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US4714694A
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Aluminum-stabilized ceria catalyst compositions, and methods of making the same
Assignee: BASF Catalysts LLC
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Filing: 1986-06-30
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Granted: 1987-12-22
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Expires: 2006-06-30
Abstract
Abstract A catalyst material comprises an aluminum-stabilized ceria which optionally may be combined with an activated alumina and may also comprise one or more platinum group metal catalytic components. A method of making the material includes impregnating bulk ceria or a bulk ceria precursor with an aluminum compound and calcining the impregnated ceria to provide an aluminum-stabilized ceria. The bulk ceria advantageously comprises a high purity (at least 90 weight percent CeO 2 ) ceria and may be admixed with activated aluminia having one or more platinum group metal catalytic components dispersed thereon. The catalyst material may be coated onto a suitable carrier substrate and then calcined. Specified minimum levels of the aluminum-stabilized bulk ceria are advantageously employed in the catalyst materials of the invention. The bulk ceria may have one or more preferably non-rhodium platinum group metal catalytic components dispersed thereon, e.g., a platinum catalytic component, and one or more platinum group metal catalytic components dispersed on the activated alumina.
Inventors
- 👤 Chung-Zong Wan
- 👤 Joseph C. Dettling
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 22:58
CPC Classifications
B; B01; B01J; B01J23/00; B01J23/38; B01J23/54; B01J23/56; B01D; B01D53/00; B01D53/34; B01D53/92; B01D53/94; B01D53/9445; B01D53/945; B01J23/10; B01J23/63; Y; Y02; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 56
Claim 1
Independent Claim
41 words
A method of making a catalyst composition comprising an aluminum-stabilized ceria, the method comprising: (a) impregnating bulk ceria or a bulk ceria precursor with a liquid dispersion of an aluminum-stabilizer precursor; and (b) calcining the impregnated ceria obtained from step (a).
Claim 2
Independent Claim
41 words
A method of making a catalyst composition comprising an aluminum-stabilized ceria, the method comprising: (a) impregnating bulk ceria or a bulk ceria precursor with a liquid dispersion of an aluminum-stabilizer precursor; and (b) calcining the impregnated ceria obtained from step (a).
Claim 3
Dependent Claim
28 words
The method of claim 1 including (c) subsequent to the calcining of the impregnated ceria, dispersing one or more non-rhodium platinum group metal catalytic components on the ceria.
Claim 4
Dependent Claim
30 words
The method of claim 1 wherein the liquid dispersion of the aluminum-stabilizer precursor comprises an aqueous solution of an aluminum compound with which the ceria or ceria precursor is impregnated.
Claim 5
Dependent Claim
39 words
The method of claim 1 including incorporating sufficient aluminum-stabilizer precursor into the ceria to provide not more than about 20 weight percent aluminum, measured as Al 2 O 3 , based on the total weight of the stabilized ceria.
Claim 6
Dependent Claim
40 words
The method of claim 4 including incorporating sufficient aluminum-stabilizer precursor into the ceria to provide from about 5 to about 10 weight percent aluminum, measured as Al 2 O 3 , based on the total weight of the stabilized ceria.
Claim 7
Dependent Claim
40 words
The method of claim 4 including incorporating sufficient aluminum-stabilizer precursor into the ceria to provide from about 0.05 to about 5 weight percent aluminum, measured as Al 2 O 3 , based on the total weight of the stabilized ceria.
Claim 8
Independent Claim
40 words
The method of any one of claims 1, 2, 3, 4, 5 or 6 including mixing with the stabilized ceria an activated alumina on which one or more platinum group metal catalytic components are dispersed, to form an alumina-ceria mixture.
Claim 9
Independent Claim
29 words
The method of any one of claims 1, 2, 3, 4, 5 or 6 wherein the liquid dispersion of the aluminum-stabilizer precursor comprises an aqueous solution of aluminum nitrate.
Claim 10
Independent Claim
34 words
The method of any one of claims 1, 2, 3, 4, 5 or 6 including carrying out the calcining of step (b) at a temperature of from about 300° C. to about 600° C.
Claim 11
Dependent Claim
19 words
The method of claim 9 including carrying out the calcining for a period of at least about one-half hour.
