US4337028A
Expired / Lapsed
US
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Catalytic monolith, method of its formulation and combustion process using the catalytic monolith
Assignee: Environmental Protection Agency
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Filing: 1980-05-27
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Granted: 1982-06-29
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Expires: 2000-05-27
Abstract
Abstract A catalyst system in which the catalytic composition comprises a catalytically active material which is homogeneously interspersed throughout a monolith structure of ceramic composition. The composition is shaped into a unitary monolith which is employed as the catalyst structure. In the method the active material or materials are admixed with a ceramic material, which can be either active or inactive, in finely divided form and then shaped into the monolith structure.
Inventors
- 👤 Meredith J. Angwin
- 👤 William C. Pfefferle
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 21:17
CPC Classifications
F; F23; F23C; F23C13/00; B; B01; B01J; B01J21/00; B01J21/005; B01J23/00; B01J23/70; B01J23/74; B01J23/76; B01J35/00; B01J35/50; B01J35/56
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
42 words
A catalytically active structurally sound ceramic in a monolithic form having gas flow passages with heterogeneous combustion surfaces formed of a catalytically active mixed base metal oxide of the perovskite, spinel, corundum or ilmenite crystal structure for the sustained combustion of fuels.
Claim 2
Dependent Claim
42 words
A catalytically active structurally sound ceramic in a monolithic form having gas flow passages with heterogeneous combustion surfaces formed of a catalytically active mixed base metal oxide of the perovskite, spinel, corundum or ilmenite crystal structure for the sustained combustion of fuels.
Claim 3
Dependent Claim
42 words
A monolithic catalytic structure comprising a catalytically active mixed base metal oxide of the perovskite crystal structure ABO 3 in intimate admixture with an additional base metal oxide of the perovskite crystal structure ABO 3 suitable for forming structurally sound catalytic ceramics.
Claim 4
Dependent Claim
42 words
A monolithic catalytic structure comprising a catalytically active mixed base metal oxide of the perovskite crystal structure ABO 3 in intimate admixture with an additional base metal oxide of the perovskite crystal structure ABO 3 suitable for forming structurally sound catalytic ceramics.
Claim 5
Dependent Claim
35 words
A catalytic structure as in claim 2 in which the active metal oxide is comprised of a metal of the cation B selected from the group consisting of Cr, Ni, Mn, Fe, Sr, and Ca.
Claim 6
Dependent Claim
51 words
A catalytic structure as in claim 2 in which the additional metal oxide is comprised of a metal of the cation A selected from the group consisting of La and Sr and is further comprised of a metal of the cation B selected from the group consisting of Al and Cr.
Claim 7
Dependent Claim
44 words
A monolithic catalytic structure comprising a catalytically active base metal oxide of the spinel crystal structure A[B 2 ]O 4 or B[AB]O 4 in intimate admixture with an additional base metal oxide of the spinel crystal structure suitable for forming structurally sound catalytic ceramics.
Claim 8
Dependent Claim
44 words
A monolithic catalytic structure comprising a catalytically active base metal oxide of the spinel crystal structure A[B 2 ]O 4 or B[AB]O 4 in intimate admixture with an additional base metal oxide of the spinel crystal structure suitable for forming structurally sound catalytic ceramics.
Claim 9
Dependent Claim
32 words
A catalytic structure as in claim 5 in which the active metal oxide is comprised of a metal of the cation B selected from the group consisting of Ni, Fe and Cr.
Claim 10
Dependent Claim
34 words
A catalytic structure as in claim 5 in which the active metal oxide comprises Fe 3 O 4 or NiAl 2 O 4 and the additional metal oxide comprises MgAl 2 O 4 .
Claim 11
Dependent Claim
20 words
A catalytic structure as in claim 5 in which the active metal oxide comprises Fe 3 O 4 with Cr.
Claim 12
Dependent Claim
51 words
A monolithic catalytic structure comprising a catalytically active base metal oxide of the corundum crystal structure B 2 O 3 or of the ilmenite crystal structure ABO 3 in intimate admixture with an additional base metal oxide of the corundum crystal structure suitable for formation of a structurally sound catalytic ceramic.
