# US 10,441,918 B2 · Process for producing a catalyst and catalyst article > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,441,918 B2 - Document ID: US10441918B2 - Status: Granted - Kind: B2 - Application number: 15/500,548 - Filed: 2015-07-24 - Published: 2017-08-24 - Granted: 2019-10-15 - Earliest claimed: 2014-07-31 - Assignees: Johnson Matthey Public Limited Company - Applicants: Johnson Matthey Public Limited Company - Inventors: Juergen Bauer - Web page: https://patentgrep.com/patent/US10441918B2 ## CPC - B01D 53/9418: {for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas} - B01D 53/94: by catalytic processes - B01J 23/00: Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 (B01J21/16 takes precedence) - B01J 29/763: {CHA-type, e.g. Chabazite, LZ-218} - B01J 35/397: {Egg shell like} - B01J 35/57: Honeycombs - B01J 37/0009: {Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst} - B01J 37/0018: {Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)} - B01J 37/0215: {Coating} - B01J 37/0219: {the coating containing organic compounds} - B01J 37/0246: {Coatings comprising a zeolite} - B01J 37/04: Mixing {(B01J37/0009, B01J37/0018 take precedence)} - B01J 37/08: Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} - B01J 37/082: {Decomposition and pyrolysis} - C04B 28/001: {containing unburned clay (polymer binder - clay mixtures used in well cementing C09K8/44)} - C04B 28/005: {containing gelatineous or gel forming binders, e.g. gelatineous Al(OH)3, sol-gel binders} - C04B 30/00: Compositions for artificial stone, not containing binders - C04B 38/0051: {characterised by the pore size, pore shape or kind of porosity} - F01N 3/2066: {Selective catalytic reduction [SCR]} - F01N 3/2828: {Ceramic multi-channel monoliths, e.g. honeycombs} - B01D 2255/102: Platinum group metals - B01D 2255/2065: Cerium - B01D 2255/20707: Titanium - B01D 2255/20723: Vanadium - B01D 2255/20738: Iron - B01D 2255/20761: Copper - B01D 2255/20776: Tungsten - B01D 2255/40: Mixed oxides - B01D 2255/50: Zeolites - B01D 2255/65: Catalysts not containing noble metals - B01D 2255/9155: Wall flow filters - B01D 2255/9205: Porosity - B01J 37/32: Freeze drying, i.e. lyophilisation - B01J 2229/186: not in framework positions - B01J 2229/42: Addition of matrix or binder particles - C04B 2111/00129: {Extrudable mixtures} - C04B 2111/0081: {as catalysts or catalyst carriers} - Y02A 50/20: Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters - Y02T 10/12: Improving ICE efficiencies - B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28) - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16) - Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A process for producing a ceramic catalyst involves the steps of: a) providing functional particles having a catalytically inactive pore former as a support surrounded by a layer of a catalytically active material, b) processing the functional particles with inorganic particles to form a catalytic composition, c) treating the catalytic composition thermally to form a ceramic catalyst, wherein the ceramic catalyst comprises at least porous catalytically inactive cells which are formed by the pore formers in the functional particles, which are embedded in a matrix comprising the inorganic particles, which form a porous structure and which are at least partly surrounded by an active interface layer comprising the catalytically active material of the layer of the functional particles. An SCR catalyst produced in by this method has an improved NOx conversion rate compared to a conventionally produced SCR catalyst. ## Claims ### Claim 1 A process for producing a ceramic catalyst, the process comprising: a) processing functional particles with inorganic particles to form a catalytic composition, the functional particles having a catalytically inactive pore former as a support surrounded by a layer of a catalytically active material; and b) calcining the catalytic composition to form a ceramic catalyst, wherein the ceramic catalyst comprises at least porous catalytically inactive cells which are formed by the pore formers in the functional particles, which are embedded in a matrix comprising the inorganic particles, which form a porous structure and which are at least partly surrounded by an active interface layer comprising the catalytically active material of the layer of the functional particles. ### Claim 2 (depends on 1) The process of claim 1, wherein the pore formers consist of an organic material comprising thermoplastics or elastomers. ### Claim 3 (depends on 1) The process of claim 1, wherein the pore formers consist of an inorganic porous material having at least mesoporosity. ### Claim 4 (depends on 3) The process of claim 3, wherein the inorganic material is selected from a clay mineral, diatomaceous earth, silica gel, and porous glass. ### Claim 5 (depends on 3) The process of claim 3, wherein the pore formers consist of an inorganic porous material having macroporosity. ### Claim 6 (depends on 1) The process of claim 1, wherein powder particles of the catalytically active material have been applied to the pore former. ### Claim 7 (depends on 1) The process of claim 1, wherein the layer is formed by converting an outer layer of the catalytically inactive pore formers to the catalytically active layer. ### Claim 8 (depends on 1) The process of claim 1, wherein the pore formers have a particle size in the range of from 10 μm to 200 μm. ### Claim 9 (depends on 1) The process of claim 1, wherein