cordierite frame having multiple unobstructed channels passing therethrough.
Claim 32
Dependent Claim
58 words
Process for the preparation of a catalyst according to claim 1 said process comprising contacting the catalyst carrier with an aqueous solution comprising halides of the group (a) metals and group (b) metals in said atomic ratio, drying the resulting impregnated carrier, and reducing the halides at a temperature of about 450°-1000° C in a stream of hydrogen.
Claim 33
Dependent Claim
73 words
Process for the preparation of a catalyst according to claim 1 said process comprising contacting the catalyst carrier with an aqueous solution comprising the halides of the group (a) metals and group (b) metals other than aluminum, drying the resulting impregnated carrier, treating the dried carrier with the aqueous suspension of the aluminum powder, drying the carrier, and reducing the halides at a temperature of about 450°-1000° C in a stream of hydrogen.
Claim 34
Dependent Claim
48 words
Process according to claim 31 in which the catalyst carrier is applied to a ceramic support by contacting the support with an aqueous dispersion of the carrier, removing excess quantities of the dispersion, drying the treated support and calcining the treated support at a temperature about 450°-1000° C.
Claim 35
Dependent Claim
14 words
Process according to claim 33 in which the operating steps are repeated several times.
Claim 36
Dependent Claim
35 words
Process according to claim 33 in which the ceramic support is contacted with an aqueous dispersion of gamma-aluminum oxide, its hydroxide or hydrated oxide precursor, said dispersion containing calcium nitrate, strontium nitrate, or barium nitrate.
Claim 37
Dependent Claim
43 words
Process according to claim 35 in which the dispersion contains about 0.05-0.5 mole/l of the hydroxide, or its hydrated oxide precursor, expressed as Al 2 O 3 , in suspension, and about 0.0075-1.5 mole/1 of the calcium, strontium, or barium salt in solution.
Claim 38
Dependent Claim
39 words
Process according to claim 33 in which the ceramic support is contacted with an aqueous dispersion of gamma-aluminum oxide, its hydroxide or hydrated oxide precursor, said dispersion containing an aluminum salt and calcium nitrate, strontium nitrate or barium nitrate.
Claim 39
Dependent Claim
50 words
Process according to claim 37 in which the dispersion comprises about 0.05-0.5 mole/l aluminum hydroxide or a hydrated oxide precursor, expressed as Al 2 O 3 , in suspension, and about 0.05-0.5 mole/l of the aluminum salt, and about 0.01-0.2 mole/l of the calcium, strontium or barium nitrate in solution.
Claim 40
Dependent Claim
29 words
Process according to claim 38 in which the aluminum hydroxide is one which has been freshly precipitated and then aged for 1-6 hours at ambient temperature with intensive stirring.
Claim 41
Dependent Claim
36 words
Process according to claim 37 in which the gamma-Al 2 O 3 , its hydroxide or hydrated oxide precursor contains about 0.5-5% by weight alkaline earth metal oxide based on the Al 2 O 3 .
Claim 42
Dependent Claim
29 words
Process according to claim 40 in which the alkaline earth metal-containing hydroxide or hydrated oxide precursor is prepared by coprecipitation from an alkaline earth metal- and aluminum salt-containing solution.
Claim 43
Dependent Claim
13 words
Process according to claim 35 in which the dispersion contains an anti-sedimentation agent.
Claim 44
Dependent Claim
26 words
Process according to claim 42 in which the antisedimentation agent is methyl cellulose, dextrin, tragacanth or starch, polyvinyl alcohol, polypropylene glycol, gum arabic, or mixtures thereof.
Claim 45
Dependent Claim
31 words
Process according to claim 31 in which said reduction is conducted for about 0.5-3 hours and heating at about 100°-300° C for about 0.5-3 hours to dry said resulting impregnated carrier.
Claim 46
Dependent Claim
19 words
Process according to claim 44 in which said reduction is conducted at about 500°-900° C for about 1-1.5 hours.
Claim 47
Dependent Claim
15 words
Process according to claim 44 in which said reduction is conducted at about 700°-850° C.
Claim 48
Dependent Claim
19 words
Process according to claim 44 in which said heating is conducted at about 150°-250° C for about 1-1.5 hours.
Claim 49
Dependent Claim
20 words
Process according to claim 31 in which said carrier material and said aqueous solution are contacted for about 5-40 minutes.
Claim 50
Dependent Claim
20 words
Process according to claim 31 in which said aqueous solution and said carrier material are contacted for about 10-25 minutes.
Claim 51
Dependent Claim
16 words
Process according to claim 42 in which said dispersion has a viscosity of about 3-300 centipoise.
Claim 52
Dependent Claim
16 words
Process according to claim 50 in which said dispersion has a viscosity of about 5-100 centipoise.
Claim 53
Dependent Claim
16 words
Process according to claim 43 in which said dispersion has a viscosity of about 20-50 centipoise.
Claim 54
Dependent Claim
26 words
Process according to claim 31 wherein said three metals are rhodium, platinum and aluminum and said atomic ratio is 1 : 4 to 1 : 2.4.
Claim 55
Dependent Claim
158 words
A process for the preparation of a carrier catalyst comprising an intermetallic system of at least three metals as catalytically active component, said process comprising: 1. contacting a catalyst carrier with an aqueous solution comprising a halide of at least one metal selected from the group consisting of (a) rhodium, palladium and platinum, and a halide of at least one base metal selected from the group consisting of (b) aluminum, titanium, chromium, manganese, cobalt and nickel; 2. drying the resulting impregnated carrier; and 3. reducing the halides at a temperature of about 450°-1000° C in a stream of hydrogen; wherein said group (a) metals and said group (b) metals are in an atomic ratio of group (a) metals to group (b) metals of about 1 : 4 to 1 : 1; provided that, when said system contains platinum, rhodium and at least one of said base meals, said atomic ratio is 1 : 4 to 1 : 2.4
Claim 56
Dependent Claim
158 words
A process for the preparation of a carrier catalyst comprising an intermetallic system of at least three metals as catalytically active component, said process comprising: 1. contacting a catalyst carrier with an aqueous solution comprising a halide of at least one metal selected from the group consisting of (a) rhodium, palladium and platinum, and a halide of at least one base metal selected from the group consisting of (b) aluminum, titanium, chromium, manganese, cobalt and nickel; 2. drying the resulting impregnated carrier; and 3. reducing the halides at a temperature of about 450°-1000° C in a stream of hydrogen; wherein said group (a) metals and said group (b) metals are in an atomic ratio of group (a) metals to group (b) metals of about 1 : 4 to 1 : 1; provided that, when said system contains platinum, rhodium and at least one of said base meals, said atomic ratio is 1 : 4 to 1 : 2.4
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-09-12 | 1981-03-14 | 1981-09-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-09-12 | 1985-03-14 | 1985-09-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-09-12 | 1989-03-14 | 1989-09-13 | $7700.00 | Window Closed / Lapsed |