US5037791A
Expired / Lapsed
US
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Porous metal oxide supported carbon-coated catalysts and method for producing same
Assignee: IFP Energies nouvelles
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Filing: 1990-06-21
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Granted: 1991-08-06
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Expires: 2010-06-21
Abstract
Abstract Supported carbon-coated catalyst material and a method for producing and using same in catalytic reaction processes, preferably in ebullated or fluidized catalyst beds. The catalyst materials are prepared by depositing a porous carbon layer on a support material of a selected metal oxide or compound to produce 5-40 wt. % carbon thereon, then preferentially treating the carbon based layer by partial oxidation, pyrolysis or reduction to enhance and activate the carbon layer on the catalyst. Promoter materials can also be advantageously added either to the support material or to the carbon layer in 0.5-10 wt. % to provide an improved composite carbon-coated catalyst having total pore volume of 0.3-1.0 cc/gm, substantially increased surface area of 80-600 M2/gm, low surface acidity, particle strength of 1.8-5 lb/mm with reduced particle attrition losses and improved catalyst performance characteristics.
Inventors
- 👤 Alfred G. Comolli
- 👤 Partha S. Ganguli
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 10:06
CPC Classifications
B; B01; B01J; B01J21/00; B01J21/18; B01J23/00; B01J23/16; B01J23/24; B01J23/70; B01J23/74; B01J35/00; B01J35/30; B01J35/31; B01J35/32; B01J35/34; B01J35/37; B01J35/38; B01J35/60; B01J35/61; B01J35/613; B01J35/615; B01J35/63; B01J35/633; B01J35/635; B01J37/00; B01J37/02; B01J37/024; C; C10; C10G; C10G49/00; C10G49/02
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
145 words
An improved composite supported carbon-coated catalyst material for use in catalytic reaction processes, said catalyst comprising: (a) a particulate support material selected from the group consisting of alumina, silica, silica-alumina, magnesia, and titania and mixtures thereof; (b) a porous carbon layer provided on said support material, said carbon layer being 5-40 wt. % of the composite catalyst and being treated by partial oxidation with oxygen in an inert atmospheric gas so as to increase pore volume and provide 0.3-1.0 cc/gm total pore volume, surface area of 80-600 M 2 /gm and increased particle crush strength at least about 1.5 lb/mm; and (c) at least one promoter metal or metal compound selectively added to said support material or carbon layer, said promoter being 0.5-10 wt. % of the composite catalyst, whereby a composite carbon-coated catalyst material is provided having high porosity and increased particle strength characteristics.
Claim 2
Dependent Claim
145 words
An improved composite supported carbon-coated catalyst material for use in catalytic reaction processes, said catalyst comprising: (a) a particulate support material selected from the group consisting of alumina, silica, silica-alumina, magnesia, and titania and mixtures thereof; (b) a porous carbon layer provided on said support material, said carbon layer being 5-40 wt. % of the composite catalyst and being treated by partial oxidation with oxygen in an inert atmospheric gas so as to increase pore volume and provide 0.3-1.0 cc/gm total pore volume, surface area of 80-600 M 2 /gm and increased particle crush strength at least about 1.5 lb/mm; and (c) at least one promoter metal or metal compound selectively added to said support material or carbon layer, said promoter being 0.5-10 wt. % of the composite catalyst, whereby a composite carbon-coated catalyst material is provided having high porosity and increased particle strength characteristics.
Claim 3
Dependent Claim
20 words
A catalyst material according to claim 1, wherein said carbon layer has total pore volume of 0.4 to 0.9 cc/gm.
Claim 4
Dependent Claim
16 words
A catalyst material according to claim 1, wherein the surface area is 100-500 M 2 /gm.
Claim 5
Dependent Claim
16 words
A catalyst material according to claim 1, wherein the particle crush strength is 1.5-5.0 lb/mm length.
Claim 6
Dependent Claim
25 words
A catalyst material according to claim 1, wherein particle attrition loss does not exceed 3.5 W % after 7 hour tumble test at 40 rpm.
