US4793980A — Hollow porous microspheres as substrates and cont…

Claim 1

Independent Claim 244 words

A process for carrying out a catalytic reaction which comprises contacting hollow porous microsphere catalyst with a reaction medium under conditions such that at least one constituent in the reaction medium is brought into contact with the catalyst for a period of time sufficient for said constituent to undergo a chemical change, said microsphere catalyst comprising hollow porous microspheres having a substantially uniform diameter of 200 to 10,000 microns and a substantially uniform wall thickness of 1.0 to 1000 microns, the walls of said microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said walls include entrance means through which a reactant can be introduced into the interconnecting voids and into the single central cavity of the microspheres, said microspheres have catalyst on the particles forming the walls or have catalyst contained within the single central cavity or have catalyst on the particles forming the walls and have catalyst contained within the single central cavity, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.

Claim 2

Dependent Claim 244 words

A process for carrying out a catalytic reaction which comprises contacting hollow porous microsphere catalyst with a reaction medium under conditions such that at least one constituent in the reaction medium is brought into contact with the catalyst for a period of time sufficient for said constituent to undergo a chemical change, said microsphere catalyst comprising hollow porous microspheres having a substantially uniform diameter of 200 to 10,000 microns and a substantially uniform wall thickness of 1.0 to 1000 microns, the walls of said microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said walls include entrance means through which a reactant can be introduced into the interconnecting voids and into the single central cavity of the microspheres, said microspheres have catalyst on the particles forming the walls or have catalyst contained within the single central cavity or have catalyst on the particles forming the walls and have catalyst contained within the single central cavity, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.

Claim 3

Dependent Claim 29 words

The process of claim 1 wherein the catalyst is on the particles forming the interconnecting voids and on the particles forming the inner wall surface of the microsphere walls.

Claim 4

Dependent Claim 21 words

The process of claim 1 wherein the catalyst is contained within the single central cavity in the interior of the microspheres.

Claim 5

Dependent Claim 31 words

The process of claim 1 wherein the microsphere catalysts have distributed in the walls macro pores which are 1 to 1000 microns in size and which extend through the microsphere walls.

Claim 6

Dependent Claim 18 words

The process of claim 1 wherein the microsphere catalysts are contained as a stacked bed in a reactor.

Claim 7

Dependent Claim 18 words

The process of claim 1 wherein the microsphere catalysts are contained as a moving bed in a reactor.

Claim 8

Dependent Claim 18 words

The process of claim 1 wherein the microsphere catalysts are contained as a fluidized bed in a reactor.

Claim 9

Dependent Claim 18 words

The process of claim 1 wherein the sintered particles forming the walls of the microspheres comprise ceramic particles.

Claim 10

Dependent Claim 18 words

The process of claim 1 wherein the sintered particles forming the walls of the microspheres comprise alumina particles.

Claim 11

Dependent Claim 19 words

The process of claim 3 wherein the microsphere catalysts contain in the microsphere entrance means an inorganic selective membrane.

Claim 12

Dependent Claim 20 words

The process of claim 3 wherein the microsphere catalysts contain in the microsphere entrance means an organic selective semipermeable membrane.

Claim 13

Dependent Claim 39 words

The process of claim 1 wherein the microsphere catalysts contain catalyst within the single central cavity and the catalyst is in the form selected from the group of finely divided solid particles, finely divided resin particles and a gel.

Claim 14

Independent Claim 244 words

A method for controlling CO and hydrocarbon constituents in an auto exhaust which comprises placing in a container a bed of auto emission control microsphere catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have a catalyst selected from the group consisting of platinum, palladium and rhodium and mixtures thereof coated or impregnated on the inner and outer wall surfaces of the microspheres and on the particles forming the interconnecting voids in the wall of the microspheres, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles, installing the container in an engine exhaust line and contacting the engine exhaust with the microsphere catalysts to convert the CO to CO 2 and hydrocarbons to CO 2 and H 2 O and to thereby reduce the concentration of CO and hydrocarbons in the exhaust.

Claim 15

Independent Claim 244 words

A method for controlling CO and hydrocarbon constituents in an auto exhaust which comprises placing in a container a bed of auto emission control microsphere catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have a catalyst selected from the group consisting of platinum, palladium and rhodium and mixtures thereof coated or impregnated on the inner and outer wall surfaces of the microspheres and on the particles forming the interconnecting voids in the wall of the microspheres, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles, installing the container in an engine exhaust line and contacting the engine exhaust with the microsphere catalysts to convert the CO to CO 2 and hydrocarbons to CO 2 and H 2 O and to thereby reduce the concentration of CO and hydrocarbons in the exhaust.

