Method of producing high-strength high surface area catalyst supports
AssigneeCorning Glass Works
InventorsIrwin M. Lachman, Lawrence A. Nordlie
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Abstract
A catalyst support having both substantial high strength and high surface area can be produced by heating a shaped mixture of a porous oxide having a surface area of at least 20 m.sup.2 /g and the precursor of an inorganic binder for the porous oxide. The binders are precursors of alumina, silica, or titania, and are capable of imparting substantial strength to the support at relatively low firing temperatures.
Claims32
A method of producing a monolithic catalyst support having substantial strength and high surface area comprising:
- (a) Mixing into a substantially homogeneous body
- (i) a porous oxide having a surface area of at least 20 m.sup.2 /g selected from the group consisting of zeolite, silica, alumina, spinel, titania, zirconia, and mixtures of these;
- (ii) a precursor of a permanent binder for the porous oxide selected from the group consisting of alumina precursors, silica precursors, titania precursors, zirconia precursors, and mixtures of these, said binder precursor having a crystallite size below 200 angstoms;
- and
- (iii) a temporary binder;
- and
- (b) heating the body to a temperature of from 500.degree.-1000.degree. C. to result in substantial strength and substantial surface area and to substantially completely burn off said temporary binder.
A monolithic catalyst support having a modulus of rupture of at least 500 psi, comprising 70-97 parts by weight of a high surface area porous oxide phase and 3-30 parts by weight of a permanent binder for the porous oxide phase dispersed throughout wherein
- (i) the porous oxide phase has a surface area of at least 20 m.sup.2 /g and consists of alumina, silica, zeolite, spinel, zirconia, or mixtures of these;
- and
- (ii) the binder results from heating in situ, at a temperature of 500.degree.-1,000.degree. C., a binder precursor consisting of alumina precursors, silica precursors, zirconia precursors, or mixtures of these, said binder precursor having a crystallite size below 200 anstroms.
A monolithic catalyst support having a surface area of at least 20 m.sup.2 /g and a modulus of rupture of at least 500 psi, comprising 70-97 parts by weight of a high surface area porous oxide phase and 3-30 parts by weight of a permanent binder for the porous oxide phase dispersed throughout wherein (i) the porous oxide phase consists of alumina, silica, zeolite, spinel, zirconia, or a mixture or these;
- and (ii) the binder is alumina, silica, zirconia, or a mixture of these, the binder having a crystallite size of no greater than about 2000 angstroms.
Dependencies are inferred from the claim text.