Solution-based approach to make porous coatings for sinter-resistant catalysts
AssigneeGM Global Technology Operations LLC
InventorsXingcheng Xiao, Gongshin Qi, Ryan J. Day, Ming Yang
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Abstract
Catalyst systems that are resistant to high-temperature sintering and methods for preparing such catalyst systems that are resistant to sintering at high temperatures are provided. Methods of forming such catalyst systems include contacting a support having a surface including a catalyst particle with a solution comprising a metal salt and having an acidic pH. The metal salt is precipitated onto the surface of the support. Next, the metal salt is calcined to selectively generate a porous coating of metal oxide on the surface of the support distributed around the catalyst particle.
Claims16
A method of preparing a sinter-resistant catalyst system, the method comprising:
- disposing a support having a surface comprising a catalyst particle in a reducing atmosphere to promote conversion of the catalyst particle to a metallic state;
- contacting the support having the surface comprising the catalyst particle with a solution comprising a metal salt and having an acidic pH, wherein the metal salt comprises an element selected from the group consisting of:
- aluminum (Al), cerium (Ce), zirconium (Zr), titanium (Ti), silicon (Si), magnesium (Mg), zinc (Zn), sodium (Na), potassium (K), barium (Ba), calcium (Ca), and combinations thereof;
- precipitating the metal salt onto the surface of the support;
- and
- calcining the metal salt to selectively generate a porous coating of metal oxide on the surface of the support distributed around the catalyst particle, so that at least a portion of the catalyst particle is exposed and available for reaction.
A method of preparing a sinter-resistant catalyst system, the method comprising:
- disposing a plurality of support particles each comprising a surface bearing at least one catalyst particle in a reducing atmosphere to promote conversion of the catalyst particle to a metallic state;
- contacting the plurality of support particles each comprising the surface bearing at least one catalyst particle with a liquid comprising a metal salt and having a pH of less than or equal to about 6, wherein the metal salt comprises an element selected from the group consisting of:
- aluminum (Al), cerium (Ce), zirconium (Zr), titanium (Ti), silicon (Si), magnesium (Mg), zinc (Zn), sodium (Na), potassium (K), barium (Ba), calcium (Ca), and combinations thereof;
- precipitating the metal salt onto the surface bearing the at least one catalyst particle;
- and
- calcining the metal salt to selectively generate a porous coating of metal oxide on the surface bearing the at least one catalyst particle, wherein the porous coating is distributed around the at least one catalyst particle on the surface, so that at least a portion of the catalyst particle is exposed and available for reaction.
A method of preparing a sinter-resistant catalyst system, the method comprising:
- disposing a support having a surface comprising a catalyst particle in a reducing atmosphere to promote conversion of the catalyst particle to a metallic state;
- contacting the support having the surface comprising the catalyst particle with a solution comprising a metal salt and having an acidic pH, wherein the metal salt comprises an element selected from the group consisting of:
- aluminum (Al), cerium (Ce), zirconium (Zr), titanium (Ti), silicon (Si), magnesium (Mg), zinc (Zn), sodium (Na), potassium (K), barium (Ba), calcium (Ca), and combinations thereof and the catalyst particle comprises a metal selected from the group consisting of:
- platinum (Pt), ruthenium (Ru), rhodium (Rh), palladium (Pd), osmium (Os), iridium (Ir), gold (Au), iron (Fe), nickel (Ni), and combinations thereof;
- precipitating the metal salt onto the surface of the support;
- and
- calcining the metal salt to selectively generate a porous coating of metal oxide on the surface of the support distributed around the catalyst particle, so that at least a portion of the catalyst particle is exposed and available for reaction.
Dependencies are inferred from the claim text.