US4902664A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Thermally stabilized catalysts containing alumina and methods of making the same
Assignee: BASF Catalysts LLC
•
Filing: 1988-12-07
•
Granted: 1990-02-20
•
Expires: 2008-12-07
Abstract
Abstract A catalyst comprises (a) an activated alumina, (b) a substantially water-insoluble bulk stabilizer present in an amount at least sufficient to stabilize the activated alumina against thermal degradation, and (c) one or more platinum group metal catalytic components. The bulk stabilizer may be one or more of calcium sulfate, strontium sulfate or, preferably, barium sulfate. A mixture of activated alumina (and/or activated alumina precursor) and bulk stabilizer particles, e.g., gamma-alumina particles and barium sulfate particles, may be slurried in an aqueous medium and coated onto a carrier substrate. One or more platinum group metal catalytic components may be dispersed onto the activated alumina, e.g., it may be dispersed onto a mixture of activated alumina and bulk stabilizer. The coated carrier substrate may be calcined in air to provide the catalyst.
Inventors
- 👤 Chung-Zong Wan
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 09:06
CPC Classifications
B; B01; B01J; B01J37/00; B01J37/02; B01J37/024; B01J27/00; B01J27/02; B01J27/053
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
54 words
A catalyst comprising (a) activated alumina, (b) a substantially water-insoluble bulk stabilizer selected from the group consisting of one or more of strontium sulfate and barium sulfate, the bulk stabilizer being present in an amount sufficient to stabilize the activated alumina against thermal degradation; and (c) a catalytic component dispersed on the activated alumina.
Claim 2
Dependent Claim
54 words
A catalyst comprising (a) activated alumina, (b) a substantially water-insoluble bulk stabilizer selected from the group consisting of one or more of strontium sulfate and barium sulfate, the bulk stabilizer being present in an amount sufficient to stabilize the activated alumina against thermal degradation; and (c) a catalytic component dispersed on the activated alumina.
Claim 3
Dependent Claim
12 words
The catalyst of claim 1 wherein the bulk stabilizer comprises barium sulfate.
Claim 4
Dependent Claim
16 words
The catalyst of claim 1 including a carrier substrate on which the activated alumina is disposed.
Claim 5
Dependent Claim
44 words
The catalyst of claim 1, claim 2 or claim 3 comprising an admixture of the activated alumina and the bulk stabilizer, the bulk stabilizer being present in an amount of from about 0.5 to 50% by weight of the weight of the activated alumina.
Claim 6
Dependent Claim
26 words
The catalyst of claim 4 wherein the bulk stabilizer is present in an amount of from about 1 to 30% by weight of the activated alumina.
Claim 7
Dependent Claim
16 words
The catalyst of claim 4 wherein the admixture further includes one or more of catalytic modifiers.
Claim 8
Dependent Claim
25 words
The catalyst of claim 1, claim 2 or claim 3 wherein the bulk stabilizer is comprised of particles at least about 0.1 micron in diameter.
Claim 9
Dependent Claim
31 words
The catalyst of claim 1, claim 2 or claim 3 wherein the activated alumina is an unstabilized alumina except insofar as it is stabilized by the presence of the bulk stabilizer.
Claim 10
Dependent Claim
26 words
The catalyst of claim 1, claim 2 or claim 3 wherein the activated alumina is a stabilized alumina independently of the presence of the bulk stabilizer.
Claim 11
Dependent Claim
26 words
The catalyst of claim 1, claim 2 or claim 3 wherein the catalytic component is a platinum group metal catalytic component dispersed on the activated alumina.
Claim 12
Dependent Claim
34 words
The catalyst of claim 10 wherein an admixture of he activated alumina and bulk stabilizer is coated upon a carrier substrate comprising a structure having a plurality of fine gas flow passages extending therethrough.
Claim 13
Dependent Claim
33 words
The catalyst of claim 10 wherein the platinum group metal catalytic component is selected from the group consisting of one or more of a platinum component, a palladium component and a rhodium component.
Claim 14
Dependent Claim
57 words
A catalyst comprising (a) a carrier substrate; (b) a coating on the substrate of an admixture of activated alumina and a thermally-stabilizing amount of a substantially water-insoluble bulk stabilizer selected from the group consisting of one or more of strontium sulfate and barium sulfate; and (c) a platinum group metal catalytic component dispersed on the activated alumina.
Claim 15
Dependent Claim
57 words
A catalyst comprising (a) a carrier substrate; (b) a coating on the substrate of an admixture of activated alumina and a thermally-stabilizing amount of a substantially water-insoluble bulk stabilizer selected from the group consisting of one or more of strontium sulfate and barium sulfate; and (c) a platinum group metal catalytic component dispersed on the activated alumina.
