Catalyst and process for its manufacture
OwnerBruce MacDonald Lacey, Steven Lynn McMahon +1inventors
InventorsBruce MacDonald Lacey, Steven Lynn McMahon, Ding Jun Wang
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Abstract
The inventive catalyst composition is a sponge metal catalyst comprising at least one skeletal porous sponge metal selected from the group consisting of nickel, cobalt, iron and copper, together with a first promoter metal selected from the group consisting of palladium, platinum, ruthenium, rhodium, osmium and iridium and a second promoter metal selected from the group consisting of iron, nickel, cobalt, zinc, vanadium, cerium, copper, tungsten, molybdenum, titanium, niobium, manganese, silver, cadmium, praseodymium and neodymium. Processes for the manufacture of the catalyst include impregnation or precipitation of the promoter metals onto the sponge metal catalyst.
Claims19
A catalyst composition comprising:
- (i) at least one skeletal porous sponge metal selected from the group consisting of nickel, cobalt, iron and copper;
- (ii) a first promoter metal selected from the group consisting of palladium, platinum, ruthenium, rhodium, osmium and iridium;
- and
- (iii) a second promoter metal selected from the group consisting of iron, nickel, cobalt, zinc, vanadium, cerium, copper, tungsten, molybdenum, titanium, niobium, manganese, silver, cadmium, praseodymium and neodymium.
A method for manufacuring a catalyst composition comprising the steps of:
- a) forming a sponge metal catalyst in which tean active skeletal metal is selected from at least one of nickel, cobalt, iron and copper and from 0-20% by weight of a metal selected from the group consisting of titanium, chromium, zirconium, vanadium, molybdenum, manganese and zinc;
- b) depositing upon La surface of said sponge metal catalyst at least one compound of a metal selected from the group consisting of palladium, platinum, ruthenium, rhodium, osmium and iridium;
- and
- c) depositing upon the surface of said sponge metal catalyst at least one compound of a metal selected from the group consisting of iron, nickel, cobalt, zinc, vanadium, cerium, copper, tungsten, molybdenum, titanium, niobium, manganese, silver, cadmium, praseodymium and neodymium.
A method for manufacturing a catalyst composition comprising the steps of:
- a) forming an alloy comprising from 70-40% wt of a leachable metal, from 30-60% wt of at least one active skeletal metal selected from the group consisting of at least one of nickel, cobalt, iron and copper, and at least one of
- (i) a first promoter metal selected from the group consisting of palladium, platinum, ruthenium, rhodium, osmium and iridium and
- (ii) a second promoter metal selected from the group consisting of iron, nickel, cobalt, zinc, vanadium, cerium, copper, tungsten, molybdenum, titanium, niobium, manganese, silver, cadmium, praseodymium and neodymium;
- b) grinding said alloy into particles having an average size of from 1 to 500μ;
- c) contacting said particles with a- solution of an alkali metal hydroxide for sufficient time and under conditions suitable to effect leaching of at least 80% of said leachable metal from the alloy to form a sponge metal catalyst;
- and optionally
- d) depositing on a surface of said sponge metal catalyst a compound of at least one of
- (i) a first promoter metal selected from the group consisting of palladium, platinum, ruthenium, rhodium, osmium and iridium and
- (ii) a second promoter metal selected from the group consisting of iron, nickel, cobalt, zinc, vanadium, cerium, copper, tungsten, molybdenum, titanium, niobium, manganese, silver, cadmium, praseodymium and neodymium.
Dependencies are inferred from the claim text.