Catalyst for oxidation of carbon monoxide and process for preparing the catalyst

Claim 2

A process for preparing a composition of matter, which is useful and effective as catalyst composition for CO oxidation and consists essentially of (i) at least one metal oxide selected from the group consisting of alumina and magnesia, (ii) at least one noble metal selected from the group consisting of platinum and palladium and (iii) iron oxide, said process comprising the steps of (a) contacting a support material consisting essentially of at least one metal oxide selected from the group consisting of alumina and magnesia with a solution comprising at least one dissolved compound of at least one noble metal selected from the group consisting of platinum and palladium and at least one dissolved iron compound, (b) heating the material obtained in step (a) under such conditions as to substantially dry said material obtained in step (a), to substantially convert said at least one compound of at least one noble metal to at least one of oxides of Pt, oxides of Pd, Pt metal and Pd metal and to substantially convert said at least one iron compound to iron oxide; and (c) heating the material obtained in step (b) in a reducing gas atmosphere at a temperature in the range of from about 550° to about 700° C., under such conditions as to activate said material obtained in step (b) and to form said composition of matter.

Claim 3

A process in accordance with claim 1, wherein said reducing gas atmosphere is a free hydrogen containing gas.

Claim 4

A process in accordance with claim 2, wherein said free hydrogen containing gas is a stream of H 2 .

Claim 5

A process in accordance with claim 1, wherein step (c) is carried out in a stream of H 2 at a temperature in the range of from about 600° to about 660° C., for a period of time in the range of from about 0.5 to about 20 hours.

Claim 6

A process in accordance with claim 1, wherein said composition of matter comprises about 0.5 to about 5 weight percent of said noble metal and about 0.2 to about 4 weight percent Fe.

Claim 7

A process in accordance with claim 1, wherein step (b) is carried out in two sub-steps; (b1) heating the material obtained in step (a) at a first temperature so as to remove substantially all liquids from said material obtained in step (a), and (b2) heating the substantially dried material obtained in step (b1) in an oxidizing atmosphere at a second temperature, which is higher than said first temperature, so as to substantially convert said at least one compound of at least one noble metal to at least one of oxides of Pt, oxides of Pd, Pt metal and Pd metal, and to substantially convert said at least one iron compound to iron oxide.

Claim 8

A process in accordance with claim 6, wherein said first temperature is in the range of from about 30° to about 200° C., and said second temperature is in the range of from about 300° to about 700° C.

Claim 9

A process in accordance with claim 1, wherein said at least one metal oxide is alumina.

Claim 10

A process in accordance with claim 1, wherein said at least one metal oxide is magnesia.

Claim 11

A process in accordance with claim 1, wherein said at least one metal oxide is a mixture of alumina and magnesia.

Claim 12

A process in accordance with claim 1, wherein said at least one noble metal is platinum.

Claim 13

A process in accordance with claim 1, wherein said at least one noble metal is palladium.

Claim 14

A process in accordance with claim 1, wherein said at least one metal oxide is alumina and said at least on noble metal is platinum.

Claim 15

A process in accordance with claim 1, wherein said composition of matter comprises about 0.5 to about 5 weight Pt and about 0.2 to about 4 weight-% Fe.

Claim 16

A process for preparing a composition of matter, which is useful and effective as a catalyst composition for CO oxidation and consists essentially of (i) at least one metal oxide selected from the group consisting of alumina and magnesia, (ii) at least one noble metal selected from the group consisting of platinum and palladium and (iii) iron oxide, said process comprising the steps of (a) contacting a support material consisting essentially of at least one metal oxide selected from the group consisting of alumina and magnesia with a solution comprising at least one dissolved compound of at least one noble metal selected from the group consisting of platinum and palladium; (b) heating the material obtained in step (a) under such conditions as to substantially dry said material obtained in step (a), and to at least partially convert said at least one compound of at least one noble metal to at least one of oxides of Pt, oxides of Pd, Pt metal and Pd metal; (a*) impregnating the material obtained in step (b) with a solution comprising at least one iron compound; (b*) heating the material obtained in step (a*) under such condtions as to substantially dry said material obtained in step (a*), and to substantially convert said at least one iron compound to iron oxide; and (c) heating the material obtained in step (b*) in a reducing gas atmosphere at a temperature in the range of from about 550° C. to about 700° C., under such conditions as to activate said material obtained in step (b*) and to form said composition of matter.

Claim 17

A process for preparing a composition of matter, which is useful and effective as a catalyst composition for CO oxidation and consists essentially of (i) at least one metal oxide selected from the group consisting of alumina and magnesia, (ii) at least one noble metal selected from the group consisting of platinum and palladium and (iii) iron oxide, said process comprising the steps of (a) contacting a support material consisting essentially of at least one metal oxide selected from the group consisting of alumina and magnesia with a solution comprising at least one dissolved compound of at least one noble metal selected from the group consisting of platinum and palladium; (b) heating the material obtained in step (a) under such conditions as to substantially dry said material obtained in step (a), and to at least partially convert said at least one compound of at least one noble metal to at least one of oxides of Pt, oxides of Pd, Pt metal and Pd metal; (a*) impregnating the material obtained in step (b) with a solution comprising at least one iron compound; (b*) heating the material obtained in step (a*) under such condtions as to substantially dry said material obtained in step (a*), and to substantially convert said at least one iron compound to iron oxide; and (c) heating the material obtained in step (b*) in a reducing gas atmosphere at a temperature in the range of from about 550° C. to about 700° C., under such conditions as to activate said material obtained in step (b*) and to form said composition of matter.

Claim 18

A process in accordance with claim 15, wherein said reducing gas atmosphere is a free hydrogen containing gas.

Claim 19

A process in accordance with claim 53, wherein said free hydrogen containing gas is a stream of H 2 .