Claim 16
Dependent Claim
41 words
The catalyst of claim 13 wherein the bulk stabilizer is present in an amount of from about 0.5 to 50% by weight of the weight of activated alumina and is comprised of particles of at least about 0.1 micron in diameter.
Claim 17
Dependent Claim
31 words
The catalyst of claim 13 wherein the carrier substrate has extending therethrough a plurality of gas flow passages defined by passage walls, and the coating is disposed on the passage walls.
Claim 18
Dependent Claim
33 words
The catalyst of claim 13 wherein the platinum group metal catalytic component is selected from the group consisting of one or more of a platinum component, a palladium component and a rhodium component.
Claim 19
Dependent Claim
19 words
The catalyst of any one of claims 13, 14, 15 or 16 wherein the bulk stabilizer comprises barium sulfate.
Claim 20
Independent Claim
81 words
A method of making a catalyst comprising activated alumina and a thermally stabilizing amount of a substantially water-insoluble bulk thermal stabilizer selected from the group consisting of one or more of strontium sulfate and barium sulfate, the method comprising: (a) combining the bulk stabilizer in particulate form with one or both of the activated alumina and activated alumina precursor, (b) depositing a catalytic component on the activated alumina and (c) when said precursor is present, converting said precursor to activated alumina.
Claim 21
Independent Claim
81 words
A method of making a catalyst comprising activated alumina and a thermally stabilizing amount of a substantially water-insoluble bulk thermal stabilizer selected from the group consisting of one or more of strontium sulfate and barium sulfate, the method comprising: (a) combining the bulk stabilizer in particulate form with one or both of the activated alumina and activated alumina precursor, (b) depositing a catalytic component on the activated alumina and (c) when said precursor is present, converting said precursor to activated alumina.
Claim 22
Dependent Claim
12 words
The method of claim 18 wherein the bulk stabilizer comprises barium sulfate.
Claim 23
Dependent Claim
23 words
The method of claim 18 or claim 19 including dispersing on the activated alumina a platinum group metal component as said catalytic component.
Claim 24
Dependent Claim
61 words
The method of claim 18 or claim 19 further including (c) applying the bulk stabilizer and one or both of the activated alumina and activated alumina precursor as a coating to a carrier substrate; and (d) calcining the resultant coated substrate having the platinum group metal catalytic component dispersed thereon, to provide a calcined coating of the same on the carrier.
Claim 25
Dependent Claim
34 words
The method of claim 21 wherein the activated alumina precursor is selected from the class consisting of one or more of alumina sol and soluble aluminum salts which convert to activated alumina upon calcining.
Claim 26
Dependent Claim
30 words
The method of claim 21 including combining the activated alumina with an amount of bulk stabilizer of from about 0.5 to 50% by weight of the weight of activated alumina.
Claim 27
Dependent Claim
19 words
The method of claim 21 wherein the bulk stabilizer comprises particles of at least about 0.1 micron in diameter.
Claim 28
Dependent Claim
26 words
The method of claim 21 wherein the activated alumina is an unstabilized alumina except insofar as it is stabilized by the presence of the bulk stabilizer.
Claim 29
Dependent Claim
18 words
The method of claim 21 including stabilizing the activated alumina independently of the presence of the bulk stabilizer.
Claim 30
Dependent Claim
36 words
The method of claim 21 including a preliminary step of mixing the alumina and/or its precursors and stabilizer to form an admixture thereof; and carrying out step (c) by applyng the admixture to the carrier substrate.
Claim 31
Dependent Claim
12 words
The method of claim 21 including employing activated alumina in step (a).
Claim 32
Dependent Claim
15 words
The method of claim 18 or claim 19 including employing activated alumina in step (a).
Claim 33
Dependent Claim
37 words
The method of claim 18 or claim 19 wherein the activated alumina precursor is selected from the class consisting of one or more of alumina sol and soluble aluminum salts which convert to activated alumina upon calcining.
Claim 34
Dependent Claim
18 words
The method of claim 18 or claim 19 including adding one or more catalyst modifiers to the catalyst.
Claim 35
Dependent Claim
33 words
The method of claim 18 or claim 19 wherein the combining of step (b) comprises mixing one or both of the alumina and alumina precursor and the stabilizer to form an admixture thereof.
References Cited (Backward Citations)
US2767202A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-02-19 | 1993-08-21 | 1994-02-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-02-19 | 1997-08-21 | 1998-02-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-02-19 | 2001-08-21 | 2002-02-20 | $7700.00 | Window Closed / Lapsed |