Nova Patents
WO0154812B1

Catalyst, method of making, and reactions using the catalyst

Abstract

The present invention includes a catalyst having a layered structure with, (1) a porous support, (2) a buffer layer, (3) an interfacial layer, and optionally (4) a catalyst layer. The invention also provides a process in which a reactant is converted to a product by passing though a reaction chamber containing the catalyst.

Term

No projected expiry on record.

  1. Priority and filed
  2. Published
  3. Today

6 claims: 3 independent, 3 dependent

  1. 1
    AMENDED CLAIMS [received by the International Bureau on 30 August 2001 (30.08.01);original claims 1, 2, 4, 6 and 22 amended;new claims 23-56 added;remaining claims unchanged (4 pages)] 1 A catalyst comprising a porous metal support, a buffer layer, an interfacial layer, and a catalytically active layer on the surface;wherein the porous metal support has an average pore size of from 1 μm to 1000 μm;wherein the porous metal support is selected from the group consisting of honeycomb, foam, felt, and wad;wherein the buffer layer is disposed between the porous support and the interfacial layer, and the interfacial layer is disposed between the catalytically active layer and the buffer layer.
  2. 2
    A catalyst comprising a porous metal support, a buffer layer, and an interfacial layer;wherein the porous metal support has an average pore size of from 1 μm to 1000 μm;wherein the porous metal support is selected from the group consisting of honeycomb, foam, felt, and wad;wherein the buffer layer is comprised of at least two compositionaily different sublayers;and wherein the buffer layer is disposed between the porous support and the interfacial layer.
  3. 4
    A catalyst comprising a porous metal support, a buffer layer, and an interfacial layer;wherein the porous metal support has an average pore size of from 1 μm to 1000 μm;wherein the porous metal support is selected from the group consisting of honeycomb, foam, felt, and wad;wherein the buffer layer is disposed between the porous support and the interfacial layer;and wherein the catalyst possesses thermal cycling stability such that, if exposed to 3 thermal cycles in air, the catalyst exhibits less than 2% flaking.
  4. 6
    A method of making a catalyst comprising the steps of:selecting a porous support selected from the group consisting of honeycomb, foam, felt, and wad;vapor depositing a buffer layer on said porous support;depositing an interfacial layer on said buffer layer. -19- an interfacial layer;and a catalytically active layer. 21. The catalyst of claim 1 wherein the catalyst possesses oxidation resistance such that, if it is heated at 750 β C in air for 1500 minutes, the catalyst increases in weight by less than 0.5%. 22. The catalyst of claim 1 wherein the porous support is a metal and the catalytically active layer is distributed on surfaces throughout catalyst such that reactants passing through the catalyst can react anywhere along the passage through the catalyst. 23. The catalyst of claim 2 wherein said at least two sublayers comprise a first sublayer in contact with the porous support composed of Ti0 2 , and a second sublayer composed of α-AI 2 0 3 . 24. The catalyst of claim 1 wherein said buffer layer is noπporous. 25. The catalyst of claim 5 wherein the buffer layer is between 0.05 and 10 μm thick. 26. The catalyst of claim 2 wherein the interfacial layer consists of a metal oxide. 27. The catalyst of claim 2 wherein the interfacial layer can serve as a catalytically active layer without any further catalytically active material deposited thereon. 28. The catalyst of claim 2 wherein the interfacial layer comprises at least two compositionaily different sub-layers. 29. The catalyst of claim 1 wherein the interfacial layer has a BET surface area of at least 1 m 2 /g. 30. The catalyst of claim 4 wherein the catalyst is a monolith having a width of 0.1 mm to about 2 cm and a thickness of less than 1 cm. 31. The process of claim 6 wherein a catalytically active material is simultaneously deposited with the interfacial layer. 32. The method of claim 6 wherein the interfacial layer is deposited from solution. 33. The method of claim 6 wherein the step of vapor depositing comprises chemical vapor depositing. -20- O 01/54812 34 The method of claim 6 comprising the steps of vapor depositing a TιO 2 layer, vapor depositing a dense alumina layer over the Tι0 2 layer;and depositing a less dense, high surface area alumina layer over the dense alumina layer. 35. The method of claim 6 wherein the porous support comprises a metal foam and the catalyst has a surface area of greater than 2.0 g per cubic centimeter 36. The method of claim 6 wherein the porous support comprises a metal foam and the metal foam is etched prior to vapor depositing the buffer layer. 37 The method of claim 33 wherein the support compπses a metal foam and wherein the chemical vapor deposition is conducted in a temperature range of 250 to 800 °C. 38. The method of claim 33 wherein a precursor for the chemical vapor deposition is selected from the group consisting of: organometallic compounds, halides, carbonyls, acetonates, and acetates 39. The method of claim 6, wherein the support comprises a metal selected from the group consisting of honeycomb, foam, felt, and wad;and the catalyst possesses oxidation resistance such that, if it heated at 750 °C in air for 1500 minutes the catalyst increases in weight by less than 0.5% 40. The catalyst of claim 1 wherein the interfacial layer comprises a material selected from the group consisting of nitrides, carbides, sulfides, halides and carbon. 41. The catalyst of claim 23 wherein the interfacial layer comprises a layer of high surface area alumina that is less dense than the second sublayer. 42. The catalyst of claim 41 further comprising a catalyst disposed on the interfacial layer. 43. The catalyst of claim 1 having oxidation resistance such that, if it heated at 750 *C in air for 1500 minutes the catalyst increases in weight by less than 0.5%. 44 The method of claim 6 wherein the porous support has a porosity in the range of 70 to 98%. 45. The catalyst of claim 2 wherein the porous support has a porosity in the range of 70 to 98%. 46. The catalyst of claim 4 wherein the porous support has a porosity in the range of 70 to 98%. 47 The catalyst of claim 1 wherein the porous support comprises a foam, felt, wad or combination thereof. 48. The catalyst of claim 2 wherein the porous support comprises a foam, felt, wad or combination thereof. -21- O 01/54812 49. The catalyst of claim 4 wherein the porous support comprises a foam, felt, wad or combination thereof. 50. The method of claim 6 wherein the porous support comprises a foam, felt, wad, or combination thereof. 51. The method of claim 50 wherein the step of vapor depositing comprises chemical vapor depositing, 52. The catalyst of claim 1 wherein the porous metal support has an average pore size of from 1 to 500 μm. 53. The catalyst of claim 4 wherein the porous metal support has an average pore size of from 1 to 500 μm. 54. The catalyst of claim 1 wherein the interfacial layer has a thickness that ranges from 1 to 50 μm. 55. The catalyst of claim 2 wherein the interfacial layer has a thickness that ranges from 1 to 50 μm. 56. The catalyst of claim 4 wherein the interfacial layer has a thickness that ranges from 1 to 50 μm. -22- STATEMENT UNDER ARTICLE 19(1) Applicant provides the Amendment and enclosed replacement pages 14 and 18 of claims. Also included is the following summary of amendments for consideration toward a positive International Preliminary Examination Report. SUMMARY OF AMEMnMFNTR The claims have been amended as in the priority application. More specifically, the claims have been amended to duplicate the claims in the priority application, U.S. Ser. No. 09/492,950. Substitute pages 14 and 18 are attached to this Response including amended claims 1, 2, 4, 6 and 22 and added claims 23-56. It is believed that none of the amendments to the claims contain new matter. -23-
Independent claims4