Claim 7
Dependent Claim
37 words
A catalyst material according to claim 1, wherein said carbon layer is treated to increase pore volume by partial oxidation using 0.5-6 vol. % oxygen in an inert atmospheric gas at 650°-850° F. temperature for 1-300 minutes.
Claim 8
Dependent Claim
37 words
A catalyst material according to claim 1, wherein said promoter metal or compound provided for said carbon layer is selected from the group consisting of cobalt, chromium, iron, molybdenum, nickel, titania, tungsten, vanadium, zinc and combinations thereof.
Claim 9
Dependent Claim
25 words
A catalyst material according to claim 1, wherein the catalyst is in the form of extrudates or spheres having an effective diameter of 0.016-0.130 inch.
Claim 10
Dependent Claim
170 words
A composite supported carbon-coated catalyst material for use in catalytic reaction processes, said catalyst comprising: (a) a particulate support material selected from the group consisting of alumina, silica, silica-alumina, magnesia, and titania and mixtures thereof; (b) a porous carbon layer provided on said support material, said carbon layer being 10-30 wt. % of the composite catalyst and being treated by partial oxidation using 0.5-6 vol. % oxygen in an inert atmospheric gas at 650°-850° F. temperature for 1-300 minutes, so as to provide total pore volume of 0.4-0.9 cc/gm, surface area of 100-500 M 2 /gm, and increased catalyst particle crush strength of 1.8-3.5 lb/mm; and (c) at least one promoter metal or metal compound selected from the group consisting of cobalt, chromium, iron, molybdenum, nickel, titania, tungsten, vanadium, zinc, and combinations thereof selectively added to said support material or carbon layer, said promoter metal being 0.5-10 wt. % of the composite catalyst, whereby a composite carbon coated catalyst material is provided having high porosity and increased particle strength characteristics.
Claim 11
Dependent Claim
170 words
A composite supported carbon-coated catalyst material for use in catalytic reaction processes, said catalyst comprising: (a) a particulate support material selected from the group consisting of alumina, silica, silica-alumina, magnesia, and titania and mixtures thereof; (b) a porous carbon layer provided on said support material, said carbon layer being 10-30 wt. % of the composite catalyst and being treated by partial oxidation using 0.5-6 vol. % oxygen in an inert atmospheric gas at 650°-850° F. temperature for 1-300 minutes, so as to provide total pore volume of 0.4-0.9 cc/gm, surface area of 100-500 M 2 /gm, and increased catalyst particle crush strength of 1.8-3.5 lb/mm; and (c) at least one promoter metal or metal compound selected from the group consisting of cobalt, chromium, iron, molybdenum, nickel, titania, tungsten, vanadium, zinc, and combinations thereof selectively added to said support material or carbon layer, said promoter metal being 0.5-10 wt. % of the composite catalyst, whereby a composite carbon coated catalyst material is provided having high porosity and increased particle strength characteristics.
Claim 12
Independent Claim
116 words
A method for producing a composite supported carbon-coated catalyst material, said method comprising: (a) providing a particulate support material selected from the group consisting of alumina, silica, silica-alumina, magnesia, titania and mixtures thereof; (b) providing a carbon-containing precursor material layer on said support material, said precursor layer being sufficient to produce after pyrolysis a porous carbon layer on the support consisting of 5-40 wt. % of the composite catalyst; and (c) treating the porous carbon layer by partial oxidation with oxygen in an inert atmospheric gas to provide increased total pore volume of 0.3-1.0 cc/gm, surface area of 80-600 M 2 /gm, and increased particle crush strength for the catalyst of at least about 1.5 lb/mm.
Claim 13
Independent Claim
116 words
A method for producing a composite supported carbon-coated catalyst material, said method comprising: (a) providing a particulate support material selected from the group consisting of alumina, silica, silica-alumina, magnesia, titania and mixtures thereof; (b) providing a carbon-containing precursor material layer on said support material, said precursor layer being sufficient to produce after pyrolysis a porous carbon layer on the support consisting of 5-40 wt. % of the composite catalyst; and (c) treating the porous carbon layer by partial oxidation with oxygen in an inert atmospheric gas to provide increased total pore volume of 0.3-1.0 cc/gm, surface area of 80-600 M 2 /gm, and increased particle crush strength for the catalyst of at least about 1.5 lb/mm.
