US4585752A
Expired / Lapsed
US
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Catalyst composition for ultra high temperature operation
Assignee: WR Grace and Co Conn
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Filing: 1984-08-15
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Granted: 1986-04-29
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Expires: 2004-08-15
Abstract
Abstract A high temperature stable catalyst is made with fine particles of a base metal such as chromium, hafnium and niobium or their oxides dispersed throughout a matrix made of composite particles having at least one platinum group metal on a ceria promoted, high temperature chemically stabilized refractory oxide powder. The refractory oxide powder can be either alumina, alumina powder which has been calcined at a temperature near incipient alpha alumina formation, silica-alumina or zirconia. The base metal or base metal oxide comprises about 15% to 90% by weight of the total weight and the platinum group metal comprises 0.05% to 10% by weight of the total weight. The catalyst composition can be applied as a washcoat to conventional substrates or it can be formed into shaped catalysts. The washcoat is made by mixing together one slip containing the composite particles with a second slip containing the base metal or base metal oxide particles.
Inventors
- 👤 Michael V. Ernest
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 23:30
CPC Classifications
B; B01; B01J; B01J23/00; B01J23/38; B01J23/54; B01J23/56; B01J23/64; B01J23/648; B01J23/40; B01J23/63; B01J23/652; B01J23/6522; B01J37/00; B01J37/04
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
107 words
A high temperature stable catalyst comprising a mixture of: (a) fine particles of a base metal or base metal oxide selected from the group consisting of chromium, hafnium, niobium, chromium oxide, hafnium oxide, niobium oxide and mixtures thereof; and (b) composite particles of a ceria promoted, high temperature chemically stabilized refractory oxide powder having at least one platinum group metal thereon, said composite particles serving as a bonding vehicle for said base metal or base metal oxide particles whereby said base metal or base metal oxide particles are dispersed throughout the mixture and whereby said base metal or base metal oxide exists in a fine particulate form.
Claim 2
Dependent Claim
107 words
A high temperature stable catalyst comprising a mixture of: (a) fine particles of a base metal or base metal oxide selected from the group consisting of chromium, hafnium, niobium, chromium oxide, hafnium oxide, niobium oxide and mixtures thereof; and (b) composite particles of a ceria promoted, high temperature chemically stabilized refractory oxide powder having at least one platinum group metal thereon, said composite particles serving as a bonding vehicle for said base metal or base metal oxide particles whereby said base metal or base metal oxide particles are dispersed throughout the mixture and whereby said base metal or base metal oxide exists in a fine particulate form.
Claim 3
Dependent Claim
30 words
A catalyst according to claim 1, wherein the refractory oxide powder is alumina, alumina powder which has been calcined at a temperature near incipient alpha alumina formation, silica-alumina or zirconia.
Claim 4
Dependent Claim
33 words
A catalyst according to claim 1, wherein the high temperature stable refractory oxide powder is a lanthana stabilized alumina, a lanthana rich rare earth oxide stabilized alumina or a barium oxide stabilized alumina.
Claim 5
Dependent Claim
25 words
A catalyst according to claim 1, wherein the base metal or base metal oxide comprise about 15% to 90% by weight of the total weight.
Claim 6
Dependent Claim
21 words
A catalyst according to claim 1, wherein the platinum group metal comprises 0.05% to 10% by weight of the total weight.
Claim 7
Dependent Claim
17 words
A catalyst according to claim 1, further comprising a substrate on which said catalyst composition is coated.
Claim 8
Dependent Claim
12 words
A catalyst according to claim 6, wherein the substrate is a honeycomb.
Claim 9
Dependent Claim
13 words
A catalyst according to claim 6, wherein the substrate is in particulate form.
Claim 10
Dependent Claim
13 words
A catalyst according to claim 6, wherein the substrate is a fibrous composite.
Claim 11
Dependent Claim
26 words
A catalyst according to claim 1, wherein said particles of a base metal or base metal oxide have a particle size of less than 10 microns.
Claim 12
Independent Claim
137 words
A method of making a high temperature stable catalyst comprising: forming a catalyst washcoat by mixing together (a) a first slip containing composite particles comprising at least one platinum group metal on a ceria promoted, high temperature chemically stabilized refractory oxide powder, and (b) a second slip containing fine particles of a base metal or base metal oxide selected from the group consisting of chromium, hafnium, niobium, chromium oxide, hafnium oxide, niobium oxide and mixtures thereof; applying the washcoat to a rigid catalyst support substrate capable of maintaining its shape and strength at high temperatures; and heating the coated support to remove volatile materials wherein said composite particles serve as a bonding vehicle for said base metal or base metal oxide particles and wherein said base metal or base metal oxide exists in a fine particulate form.
Claim 13
Independent Claim
137 words
A method of making a high temperature stable catalyst comprising: forming a catalyst washcoat by mixing together (a) a first slip containing composite particles comprising at least one platinum group metal on a ceria promoted, high temperature chemically stabilized refractory oxide powder, and (b) a second slip containing fine particles of a base metal or base metal oxide selected from the group consisting of chromium, hafnium, niobium, chromium oxide, hafnium oxide, niobium oxide and mixtures thereof; applying the washcoat to a rigid catalyst support substrate capable of maintaining its shape and strength at high temperatures; and heating the coated support to remove volatile materials wherein said composite particles serve as a bonding vehicle for said base metal or base metal oxide particles and wherein said base metal or base metal oxide exists in a fine particulate form.