Claim 12
Dependent Claim
15 words
The method of claim 9 including carrying out the calcining of step (b) in air.
Claim 13
Dependent Claim
29 words
The method of claim 7 including mixing the ceria and alumina in proportions to provide a catalyst material comprising from about 5 to 95 weight percent of aluminum-stabilized ceria.
Claim 14
Dependent Claim
17 words
The method of claim 7 including applying a coating of the alumina-ceria mixture to a carrier substrate.
Claim 15
Independent Claim
131 words
A method of making a catalyst composition comprising a mixture of an activated alumina and an aluminum-stabilized ceria and one or more platinum group metal catalytic components including at least one platinum group catalytic component other than rhodium, the method comprising: (a) impregnating bulk ceria or a bulk ceria precursor with a liquid dispersion of an aluminum-stabilizer precursor and calcining the impregnated ceria to provide an aluminum-stabilized ceria; (b) combining the ceria from step (a) with an activated alumina to form a mixture of alumina and aluminum-stabilized ceria; and (c) dispersing one or more platinum group metal catalytic components on at least one of the aluminum-stabilized ceria, the activated alumina, and the mixture thereof, with the proviso that, only platinum group catalytic components other than rhodium are deposited on the ceria.
Claim 16
Independent Claim
131 words
A method of making a catalyst composition comprising a mixture of an activated alumina and an aluminum-stabilized ceria and one or more platinum group metal catalytic components including at least one platinum group catalytic component other than rhodium, the method comprising: (a) impregnating bulk ceria or a bulk ceria precursor with a liquid dispersion of an aluminum-stabilizer precursor and calcining the impregnated ceria to provide an aluminum-stabilized ceria; (b) combining the ceria from step (a) with an activated alumina to form a mixture of alumina and aluminum-stabilized ceria; and (c) dispersing one or more platinum group metal catalytic components on at least one of the aluminum-stabilized ceria, the activated alumina, and the mixture thereof, with the proviso that, only platinum group catalytic components other than rhodium are deposited on the ceria.
Claim 17
Independent Claim
102 words
A method of making a catalyst composition comprising a mixture of an activated alumina and an aluminum-stabilized ceria and one or more platinum group metal catalytic components, the method comprising: (a) dispersing one or more platinum group metal catalytic components on an activated alumina; (b) impregnating bulk ceria or a bulk ceria precursor with a liquid dispersion of an aluminum-stabilizer precursor and calcining the impregnated ceria to provide an aluminum-stabilized ceria; (c) dispersing one or more non-rhodium platinum group metal components on the aluminum-stabilized ceria; and (d) combining the ceria from step (b) with the activated alumina to form an alumina-ceria mixture.
Claim 18
Independent Claim
102 words
A method of making a catalyst composition comprising a mixture of an activated alumina and an aluminum-stabilized ceria and one or more platinum group metal catalytic components, the method comprising: (a) dispersing one or more platinum group metal catalytic components on an activated alumina; (b) impregnating bulk ceria or a bulk ceria precursor with a liquid dispersion of an aluminum-stabilizer precursor and calcining the impregnated ceria to provide an aluminum-stabilized ceria; (c) dispersing one or more non-rhodium platinum group metal components on the aluminum-stabilized ceria; and (d) combining the ceria from step (b) with the activated alumina to form an alumina-ceria mixture.
Claim 19
Dependent Claim
32 words
The method of claim 15 further including: (e) applying a coating of the mixture of alumina and aluminum-stabilized ceria to a carrier substrate; and (f) calcining the substrate coated with the mixture.
Claim 20
Dependent Claim
23 words
The method of claim 16 including carrying out the calcining of step (b) at a temperature of not more than about 350° C.
Claim 21
Dependent Claim
12 words
The method of claim 17 including carrying out the calcining in air.
Claim 22
Dependent Claim
53 words
The method of claim 15 further including: (e) impregnating at least the activated alumina with a solution of a thermal stabilizer precursor chosen from the group consisting of precursors for rare earth metal oxides, alkaline earth metal oxides, zirconia, titania, hafnia, silicon dioxide and mixtures thereof,; and (f) calcining the stabilizer-impregnated activated alumina.
