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US 2026/0200817 A1Published application
Alkane Dehydrogenation Catalyst and Methods of Converting Alkanes to Alkenes
AssigneesUchicago Argonne, LLC, Forge Nano, Inc.
InventorsChristopher L. Marshall, Zheng Lu, Jeffrey W. Elam, Christopher Nicholas, Paul T. Barger, Martha Leigh Abrams, Arrelaine Dameron, Ryon W. Tracy
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Abstract
Provided herein is an alkane dehydrogenation catalyst, a method of manufacturing an alkane dehydrogenation catalyst, and a method of converting alkanes to alkenes.
Claims48
A method of manufacturing an alkane dehydrogenation catalyst comprising a catalyst support, catalytic nanoparticles, and an overcoat, the method comprising:
- calcining the catalyst support at a temperature in a range of about 500° C. to about 1200° C., wherein after calcining, the calcined catalyst support has a total surface area of 50 m2/g to 350 m2/g;
- and
- immersing the calcined catalyst support in a nanoparticle precursor solution comprising a nanoparticle precursor, under conditions sufficient to impregnate the calcined catalyst support with the nanoparticle precursor and form an impregnated catalyst precursor;
- calcining the impregnated catalyst precursor under conditions sufficient to convert the nanoparticle precursor impregnated in the impregnated catalyst precursor to catalytic nanoparticles to form a calcined impregnated catalyst precursor, wherein the calcining is done at a temperature in a range of about 150° C. to about 600° C.;
- depositing by atomic layer deposition (ALD) the overcoat onto the calcined catalyst precursor by contacting the calcined catalyst precursor with an ALD precursor and water at a temperature in a range of about 150° C. to about 300° C., and repeating the depositing step one or more times, thereby forming a catalyst intermediate;
- annealing the catalyst intermediate in air at a temperature of less than about 600° C. for about 30 minutes to about 2 hours, thereby forming the alkane dehydrogenation catalyst.
3 more elements
An alkane dehydrogenation catalyst, comprising:
- a catalyst support infiltrated with a plurality of catalytic nanoparticles, and;
- an atomic layer deposition overcoat;
- wherein the plurality of catalytic nanoparticles have an average size of about 0.6 nm to about 1.2 nm, the atomic layer deposition overcoat has a thickness of about 1.2 Å to about 1.2 nm, the catalyst support has a total surface area of 90 m2/g to 300 m2/g, a pore volume of 0.8 cm3/g to 0.4 cm3/g, and an average pore size of 6 nm to 17 nm.
An ALD coated alkane dehydrogenation catalyst, comprising:
- a catalyst support infiltrated with a plurality of catalytic nanoparticles to form an alkane dehydrogenation catalyst, wherein the catalytic nanoparticles comprise at least one metal selected from group 8 metals, and the catalyst support is an extrudate, and
- an atomic layer deposition overcoat arranged in contact with a portion of a surface of the catalytic nanoparticles to form the ALD coated alkane dehydrogenation catalyst,
- wherein the alkane dehydrogenation catalysis has a hydrogen chemisorption capacity that is substantially the same as a hydrogen chemisorption capacity of the ALD coated alkane dehydrogenation catalyst.
An ALD coated alkane dehydrogenation catalyst, comprising:
- a catalyst support infiltrated with a plurality of catalytic nanoparticles to form an alkane dehydrogenation catalyst, wherein the catalytic nanoparticles comprise at least one metal selected from group 8 metals, and the catalyst support is an extrudate;
- and
- an atomic layer deposition overcoat,
- wherein the atomic layer deposition overcoat is deposited onto the alkane dehydrogenation catalyst by 2-5 cycles of atomic layer deposition when the alkane dehydrogenation catalyst has a surface area of about 80 m2/g to about 100 m2/g or 5-8 cycles of atomic layer deposition when the alkane dehydrogenation catalyst has a surface area of about 80 m2/g to about 100 m2/g.
1 more element
An ALD coated alkane dehydrogenation catalyst, comprising:
- a catalyst support infiltrated with a plurality of catalytic nanoparticles to form an alkane dehydrogenation catalyst, wherein the catalytic nanoparticles comprise at least one metal selected from group 8 metals, and the catalyst support is an alumina extrudate;
- and
- an atomic layer deposition overcoat;
- wherein the alumina extrudate is in a γ phase, a θ phase, a α phase, or a combination thereof.
1 more element
Dependencies are inferred from the claim text.