Claim 13
Dependent Claim
51 words
A monolithic catalytic structure comprising a catalytically active base metal oxide of the corundum crystal structure B 2 O 3 or of the ilmenite crystal structure ABO 3 in intimate admixture with an additional base metal oxide of the corundum crystal structure suitable for formation of a structurally sound catalytic ceramic.
Claim 14
Dependent Claim
35 words
A catalytic structure as in claim 9 in which the active metal oxide of the corundum structure is comprised of a metal of the cation B selected from the group consisting of Co and Fe.
Claim 15
Dependent Claim
31 words
A catalytic structure as in claim 9 in which the active metal oxide of the ilmenite structure is comprised of a metal selected from the group consisting of Fe and Cr.
Claim 16
Dependent Claim
25 words
A catalytic structure as in claim 10 or 11 in which the additional metal oxide is comprised of the metal Al of the cation B.
Claim 17
Dependent Claim
23 words
A catalytic structure as in claim 9 in which the active metal oxide comprises yttria-stabilized Co 2 O 3 of corundum crystal structure.
Claim 18
Dependent Claim
51 words
A combustion process comprising combusting reactants in the presence of a catalytically active structurally sound ceramic in a monolithic form having gas flow passages with heterogeneous combustion surfaces formed of a catalytically active base metal oxide of the perovskite, spinel, corundum or ilmenite crystal structure for the sustained combustion of fuels.
Claim 19
Dependent Claim
51 words
A combustion process comprising combusting reactants in the presence of a catalytically active structurally sound ceramic in a monolithic form having gas flow passages with heterogeneous combustion surfaces formed of a catalytically active base metal oxide of the perovskite, spinel, corundum or ilmenite crystal structure for the sustained combustion of fuels.
Claim 20
Dependent Claim
65 words
A combustion process comprising combusting reactants in the presence of a catalytically active structurally sound ceramic in a monolithic form having gas flow passages with heterogeneous combustion services formed of a catalytically active base metal oxide of the perovskite crystal structure ABO 3 in intimate admixture with additional base metal oxide of the perovskite crystal structure ABO 3 suitable for forming structurally sound catalytic ceramics.
Claim 21
Dependent Claim
65 words
A combustion process comprising combusting reactants in the presence of a catalytically active structurally sound ceramic in a monolithic form having gas flow passages with heterogeneous combustion services formed of a catalytically active base metal oxide of the perovskite crystal structure ABO 3 in intimate admixture with additional base metal oxide of the perovskite crystal structure ABO 3 suitable for forming structurally sound catalytic ceramics.
Claim 22
Dependent Claim
35 words
A combustion process as in claim 15 in which the active metal oxide is comprised of a metal of the cation B selected from the group consisting of Cr, Ni, Mn, Fe, Sr, and Ca.
Claim 23
Dependent Claim
51 words
A combustion process as in claim 15 in which the additional metal oxide is comprised of a metal of the cation A selected from the group consisting of La and Sr and is further comprised of a metal of the cation B selected from the group consisting of Al and Cr.
Claim 24
Dependent Claim
54 words
A combustion process comprising combusting reactants in the presence of a monolithic catalytic structure comprising a catalytically active base metal oxide of the spinel crystal structure A[B 2 ]O 4 or B[AB]O 4 in intimate admixture with an additional base metal oxide of the spinel crystal structure suitable for forming structurally sound catalytic ceramics.
Claim 25
Dependent Claim
54 words
A combustion process comprising combusting reactants in the presence of a monolithic catalytic structure comprising a catalytically active base metal oxide of the spinel crystal structure A[B 2 ]O 4 or B[AB]O 4 in intimate admixture with an additional base metal oxide of the spinel crystal structure suitable for forming structurally sound catalytic ceramics.
Claim 26
Dependent Claim
32 words
A combustion process as in claim 18 in which the active metal oxide is comprised of a metal of the cation B selected from the group consisting of Ni, Fe and Cr.
Claim 27
Dependent Claim
34 words
A combustion process as in claim 18 in which the active metal oxide comprises Fe 3 O 4 or NiAl 2 O 4 and the additional metal oxide comprises MgAl 2 O 4 .
Claim 28
Dependent Claim
20 words
A combustion process as in claim 18 in which the active metal oxide comprises Fe 3 O 4 with Cr.