Claim 20

A process in accordance with claim 15, wherein step (c) is carried out in a stream of H 2 at a temperature in the range of from about 600° to about 660° C., for a period of time in the range of from aout 0.5 to about 20 hours.

Claim 21

A process in accordance with claim 15, wherein said composition of matter comprises about 0.5 to about 5 weight-% of said noble metal and about 0.2 to about 4 weight-% Fe.

Claim 22

A process in accordance with claim 15, wherein step (b) is carried out in two sub-steps; (b1) heating the material obtained in step (a) at a first temperature so as to remove substantially all liquids from said material obtained in step (a), and (b2) heating the substantially dried material obtained in step (b1) in an oxidizing atmosphere at a second temperature, which is higher than said first temperature, so as to at least partially convert said at least one compound of at least one noble metal to at least one of oxides of Pt, oxides of Pd, Pt metal and Pd metal.

Claim 23

A process in accordance with claim 20, wherein said first temperature is in the range of from about 30° to about 200° C., and said second temperature is in the range of from about 300° to about 700° C.

Claim 24

A process in accordance with claim 15, wherein said at least one metal oxide is alumina.

Claim 25

A process in accordance with claim 15, wherein said at least one metal oxide is magnesia.

Claim 26

A process in accordance with claim 15, wherein said at least one metal oxide is a mixture of alumina and magnesia.

Claim 27

A process in accordance with claim 15, wherein said at least one noble metal is platinum.

Claim 28

A process in accordance with claim 15, wherein said at least one noble metal is palladium.

Claim 29

A process in accordance with claim 15, wherein said at least one metal oxide is alumina and said at least one noble metal is platinum.

Claim 30

A process in accordance with claim 15, wherein said composition of matter comprises about 0.5 to about 5 weight-% Pt and about 0.2 to about 4 weight-% Fe.

Claim 31

A composition of matter which is useful and effective as a catalyst composition for CO oxidation, consisting essentially of (i) at least one metal oxide selected from the group consisting of alumina and magnesia, (ii) at least one noble metal selected from the group consisting of platinum and palladium, and (iii) iron oxide.

Claim 32

A composition of matter which is useful and effective as a catalyst composition for CO oxidation, consisting essentially of (i) at least one metal oxide selected from the group consisting of alumina and magnesia, (ii) at least one noble metal selected from the group consisting of platinum and palladium, and (iii) iron oxide.

Claim 33

A composition of matter in accordance with claim 29, wherein said composition of matter has been activated by heating in a reducing gas atmosphere at a temperature in the range of from about 550 to about 700° C.

Claim 34

A composition of matter in accordance with claim 29, having been prepared by a process comprising the steps of (a) contacting a support material consisting essentially of at least one metal oxide selected from the group consisting of alumina and magnesia with a solution comprising at least one dissolved compound of at least one noble metal selected from the group consisting of platinum and palladium and at least one dissolved iron compound, (b) heating the material obtained in step (a) under such conditions as to substantially dry said material obtained in step (a), to substantially convert said at least one compound of at least one noble metal to at least one of oxides of Pt, oxides of Pd, Pt metal and Pd metal, and to substantially convert said at least one iron compound to iron oxide; and (c) heating the material obtained in step (b) in a reducing gas atmosphere at a temperature in the range of from about 550° to about 700° C., under such conditions as to activate said material obtained in step (b) and to form said composition of matter.

Claim 35

A composition of matter in accordance with claim 31, wherein said reducing gas atmosphere is a free hydrogen containing gas.

Claim 36

A composition of matter in accordance with claim 29, having been prepared by a process comprising the steps of (a) contacting a support material consisting essentially of at least one metal oxide selected from the group consisting of alumina and magnesia with a solution comprising at least one dissolved compound of at least one noble metal selected from the group consisting of platinum and palladium; (b) heating the material obtained in step (a) under such conditions as to substantially dry said material obtained in step (a), and to at least partially convert said at least one compound of at least one noble metal to at least one of oxides of Pt, oxides of Pd, Pt metal and Pd metal; (a*) impregnating the material obtained in step (b) with a solution comprising at least one iron compound; (b*) heating the material obtained in step (a*) under such conditions as to substantially dry said material obtained in step (a*), and to substantially convert said at least one iron compound to iron oxide; and (c) heating the material obtained in step (b*) in a reducing gas atmosphere at a temperature in the range of from about 550° C. to about 700° C., under such conditions as to activate said material obtained in step (b*) and to form said composition of matter.

Claim 37

A composition of matter in accordance with claim 33, wherein said reducing gas atmosphere is a free hydrogen containing gas atmosphere.

Claim 38

A composition of matter in accordance with claim 29 comprising about 0.5 to about 5 weight-% of said noble metal and about 0.2 to about 4 weight-% Fe.

Claim 39

A composition of matter in accordance with claim 29, wherein said at least one metal oxide is alumina.

Claim 40

A composition of matter in accordance with claim 29, wherein said at least one metal oxide is magnesia.

Claim 41

A composition of matter in accordance with claim 29, wherein said at least one metal oxide is a mixture of alumina and magnesia.

Claim 42

A composition of matter in accordance with claim 29, wherein said at least one metal is platinum.

Claim 43

A composition of matter in accordance with claim 29, wherein said at least one noble metal is palladium.

Claim 44

A composition of matter in accordance with claim 29 wherein said at least one metal oxide is alumina and said at least on noble metal is platinum.

Claim 45

A composition of matter in accordance with claim 29 comprising about 0.5 to about 5 weight-% Pt and about 0.2 to about 4 weight-% Fe.

Claim 46

A composition of matter in accordance with claim 29 comprising about 1 to about 3 weight-% Pt and about 0.5 to about 2 weight-% Fe.