US 10,532,346 B2 · Method for producing a metal-supported catalyst and catalyst substrate

Abstract

The present invention relates to methods for producing metal-supported thin layer skeletal catalyst structures, to methods for producing catalyst support structures without separately applying an intermediate washcoat layer, and to novel catalyst compositions produced by these methods. Catalyst precursors may be interdiffused with the underlying metal support then activated to create catalytically active skeletal alloy surfaces. The resulting metal-anchored skeletal layers provide increased conversion per geometric area compared to conversions from other types of supported alloy catalysts of similar bulk compositions, and provide resistance to activity loss when used under severe on-stream conditions. Particular compositions of the metal-supported skeletal catalyst alloy structures can be used for conventional steam methane reforming to produce syngas from natural gas and steam, for hydrodeoxygenation of pyrolysis bio-oils, and for other metal-catalyzed reactions inter alia.

Claims17

Dependent claims

A method of producing a structured catalyst comprising:

(a) preparing a slurry comprising one or more metal powders, including aluminum;
(b) coating a metal substrate, or a mat of metal fiber or a woven metal fiber assembly, with said slurry;
(c) subjecting the coated metal substrate, coated metal fiber mat or coated woven metal fiber assembly to heat under an inert or reducing atmosphere wherein at least one of the one or more metal powders melts and interdiffuses into the surface of the metal substrate, or metal fiber mat or woven metal fiber assembly;
(d) leaching the coated metal substrate or coated metal fiber mat or coated woven metal fiber assembly obtained in step (c) in a caustic solution;
(e) bathing the coated metal substrate, coated metal fiber mat or coated woven metal fiber assembly obtained in step (d) in a chelating acid solution;
(f) passivating the coated metal substrate, coated metal fiber mat or coated woven metal fiber assembly obtained in step (e);
and
(g) optionally abrading the surface of the coated metal substrate obtained in step (f).

5 more elements

Dependencies are inferred from the claim text.

Method for producing a metal-supported catalyst and catalyst substrate

Life of this patent

Method for producing a metal-supported catalyst and catalyst substrate

Life of this patent

Abstract

Claims17