Claim 23
Dependent Claim
23 words
The method of claim 19 including carrying out the calcining of step (f) at a temperature of not more than about 350° C.
Claim 24
Dependent Claim
15 words
The method of claim 20 including carrying out the calcining of step (f) in air.
Claim 25
Dependent Claim
25 words
The method of claim 19 wherein the activated alumina which is impregnated with the solution of the thermal stabilizer precursor is an unstabilized activated alumina.
Claim 26
Dependent Claim
21 words
The method of claim 19 wherein the thermal stabilizer precursor comprises a mixture of a barium compound and a lanthanum compound.
Claim 27
Dependent Claim
48 words
The method of claim 7 including dispersing onto at least the activated alumina a modifier selected from the group consisting of one or more of alkaline earth metal oxides, rare earth metal oxides, silicon dioxide, Group IVB metal oxides, chromium oxide, iron oxide, nickel oxide, and precursors thereof.
Claim 28
Dependent Claim
51 words
The method of claim 14 or claim 15 including dispersing onto at least the activated alumina a modifier selected from the group consisting of one or more of alkaline earth metal oxides, rare earth metal oxides, silicon dioxide, Group IVB metal oxides, chromium oxide, iron oxide, nickel oxide, or precursors thereof.
Claim 29
Independent Claim
26 words
The method of any one of claims 2, 14, or 15 wherein the one or more non-rhodium platinum group metal catalytic components comprise a platinum component.
Claim 30
Independent Claim
43 words
The method of any one of claims 1, 2, 3, 4, 5, 6, 14 or 15 wherein the aluminum-stabilized ceria has a particle size range such that at least 95% by weight of the particles has a diameter of greater than 0.5 microns.
Claim 31
Independent Claim
57 words
The method of any one of claims 1, 2, 3, 4, 5, 6, 14 or 15 wherein ceria is added as a component in a mixture of rare earth oxides, the ceria comprising at least about 90 weight percent measured as CeO 2 , of the total of rare earth oxide constituents exclusive of its aluminum-stabilizer content.
Claim 32
Independent Claim
57 words
The method of any one of claims 1, 2, 3, 4, 5, 6, 14 or 15 wherein ceria is added as a component in a mixture of rare earth oxides the ceria comprising at least about 95 weight percent measured as CeO 2 , of the total of rare earth oxide constituents exclusive of its aluminum-stabilizer content.
Claim 33
Independent Claim
57 words
The method of any one of claims 1, 2, 3, 4, 5, 6, 14 or 15 wherein ceria is added as a component in a mixture of rare earth oxides the ceria comprising at least about 99 weight percent measured as CeO 2 , of the total of rare earth oxide constituents exclusive of its aluminum-stabilizer content.
Claim 34
Dependent Claim
33 words
The method of claim 14 or claim 15 including combining the aluminum-stabilized ceria and alumina in proportions to provide a catalyst material comprising from about 5 to about 95 weight percent aluminum-stabilized ceria.
Claim 35
Dependent Claim
31 words
A catalyst composition comprising aluminum-stabilized bulk ceria containing not more than about 20% by weight aluminum, measured as Al 2 O 3 , based on the total weight of stabilized ceria.
Claim 36
Dependent Claim
31 words
A catalyst composition comprising aluminum-stabilized bulk ceria containing not more than about 20% by weight aluminum, measured as Al 2 O 3 , based on the total weight of stabilized ceria.
Claim 37
Dependent Claim
22 words
The catalyst composition of claim 32 including the one or more non-rhodium platinum group metal catalytic components dispersed on the aluminum-stabilized ceria.
Claim 38
Dependent Claim
40 words
The catalyst composition of claim 32 or claim 33 further including activated alumina having one or more platinum group metal catalytic components dispersed thereon, said ceria and said alumina being dispersed together on a carrier substrate as a catalytic coating.
Claim 39
Dependent Claim
38 words
The catalyst composition of claim 32 or claim 33 wherein the aluminum-stabilized ceria contains from about 5 to about 10 weight percent aluminum, measured as Al 2 O 3 , based on the total weight of stabilized ceria.