the inorganic particles comprise a binder component wherein, after the treatment in step b), the binder component forms a ceramic matrix. ### Claim 10 (depends on 1) The process of claim 1, further comprising forming a shaped body from the catalytic composition by extrusion and then thermally treating the shaped body. ### Claim 11 (depends on 1) The process of claim 1, wherein the catalytic composition is applied as a washcoat to a monolithic support and the coated support is then treated thermally. ### Claim 12 (depends on 1) The process of claim 1, wherein the application of the layer to the pore former for formation of the functional particles and the processing of the catalytic composition are conducted in a single process step. ### Claim 13 (depends on 1) The process of claim 1, wherein the pore formers account for a proportion in the range of from 40% by volume to 80% by volume, based on the dry catalytic composition. ### Claim 14 (depends on 1) The process of claim 1, wherein catalytically active materials used are any one or more of: a crystalline molecular sieve; a tungsten/cerium-based catalytic system; a metal oxide or mixed oxide comprising one or more titanium oxide, vanadium oxide, tungsten oxide, or a combination thereof; or a platinum group metal-based system. ### Claim 15 (depends on 14) The process of claim 14, wherein the crystalline molecular sieve is present as individual crystallites. ### Claim 16 (depends on 14) The process of claim 14, wherein the crystalline molecular sieve has at least mesoporosity as defined by the IUPAC definition in addition to their inherent microporosity. ### Claim 17 (depends on 14) The process of claim 14, wherein the metal oxide or mixed metal oxide of the catalytically active material comprises a titanium-vanadium-tungsten system, a titanium-vanadium-tungsten-silicon system, a titanium-vanadium-silicon system, a titanium-vanadium-tungsten-iron system, a titanium-vanadium-tungsten-silicon-iron system, a titanium-vanadium-silicon-iron system, an iron vanadate system and/or and an iron aluminum vanadate system. ### Claim 18 (depends on 1) The process of claim 1, further comprising introducing particles of another catalytically active material into the catalytic composition in step a). ### Claim 19 (depends on 1) The process of claim 1, wherein the pore formers have differing particle size distribution. ### Claim 20 (depends on 1) The process of claim 1, wherein the catalytic composition comprises two or more different functional particles which differ in terms of the catalytically active material used for the layer, wherein: a mixture of two or more different catalytically active materials is used for the layer; and/or a different catalytically active material is applied to each of the individual pore formers, and where first and second functional particles are obtained and mixed to form the catalytic composition. ### Claim 21 A catalyst article comprising a catalyst having a composite structure having a porous structure embedded into an inorganic matrix, wherein the porous structure is formed from catalytically inactive, at least porous cells at least partly surrounded by an active interface layer comprising a catalytically active material, wherein said catalyst article is any of: an extruded catalyst article consisting of the catalyst, a honeycomb consisting of the catalyst, a plate catalytic converter consisting of the catalyst, pellets consisting of the catalyst, a monolithic support body coated with a washcoat consisting of the catalyst, a wall-flow filter comprising a honeycomb, wherein the honeycomb consists of the catalyst and/or the honeycomb has been coated with a washcoat composed of the catalyst. ### Claim 22 (depends on 21) The catalyst article of claim 21, wherein the ceramic matrix is at least substantially free of catalytically active material. ### Claim 23 (depends on 21) The catalyst article of claim 21, having two or more different catalytically active materials, wherein the catalytically active material in an active interface layer that bounds a first cell is different from the catalytically active material in an active interface layer that bounds a second cell and/or an active interface layer that bounds a particular cell contains two or more different catalytically active materials. ### Claim 24 (depends on 21) The catalyst article of claim 21, wherein the catalytically active material is selected from a crystalline molecular sieve; a tungsten/cerium-based catalytic system; a metal oxide or mixed oxide comprising one or more titanium oxide, vanadium oxide, tungsten oxide, or a combination thereof; or a platinum group metal-based system. ### Claim 25 (depends on 24) The catalytic article of claim 24, wherein the metal oxide or mixed metal oxide of the catalytically active material comprises a titanium-vanadium-tungsten system, a titanium-vanadium-tungsten-silicon system, a titanium-vanadium-silicon system, a titanium-vanadium-tungsten-iron system, a titanium-vanadium-tungsten-silicon-iron system, a titanium-vanadium-silicon-iron system, an iron vanadate system and/or and an iron aluminum vanadate system. ### Claim 26 Functional particles which comprise a pore former which takes the form of a support surrounded by a layer of a catalytically active material, wherein the pore former consists of an organic material comprising thermoplastics or elastomers, or wherein the pore former consists of an inorganic porous material having at least mesoporosity.