Claim 29
Dependent Claim
61 words
A combustion process comprising combusting reactants in the presence of a monolithic catalytic structure comprising a catalytically active base metal oxide of the corundum crystal structure B 2 O 3 or of the ilmenite crystal structure ABO 3 in intimate admixture with an additional base metal oxide of the corundum crystal structure suitable for formation of a structurally sound catalytic ceramic.
Claim 30
Dependent Claim
61 words
A combustion process comprising combusting reactants in the presence of a monolithic catalytic structure comprising a catalytically active base metal oxide of the corundum crystal structure B 2 O 3 or of the ilmenite crystal structure ABO 3 in intimate admixture with an additional base metal oxide of the corundum crystal structure suitable for formation of a structurally sound catalytic ceramic.
Claim 31
Dependent Claim
35 words
A combustion process as in claim 22 in which the active metal oxide of the corundum structure is comprised of a metal of the cation B selected from the group consisting of Co and Fe.
Claim 32
Dependent Claim
31 words
A combustion process as in claim 22 in which the active metal oxide of the ilmenite structure is comprised of a metal selected from the group consisting of Fe and Cr.
Claim 33
Dependent Claim
25 words
A combustion process as in claim 23 or 24 in which the additional metal oxide is comprised of the metal Al of the cation B.
Claim 34
Dependent Claim
20 words
A combustion process as in claim 22 in which the active metal oxide comprises yttria-stabilized Co 2 O 3 .
Claim 35
Independent Claim
84 words
A method of formulating a catalyst system comprising the steps of preparing an intimate admixture of a catalytically active base metal oxide having the perovskite crystal structure and an average particle size on the order of 10-20 microns with an additional base metal oxide having the perovskite crystal structure of the type suitable for formation of structurally sound catalytic ceramics and with an average particle size on the order of 10-20 microns, forming the mixture into a unitary structure, and calcining the formed structure.
Claim 36
Independent Claim
84 words
A method of formulating a catalyst system comprising the steps of preparing an intimate admixture of a catalytically active base metal oxide having the perovskite crystal structure and an average particle size on the order of 10-20 microns with an additional base metal oxide having the perovskite crystal structure of the type suitable for formation of structurally sound catalytic ceramics and with an average particle size on the order of 10-20 microns, forming the mixture into a unitary structure, and calcining the formed structure.
Claim 37
Independent Claim
84 words
A method of formulating a catalyst system comprising the steps of preparing an intimate admixture of a catalytically active base metal oxide of the spinel crystal structure and an average particle size on the order of 10-20 microns with an additional base metal oxide of the spinel crystal structure of the type suitable for formation of structurally sound catalytic ceramics and with an average particle size on the order of 10-20 microns, forming the mixture into a unitary structure, and calcining the formed structure.
Claim 38
Independent Claim
84 words
A method of formulating a catalyst system comprising the steps of preparing an intimate admixture of a catalytically active base metal oxide of the spinel crystal structure and an average particle size on the order of 10-20 microns with an additional base metal oxide of the spinel crystal structure of the type suitable for formation of structurally sound catalytic ceramics and with an average particle size on the order of 10-20 microns, forming the mixture into a unitary structure, and calcining the formed structure.
Claim 39
Independent Claim
94 words
A method of formulating a catalyst structure comprising the steps of preparing an intimate admixture of a catalytically active base metal oxide of the corundum crystal structure or of the ilmenite crystal structure, said active metal oxides having an average particle size on the order of 10-20 microns, with an additional base metal oxide of the corundum crystal structure of the type suitable for formation of structurally sound catalytic ceramics and having an average particle size on the order of 10-20 microns, forming the mixture into a unitary structure, and calcining the formed structure.
Claim 40
Independent Claim
94 words
A method of formulating a catalyst structure comprising the steps of preparing an intimate admixture of a catalytically active base metal oxide of the corundum crystal structure or of the ilmenite crystal structure, said active metal oxides having an average particle size on the order of 10-20 microns, with an additional base metal oxide of the corundum crystal structure of the type suitable for formation of structurally sound catalytic ceramics and having an average particle size on the order of 10-20 microns, forming the mixture into a unitary structure, and calcining the formed structure.
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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) | 1985-06-28 | 1985-12-28 | 1986-06-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1989-06-28 | 1989-12-28 | 1990-06-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1993-06-28 | 1993-12-28 | 1994-06-29 | $7700.00 | Window Closed / Lapsed |