Claim 16

Dependent Claim 34 words

The method of claim 13 for controlling CO and hydrocarbon constituents in an auto exhaust wherein the engine exhaust is contacted with the microsphere catalyst at a temperature of about 200 to 300° C.

Claim 17

Dependent Claim 25 words

The method of claim 14 wherein the CO and hydrocarbon constituents of the exhaust gas are reduced by at least 30 to 50% by volume.

Claim 18

Dependent Claim 31 words

The method of claim 13 wherein the microsphere catalyst have distributed in the walls macro pores which are 5 to 400 microns in size and which extend through the microsphere walls.

Claim 19

Independent Claim 207 words

A method for reducing the sulfur and nitrogen content of a hydrocarbon feed containing sulfur or nitrogen which comprises contacting a hydrodinitrification and hydrodesulfurization catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity and have within the interconnecting voids a catalyst selected from the group consisting of cobalt-molybdenum, nickel-molybdenum and nickel-tungsten and the oxides and sulfides thereof and mixtures thereof, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned walls portions or sections and bubbles in a reactor vessel with the hydrocarbon feed and hydrogen and removing sulfur and nitrogen from the hydrocarbon feed.

Claim 20

Independent Claim 207 words

A method for reducing the sulfur and nitrogen content of a hydrocarbon feed containing sulfur or nitrogen which comprises contacting a hydrodinitrification and hydrodesulfurization catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity and have within the interconnecting voids a catalyst selected from the group consisting of cobalt-molybdenum, nickel-molybdenum and nickel-tungsten and the oxides and sulfides thereof and mixtures thereof, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned walls portions or sections and bubbles in a reactor vessel with the hydrocarbon feed and hydrogen and removing sulfur and nitrogen from the hydrocarbon feed.

Claim 21

Dependent Claim 44 words

The method of claim 17 wherein the hydrocarbon is contacted with the microsphere catalyst at a temperature of 250° C. to 450° C., pressures of 30-200 atmospheres and hydrogen gas rates of 2000 to 12,000 standard cubic feet of hydrogen per barrel of feed.

Claim 22

Dependent Claim 38 words

The method of claim 17 wherein hydrodinitrification of the feed is carried out and the microsphere catalyst comprises a member of the group consisting of nickel-molybdenum and nickel tungsten and the oxides and sulfides thereof and mixtures thereof.

Claim 23

Dependent Claim 35 words

The method of claim 17 wherein hydrodesulfurization of the feed is carried out and the microsphere catalyst comprises a member of the group consisting of cobalt-molybdenum and the oxides and sulfides thereof and mixtures thereof.

Claim 24

Independent Claim 193 words

A method for hydrocracking a hydrocarbon feed to obtain hydrocarbons of a lower molecular weight than said feed hydrocarbons which comprises contacting a hydrocracking catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity a nickel catalyst and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles in a reactor vessel with the hydrocarbon feed and hydrogen under hydrocarbon cracking conditions and cracking the hydrocarbon feed to obtain hydrocarbons of a lower molecular weight than the feed.

Claim 25

Independent Claim 193 words

A method for hydrocracking a hydrocarbon feed to obtain hydrocarbons of a lower molecular weight than said feed hydrocarbons which comprises contacting a hydrocracking catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity a nickel catalyst and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles in a reactor vessel with the hydrocarbon feed and hydrogen under hydrocarbon cracking conditions and cracking the hydrocarbon feed to obtain hydrocarbons of a lower molecular weight than the feed.

Claim 26

Dependent Claim 48 words

The method of claim 21 wherein the hydrocarbon is contacted with the microsphere catalyst at a temperature of about 343 to 454° C., pressures of about 500 to 2000 psia and hydrogen gas rates of about 500 to 15000 standard cubic feet of hydrogen per barrel of feed.

Claim 27

Dependent Claim 160 words

A catalytic cracking catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns and having macro pores 5.0 to 400 microns in size which extend through the walls, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity crystalline zeolite molecular sieve catalyst, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions of sections and bubbles.

Claim 28

Dependent Claim 160 words

A catalytic cracking catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns and having macro pores 5.0 to 400 microns in size which extend through the walls, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity crystalline zeolite molecular sieve catalyst, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions of sections and bubbles.

Claim 29

Dependent Claim 46 words

The catalytic cracking catalyst of claim 23 wherein the microspheres have a diameter of 2000 to 4000 microns and a wall thickness of 30 to 50 microns and the walls contain macro pores about 40-60 microns in size which extend through the walls of the microspheres.