Claim 14
Dependent Claim
30 words
A method according to claim 11, wherein the refractory oxide powder is alumina, alumina powder which has been calcined at a temperature near incipient alpha alumina formation, silica-alumina or zirconia.
Claim 15
Dependent Claim
32 words
A method according to claim 11, wherein the high temperature stable refractory oxide is a lanthana stabilized alumina, a lanthana rich rare earth oxide stabilized alumina or a barium oxide stabilized alumina.
Claim 16
Dependent Claim
47 words
A method according to claim 11, wherein the base metal or metal oxide comprises about 15% to 90% by weight of the total solids content of the washcoat and the platinum group metal comprises 0.05% to 10% by weight of the total solids content of the washcoat.
Claim 17
Dependent Claim
15 words
A method according to claim 11, further comprising activating the catalyst in a reducing atmosphere.
Claim 18
Dependent Claim
12 words
A high temperature stable catalyst made by the process of claim 11.
Claim 19
Dependent Claim
12 words
A high temperature stable catalyst made by the process of claim 12.
Claim 20
Dependent Claim
12 words
A high temperature stable catalyst made by the process of claim 13.
Claim 21
Dependent Claim
12 words
A high temperature stable catalyst made by the process of claim 14.
Claim 22
Dependent Claim
12 words
A high temperature stable catalyst made by the process of claim 15.
Claim 23
Independent Claim
129 words
A method of making a high temperature stable catalyst comprising: forming a paste mixture by mixing together (a) composite particles comprising at least one platinum group metal on a ceria promoted, high temperature chemically stabilized refractory oxide powder; (b) fine particles of a base metal or base metal oxide selected from the group consisting of chromium, hafnium, niobium, chromium oxide, hafnium oxide, niobium oxide and mixtures thereof; and (c) water; forming the paste into a catalyst shape; and calcining the shaped catalyst whereby said composite particles serve as a bonding vehicle for said base metal or base metal oxide particles and said base metal or base metal oxide particles are dispersed throughout the mixture and whereby said base metal or base metal oxide exists in a fine particulate form.
Claim 24
Independent Claim
129 words
A method of making a high temperature stable catalyst comprising: forming a paste mixture by mixing together (a) composite particles comprising at least one platinum group metal on a ceria promoted, high temperature chemically stabilized refractory oxide powder; (b) fine particles of a base metal or base metal oxide selected from the group consisting of chromium, hafnium, niobium, chromium oxide, hafnium oxide, niobium oxide and mixtures thereof; and (c) water; forming the paste into a catalyst shape; and calcining the shaped catalyst whereby said composite particles serve as a bonding vehicle for said base metal or base metal oxide particles and said base metal or base metal oxide particles are dispersed throughout the mixture and whereby said base metal or base metal oxide exists in a fine particulate form.
Claim 25
Dependent Claim
23 words
A method according to claim 21, wherein the paste is extruded to form either small individual extrudate particles or large, porous monolith bodies.
Claim 26
Dependent Claim
14 words
A method according to claim 21, wherein the paste is formed into spherical particles.
Claim 27
Dependent Claim
122 words
A washcoat composition for application to a support to produce a high temperature stable catalyst comprising a slip mixture of (a) composite particles comprising at least one platinum group metal on a ceria promoted, high temperature chemically stabilized refractory oxide powder, and (b) fine particles of a base metal or base metal oxide selected from the group consisting of chromium, hafnium, niobium, chromium oxide, hafnium oxide, niobium oxide, and mixtures thereof, said composite particles being capable upon heating of serving as a bonding vehicle for said base metal or base metal oxide particles whereby said base metal or base metal oxide particles are dispersed throughout the mixture and whereby said base metal or base metal oxide exists in a fine particulate form.
Claim 28
Dependent Claim
122 words
A washcoat composition for application to a support to produce a high temperature stable catalyst comprising a slip mixture of (a) composite particles comprising at least one platinum group metal on a ceria promoted, high temperature chemically stabilized refractory oxide powder, and (b) fine particles of a base metal or base metal oxide selected from the group consisting of chromium, hafnium, niobium, chromium oxide, hafnium oxide, niobium oxide, and mixtures thereof, said composite particles being capable upon heating of serving as a bonding vehicle for said base metal or base metal oxide particles whereby said base metal or base metal oxide particles are dispersed throughout the mixture and whereby said base metal or base metal oxide exists in a fine particulate form.
Claim 29
Dependent Claim
31 words
A washcoat composition according to claim 24, wherein the refractory oxide powder is alumina, alumina powder which has been calcined at a temperature near incipient alpha alumina formation, silica-alumina or zirconia.
Claim 30
Dependent Claim
34 words
A washcoat composition according to claim 24, wherein the high temperature stable refractory oxide powder is a lanthana stabilized alumina, a lanthana rich rare earth oxide stabilized alumina or a barium oxide stabilized alumina.
Claim 31
Dependent Claim
48 words
A washcoat composition according to claim 24, wherein the base metal or metal oxide comprise about 15% to 90% by weight of the total solids content of the washcoat and the platinum group metal comprises 0.05% to 10% by weight of the total solids content of the washcoat.
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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) | 1989-04-28 | 1989-10-28 | 1990-04-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-04-28 | 1993-10-28 | 1994-04-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-04-28 | 1997-10-28 | 1998-04-29 | $7700.00 | Window Closed / Lapsed |