Claim 14
Dependent Claim
48 words
A method for producing a catalyst material according to claim 10, wherein the carbon layer is treated by partial oxidation using 0.5-6 vol. % oxygen in an inert oxygen-containing atmospheric gas at 650°-850° F. temperature for 1-300 minutes to produce the increased pore volume and surface area characteristics.
Claim 15
Dependent Claim
30 words
A method for producing a catalyst material according to claim 10, wherein said porous carbon layer is deposited on the support material by a hydrocracking process utilizing a hydrocarbon feedstock.
Claim 16
Dependent Claim
79 words
A method for producing a catalyst material according to claim 10, wherein the carbon layer is provided by soaking the particulate support material in boiling partially polymerized furfuryl alcohol precursor material for 5-30 minutes, followed by pyrolysis of the coated support at 700°-1200° F. temperature to produce carbon deposits, and then treating the coated support by partial oxidation of the carbon coated catalyst at 650°-850° F. for 15-240 minutes to produce the increased pore volume and surface area characteristics.
Claim 17
Dependent Claim
30 words
A method for producing a catalyst material according to claim 10, wherein a metal promoter consisting of 0.5-10 wt. % of the composite catalyst is added to the carbon layer.
Claim 18
Dependent Claim
29 words
A method for producing a catalyst material according to claim 10, wherein a metal promotor is added to the metal oxide support material prior to the carbon layer step.
Claim 19
Dependent Claim
26 words
A method for producing a catalyst material according to claim 10, wherein a metal promoter is added to said support material together with the carbon layer.
Claim 20
Dependent Claim
46 words
A method for producing a catalyst material according to claim 10, wherein said porous carbon layer is provided on the catalyst support material in an ebullated bed or a fluidized bed using polyaromatic compound feed material to form a filamentary carbon structure on the support material.
Claim 21
Dependent Claim
35 words
A method for producing a catalyst according to claim 14, wherein said metal promotor is selected from the group consisting of oxides or compounds of cobalt, chromium, iron, nickel, molybdenum, titanium, tungsten and mixtures thereof.
Claim 22
Independent Claim
143 words
A method for producing a composite supported carbon-coated catalyst material, said method comprising: (a) providing a particulate support material selected from the group consisting of alumina, silica, silica-alumina, magnesia, and titania, and mixtures thereof; (b) providing a carbon precursor material on said support material sufficient to produce by subsequent pyrolization a porous carbon layer thereon consisting of 5-40 wt. % of the catalyst; (c) pyrolyzing said carbon precursor layer at temperature of 650°-850° F. and partially oxidizing with oxygen in an inert atmospheric gas the carbon layer to provide total pore volume of 0.3-1.0 cc/gm and surface area of 80-600 M 2 /gm on the catalyst and particle strength of at least about 1.5 lb/mm; and (d) adding at least one metal promoter to the carbon layer to provide a composite catalyst material having high activity and increased porosity and particle strength characteristics.
Claim 23
Independent Claim
143 words
A method for producing a composite supported carbon-coated catalyst material, said method comprising: (a) providing a particulate support material selected from the group consisting of alumina, silica, silica-alumina, magnesia, and titania, and mixtures thereof; (b) providing a carbon precursor material on said support material sufficient to produce by subsequent pyrolization a porous carbon layer thereon consisting of 5-40 wt. % of the catalyst; (c) pyrolyzing said carbon precursor layer at temperature of 650°-850° F. and partially oxidizing with oxygen in an inert atmospheric gas the carbon layer to provide total pore volume of 0.3-1.0 cc/gm and surface area of 80-600 M 2 /gm on the catalyst and particle strength of at least about 1.5 lb/mm; and (d) adding at least one metal promoter to the carbon layer to provide a composite catalyst material having high activity and increased porosity and particle strength characteristics.
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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) | 1994-08-05 | 1995-02-04 | 1995-08-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-08-05 | 1999-02-04 | 1999-08-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-08-05 | 2003-02-04 | 2003-08-06 | $7700.00 | Window Closed / Lapsed |