Hollow Microsphere Catalyst Support and Methods of Making Same
AssigneeBASF SE
InventorsPascaline Harrison Tran, Michael P. Galligan, Ye Liu, Xiaolin David Yang, Qingyuan Hu, Doan Lieu
Life of this patent
Estimating the term…
Abstract
Hollow porous metal oxide microspheres are provided. The microspheres may be used as a support for a catalyst, particularly an exhaust treatment catalyst for an internal combustion engine. Also provided are methods of making the microspheres, methods of using the microspheres as catalyst supports, and methods of exhaust treatment using catalyst articles comprising the microspheres.
Claims20
A composition comprising hollow metal oxide microspheres, the microspheres comprising walls having a thickness of about 1-5 microns surrounding a hollow center, wherein the D90 diameter of the hollow metal oxide micro spheres is about 5-15 microns.
An emissions treatment system comprising a catalyst article in emissions flow communication with an engine exhaust stream, wherein the catalyst article comprises a catalytic layer formed on a substrate, the catalytic layer comprising:
- a) hollow metal oxide microspheres, the microspheres comprising walls having a thickness of about 1-5 microns surrounding a hollow center, wherein the D90 diameter of the hollow metal oxide microspheres is about 5-15 microns, and
- b) a catalyst supported by the hollow metal oxide microspheres.
A method of making hollow metal oxide microspheres comprising:
- a) dissolving a thermodegradable soft polymer in an aqueous medium to form micelles template of the polymer;
- b) slurrying nanoparticles or water soluble salts of one or more metal oxide precursors with the dissolved polymer template;
- c) spray drying the slurry;
- and
- d) calcining the spray-dried slurry to thermodegrade the polymer template,
- thereby forming hollow metal oxide microspheres.
Dependencies are inferred from the claim text.