# US 10,478,804 B2 · Activated carbon monolith catalyst, methods for making same, and uses thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,478,804 B2 - Document ID: US10478804B2 - Status: Granted - Kind: B2 - Application number: 16/296,318 - Filed: 2019-03-08 - Published: 2019-07-04 - Granted: 2019-11-19 - Earliest claimed: 2005-04-08 - Assignees: Applied Technology Limited Partnership - Applicants: Applied Technology Limited Partnership - Inventors: Robert L. Mitchell; Lee M. Mitchell; Joseph H. Keller; Jack H. L'Amoreaux - Web page: https://patentgrep.com/patent/US10478804B2 ## CPC - B01J 21/18: Carbon - B01J 23/44: Palladium - B01J 35/57: Honeycombs - C01B 32/382: {Making shaped products, e.g. fibres, spheres, membranes or foam} - C07B 43/04: of amino groups - C07C 209/36: by reduction of nitro groups bound to carbon atoms of six-membered aromatic rings {in presence of hydrogen-containing gases and a catalyst} - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C} - C07B: GENERAL METHODS OF ORGANIC CHEMISTRY; APPARATUS THEREFOR (preparation of carboxylic acid esters by telomerisation C07C67/47; telomerisation C08F) - C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS ## Abstract Activated carbon monolith catalyst including a finished self-supporting activated carbon monolith having at least one passage therethrough, and including a supporting matrix and substantially discontinuous activated carbon particles dispersed throughout the supporting matrix and at least one catalyst precursor on the finished self-supporting activated carbon monolith. A method for making, and a method for use, of such an activated carbon monolith catalyst in catalytic chemical reactions. ## Claims ### Claim 1 A method for catalytic chemical reaction comprising contacting at least one reactant with an activated carbon monolith catalyst, wherein the catalytic chemical reaction comprises a hydrodesulfurization or a hydrodenitrogenation; and the activated carbon monolith catalyst comprises (a) a porous finished activated carbon monolith having walls defining at least one passage therethrough and comprising a supporting ceramic matrix and substantially discontinuous activated carbon particles dispersed throughout the supporting ceramic matrix, the walls having an exterior surface, depth, and passageways into the depth of the walls, and (b) at least one catalyst precursor on said porous finished activated carbon monolith, the at least one catalyst precursor applied to the porous finished activated carbon monolith and disposed on the exterior surface of the walls and within the passageways into the depth of the monolith walls of the porous finished activated carbon monolith, wherein the at least one catalyst precursor is catalytically active. ### Claim 2 (depends on 1) A method as in claim 1, wherein the at least one catalyst precursor is selected from the group consisting of reduced precious metal, precious metal oxide, precious metal with modifier, base metal, and a combination thereof, wherein the base metal is selected from the group consisting of zinc, nickel, copper, manganese, iron, chromium, vanadium, and molybdenum. ### Claim 3 (depends on 1) A method as in claim 1, wherein the at least one catalyst precursor includes a modifier selected from the group consisting of potassium hydrated oxides, potassium hydroxides, calcium hydrated oxides, calcium hydroxides, magnesium hydrated oxides, magnesium hydroxides, sodium hydrated oxides, and sodium hydroxides. ### Claim 4 (depends on 1) A method as in claim 1, wherein the at least one catalyst precursor is a precious metal selected from the group consisting of palladium, platinum, rhodium, ruthenium, iridium, osmium, silver, and gold. ### Claim 5 (depends on 1) A method as in claim 1, wherein the at least one catalyst precursor is a base metal selected from the group consisting of zinc, nickel, copper, manganese, iron, chromium, vanadium, and molybdenum. ### Claim 6 (depends on 1) A method as in claim 1, wherein the at least one catalyst precursor is a base metal catalyst selected from the group consisting of oxides, hydrated oxides, and carbonates. ### Claim 7 (depends on 1) A method as in claim 1, wherein the at least one catalyst precursor is present on the finished activated carbon monolith in an amount from about 0.01% to about 5.0% by weight of the activated carbon monolith catalyst. ### Claim 8 (depends on 1) A method as in claim 1, wherein the finished activated carbon monolith has an axial crushing strength from about 500 psi to about 1600 psi. ### Claim 9 (depends on 1) A method as in claim 1, wherein the activated carbon particles are present in the finished activated carbon monolith in an amount from about 20% to about 95% by weight of the monolith and the supporting matrix is present in the finished activated carbon monolith in an amount from about 80% to about 5% by weight of the finished activated carbon monolith. ### Claim 10 (depends on 1) A method as in claim 1, wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 600 m2/g to about 2000 m2/g. ### Claim 11 (depends on 1) A method as in claim 1, wherein the activated carbon particles are characterized by having a particle size such that more than 40% by weight of the activated carbon passes through a 200 mesh screen. ### Claim 12 (depends on 1) A method as in claim 1, wherein the finished activated carbon monolith is made according to a process comprising extruding an extrudable mixture comprising the activated carbon particles, a ceramic forming material, a flux material, and water; drying the extruded monolith; and firing the dried monolith at a temperature and for a time period sufficient to fuse the ceramic forming material together and form the ceramic matrix. ### Claim 13 (depends on 12) A method as in claim 12, wherein the flux material is a feldspathic mineral. ### Claim 14 (depends on 13) A method as in claim 13, wherein the feldspathic mineral is nepheline syenite. ### Claim 15 (depends on 12) A method as in claim 12, wherein the flux material further comprises sodium silicate. ### Claim 16 (depends on 12) A method as in claim 12, wherein the ceramic forming material is selected from the group consisting of ball clay, plastic kaolins, smectite clay minerals, bentonite, and combinations thereof. ### Claim 17 (depends on 12) A method as in claim 12, wherein the ceramic forming material further comprises a shrinkage reducing filler material. ### Claim 18 (depends on 1) A method as in claim 1, wherein the finished activated carbon monolith further has a plurality of passages therethrough for receiving a flow of fluid and an open frontal area greater than 50% and up to 85%. ### Claim 19 (depends on 1) A method as in claim 1, wherein the finished activated carbon monolith is honeycomb shaped. ### Claim 20 (depends on 1) A method as in claim 1, wherein the activated carbon particles have pores and the at least one catalyst precursor is at least partially disposed in pores of the activated carbon. ### Claim 21 (depends on 1) A method as in claim 1, wherein the contacting of the at least one reactant with the activated carbon monolith catalyst occurs under hydrogen pressure. ### Claim 22 (depends on 1) A method as in claim 1, wherein the contacting of the at least one reactant with the activated carbon monolith catalyst occurs at ambient pressure.