Claim 40
Dependent Claim
38 words
The catalyst composition of claim 32 or claim 33 wherein the aluminum-stabilized ceria contains from about 0.05 to about 5 weight percent aluminum, measured as Al 2 O 3 , based on the total weight of stabilized ceria.
Claim 41
Dependent Claim
29 words
The catalyst composition of claim 34 wherein the aluminum-stabilized ceria and the activated alumina plus the catalytic components respectively dispersed thereon, comprise a calcined coating on a carrier substrate.
Claim 42
Dependent Claim
22 words
The catalyst composition of claim 34 wherein the stabilized ceria comprises from about 5 to 95 weight percent of the catalyst composition.
Claim 43
Dependent Claim
35 words
The catalyst composition of claim 32 or claim 34 wherein the aluminum-stabilized ceria has a particle size range such that at least 95% by weight of the particles have a diameter greater than 0.5 microns.
Claim 44
Dependent Claim
51 words
The catalyst composition of claim 32 or claim 33 wherein rare earth oxide constituents other than ceria are present in the catalyst composition the aluminum-stabilized ceria comprising at least about 90 weight percent measured as CeO 2 , of the total of rare earth oxide constituents exclusive of its aluminum-stabilizer content.
Claim 45
Dependent Claim
51 words
The catalyst composition of claim 32 or claim 33 wherein rare earth oxide constituents other than ceria are present in the catalyst composition, the aluminum-stabilized ceria comprising at least about 95 weight percent measured as CeO 2 , of the total of rare earth oxide constituents exclusive of its aluminum-stabilizer content.
Claim 46
Dependent Claim
51 words
The catalyst composition of claim 32 or claim 33 wherein rare earth oxide constituents other than ceria are present in the catalyst composition, the aluminum-stabilized ceria comprising at least about 99 weight percent measured as CeO 2 , of the total or rare earth oxide constituents exclusive of its aluminum-stabilizer content.
Claim 47
Dependent Claim
59 words
The catalyst composition of claim 34 wherein at least the activated alumina dispersed together with the aluminum-stabilized ceria includes a modifier, distinct from said aluminum-stabilized ceria selected from the group consisting of one or more of alkaline earth metal oxides, rare earth metal oxides, silicon dioxide, Group IVB metal oxides, chromium oxide, iron oxide, nickel oxide, and precursors thereof.
Claim 48
Dependent Claim
20 words
The catalyst composition of claim 34 wherein the one or more platinum group metal catalytic components comprise a platinum component.
Claim 49
Dependent Claim
20 words
The catalyst composition of claim 34 wherein the one or more platinum group metal catalytic components comprise a palladium component.
Claim 50
Dependent Claim
24 words
The catalyst composition of claim 34 wherein the one or more platinum group metal catalytic components comprise a platinum component and a palladium component.
Claim 51
Dependent Claim
29 words
The catalyst composition of claim 34 wherein the one or more platinum group metal catalytic components dispersed on said activated alumina comprise a palladium component and a rhodium component.
Claim 52
Dependent Claim
29 words
The catalyst composition of claim 34 wherein the one or more platinum group metal catalytic components dispersed on said activated alumina comprise a platinum component and a rhodium component.
Claim 53
Dependent Claim
23 words
The catalyst composition of claim 33 wherein the one or more non-rhodium platinum group metal catalytic components dispersed on the ceria comprises platinum.
Claim 54
Dependent Claim
16 words
The catalyst composition of claim 32 wherein the aluminum-stabilized ceria is coated upon a carrier substrate.
Claim 55
Dependent Claim
31 words
The catalyst composition of claim 34 wherein the aluminum-stabilized ceria and the activated alumina having one or more platinum group metal catalytic components dispersed thereon, is coated upon a carrier substrate.
Claim 56
Dependent Claim
37 words
The catalyst composition of claim 50 or claim 51 wherein the carrier substrate has a plurality of gas flow passages extending therethrough, the gas flow passages being defined by walls which are coated with the catalyst composition.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1990-12-21 | 1991-06-22 | 1991-12-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-12-21 | 1995-06-22 | 1995-12-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-12-21 | 1999-06-22 | 1999-12-22 | $7700.00 | Window Closed / Lapsed |