Claim 30

Dependent Claim 25 words

The catalytic cracking catalyst of claim 23 wherein the single central cavity of the microspheres contains loose agglomerates of 13Y crystalline zeolite molecular sieve catalyst.

Claim 31

Dependent Claim 25 words

The catalytic cracking catalyst of claim 23 wherein the crystalline zeolite molecular sieve catalyst contains cation-exchanged rare earth elements of the lanthanum rare earth series.

Claim 32

Dependent Claim 37 words

The catalytic cracking catalyst of claim 23 wherein the crystaline zeolite molecular sieve catalyst contains a rare earth element selected from the group consisting of lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium and gadolinium and mixtures thereof.

Claim 33

Independent Claim 194 words

A method for catalytically cracking a hydrocarbon petroleum fraction to increase the yield of light cycle oil and gasoline which comprises contacting a catalytic cracking catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns and having macro pores 5.0 to 400 microns in size which extend through the walls, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity crystalline zeolite molecular sieve catalyst, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles in a reactor vessel with the hydrocarbon and catalytically cracking the hydrocarbon.

Claim 34

Independent Claim 194 words

A method for catalytically cracking a hydrocarbon petroleum fraction to increase the yield of light cycle oil and gasoline which comprises contacting a catalytic cracking catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns and having macro pores 5.0 to 400 microns in size which extend through the walls, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity crystalline zeolite molecular sieve catalyst, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles in a reactor vessel with the hydrocarbon and catalytically cracking the hydrocarbon.

Claim 35

Dependent Claim 33 words

The method of claim 28 wherein the petroleum hydrocarbon feed is contacted with the microsphere catalyst at temperatures of about 300° to 600° C. in a catalytic reactor and catalytically cracking the hydrocarbons.

Claim 36

Dependent Claim 160 words

A microsphere catalyst for removing SO 2 from gases and for converting NO x in gases to N 2 comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity finely divided carbon catalyst particles, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.

Claim 37

Dependent Claim 160 words

A microsphere catalyst for removing SO 2 from gases and for converting NO x in gases to N 2 comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity finely divided carbon catalyst particles, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.

Claim 38

Dependent Claim 31 words

The microsphere catalyst of claim 30 wherein the walls of said microspheres contain macro pores 5.0 to 400 microns in size which macro pores extend through the walls of the microspheres.

Claim 39

Dependent Claim 26 words

The microsphere catalyst of claim 30 wherein the finely divided carbon catalyst particles comprise molecular sieve carbon in the form of loose agglomerates of carbon particles.

Claim 40

Dependent Claim 43 words

The microsphere catalyst of claim 30 wherein the microspheres have a 2000 to 4000 micron diameter, a wall thickness of 60 to 80 microns and macro pores 60 to 80 microns in size which macro pores extend through the walls of the microspheres.

Claim 41

Dependent Claim 30 words

The microsphere catalyst of claim 32 wherein molecular sieve carbon catalyst is capable of converting SO 2 to H 2 SO 4 and of adsorbing H 2 SO 4 .

Claim 42

Dependent Claim 53 words

A method of removing SO 2 from gases containing SO 2 which comprises contacting the microsphere catalysts of claim 30 containing finely divided carbon catalyst particles in a reactor vessel with said gas, converting SO 2 to H 2 SO 4 and adsorbing H 2 SO 4 on the finely divided carbon particles.

Claim 43

Dependent Claim 44 words

A method of converting the NO x content of gases to N 2 which comprises contacting the microsphere catalysts of claim 33 containing finely divided molecular sieve carbon catalyst in a reactor vessel with said catalyst and converting NO x to N 2 .

Claim 44

Dependent Claim 19 words

The method of claim 35 wherein the contacting step is carried out at a temperature of about 200° F.

Claim 45

Dependent Claim 19 words

The method of claim 36 wherein the contacting step is carried out at a temperature of about 200° F.

Claim 46

Dependent Claim 161 words

A microsphere absorbent, for selectively removing SO 2 from a gas stream containing SO 2 , comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity polyethylene glycol which has a high solubility for SO 2 and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.

Claim 47

Dependent Claim 161 words

A microsphere absorbent, for selectively removing SO 2 from a gas stream containing SO 2 , comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity polyethylene glycol which has a high solubility for SO 2 and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.

Claim 48

Dependent Claim 31 words

The microsphere adsorbent of claim 39 wherein the walls of said microspheres contain macro pores 5.0 to 400 microns in size which macro pores extend through the walls of the microspheres.

Claim 49

Dependent Claim 33 words

The microsphere absorbent of claim 39 wherein the polyethylene glycol comprises polyethylene glycol in the form of an immobilized liquid membrane coating on the surfaces of the alumina particles forming the microsphere walls.

Claim 50

Dependent Claim 43 words

The microsphere adsorbent of claim 39 wherein the microspheres have a 2000 to 4000 micron diameter, a wall thickness of 60 to 80 microns and macro pores 60 to 80 microns in size which macro pores extend through the walls of the microspheres.

Claim 51

Dependent Claim 31 words

The microspheres adsorbent of claim 41 wherein the polyethylene glycol is capable of selectively adsorbing SO 2 from a mixture containing a high concentration of SO 2 and CO 2 .

Claim 52

Dependent Claim 41 words

A method of removing SO 2 from a gas stream containing SO 2 which comprises contacting the microsphere absorbent of claim 39 containing polyethylene glycol with said gas in an absorption vessel and selectively absorbing SO 2 in the polyethylene glycol.

Claim 53

Dependent Claim 52 words

The method of claim 44 for removing SO 2 from a gas stream containing SO 2 which comprises contacting the microsphere absorbent containing polyethylene glycol in the form of an immobilized liquid membrane said gas at elevated pressures of about 100 psia and absorbing said SO 2 into said polyethylene glycol membrane.

Claim 54

Dependent Claim 41 words

The method of claim 44 wherein the SO 2 is selectively absorbed from a gas stream containing a high concentration of SO 2 and CO 2 , and the SO 2 is desorbed by reducing the pressure to about 30 psia.

Claim 55

Dependent Claim 244 words

A process for carrying out a catalytic reaction which comprises contacting hollow porous microsphere catalyst with a reaction medium under conditions such that at least one constituent in the reaction medium is brought into contact with the catalyst for a period of time sufficient for said constituent to undergo a chemical change, said microsphere catalyst comprising hollow porous microspheres having a substantially uniform diameter of 500 to 6000 microns and a substantially uniform wall thickness of 5 to 400 microns, the walls of said microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said walls include entrance means through which a reactant can be introduced into the interconnecting voids and into the single central cavity of the microspheres, said microspheres have catalyst on the particles forming the walls or have catalyst contained within the single central cavity or have catalyst on the particles forming the walls and have catalyst contained within the single central cavity, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.

Claim 56

Dependent Claim 244 words

A process for carrying out a catalytic reaction which comprises contacting hollow porous microsphere catalyst with a reaction medium under conditions such that at least one constituent in the reaction medium is brought into contact with the catalyst for a period of time sufficient for said constituent to undergo a chemical change, said microsphere catalyst comprising hollow porous microspheres having a substantially uniform diameter of 500 to 6000 microns and a substantially uniform wall thickness of 5 to 400 microns, the walls of said microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said walls include entrance means through which a reactant can be introduced into the interconnecting voids and into the single central cavity of the microspheres, said microspheres have catalyst on the particles forming the walls or have catalyst contained within the single central cavity or have catalyst on the particles forming the walls and have catalyst contained within the single central cavity, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.

Claim 57

Dependent Claim 16 words

The process of claim 47 wherein the walls of said microspheres comprise sintered together ceramic particles.

Claim 58

Dependent Claim 16 words

The process of claim 47 wherein the walls of said microspheres comprise sintered together alumina particles.

Claim 59

Dependent Claim 16 words

The process of claim 47 wherein the walls of said microspheres comprise sintered together glass particles.

Claim 60

Dependent Claim 16 words

The process of claim 47 wherein the walls of said microspheres comprise sintered together metal particles.

Claim 61

Dependent Claim 17 words

The process of claim 47 wherein the walls of said microspheres comprise sintered together metal glass particles.

Claim 62

Dependent Claim 16 words

The process of claim 47 wherein the walls of said microspheres comprise sintered together plastic particles.

Claim 63

Dependent Claim 26 words

The process of claim 47 wherein the void content of the walls of the microspheres comprises 15 to 35 percent by volume of the microsphere walls.

Claim 64

Dependent Claim 31 words

The process of claim 47 wherein the microsphere catalyst have distributed in the walls macro pores which are 5 to 400 microns in size and which extend through the microsphere walls.

Claim 65

Dependent Claim 24 words

The process of claim 47 wherein the microsphere walls contain entrance means and there is contained in the entrance means an inorganic selective membrane.

Claim 66

Dependent Claim 25 words

The process of claim 47 wherein the microsphere walls contain entrance means and there is contained in the entrance means an organic selective semipermeable membrane.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-12-27	1992-06-27	1992-12-27	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-12-27	1996-06-27	1996-12-27	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-12-27	2000-06-27	2000-12-27	$7700.00	Window Closed / Lapsed

Hollow porous microspheres as substrates and containers for catalyst

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