Back to results
US 4,637,990 AGranted
Hollow porous microspheres as substrates and containers for catalysts and method of making same
OwnerLeonard B. Torobininventor
Life of this patent
Estimating the term…
Loading patent…
Loading patent…
OwnerLeonard B. Torobininventor
Estimating the term…
Hollow porous microspheres are used as substrates and containers for catalyst to make microsphere catalysts. The hollow porous microspheres are made from dispersed particle compositions. The microspheres have a single central cavity, have substantially uniform diameters and substantially uniform wall thickness and the walls of the microspheres have substantially uniform void content, i.e., interconnecting voids, and have substantially uniform distribution of interconnecting voids. The interconnecting voids in the walls of the microspheres are continuous and extend from the outer wall surface of the microsphere to the inner wall surface of the microsphere. The microsphere catalysts are prepared by coating or impregnating the hollow porous microspheres with a catalyst or by applying a catalyst support to the microspheres and then coating or impregnating the microspheres and catalyst support with a catalyst. The microsphere catalyst can also be prepared by filling the hollow porous microspheres with a catalyst or catalyst and catalyst support. The microsphere catalyst can be treated to immobilize the catalyst and can be treated to provide the microsphere with a selective membrane. The microsphere catalyst can be used for a wide variety of catalyst reactions.
Hollow porous microsphere catalysts of substantially uniform diameter of 200 to 10,000 microns and of substantially uniform wall thickness of 1.0 to 1000 microns, the walls of said microspheres comprise sintered together particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said walls include entrance means through which catalyst can be introduced into the interconnecting voids and into the single central cavity of the microspheres, said microspheres have catalyst on the particles forming the walls or have catalyst contained within the single central cavity or have catalyst on the particles forming the walls and have catalyst contained within the single central cavity, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.
A method of making hollow microsphere catalysts which comprises applying a catalyst to hollow porous microspheres of substantially uniform diameter of 200 to 10,000 microns and of substantially uniform wall thickness of 1.0 to 1000 microns, the walls of said microspheres comprise sintered together inorganic particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surfaces to the inner wall surfaces, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said walls include entrance means through which catalysts can be introduced into the interconnecting voids and into the single central cavity of the microspheres, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles, and said catalyst is applied to the particles forming the walls of the microspheres, is placed within the single central cavity of the microspheres or is applied to the particles forming the walls and is placed within the single central cavity of the microspheres.
An auto emission control catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns and macro pores 5.0 to 400 microns in size which extend through the walls, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surfaces to the inner wall surfaces, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have a catalyst selected from the group consisting of platinum, palladium and rhodium and mixtures thereof coated or impregnated on the inner and outer wall surfaces of the microspheres and on the particles forming the interconnecting voids in the wall of the microspheres, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.
A hydrodinitrification and hydrodesulfurization catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 microns, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surface to the inner wall surface, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity and have within the interconnecting voids a catalyst selected from the group consisting of cobalt-molybdenum, nickel-molybdenum and nickel-tungsten and the oxides and sulfides thereof and mixtures thereof, and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.
A hydrocracking catalyst comprising hollow porous microspheres of substantially uniform diameter of 500 to 6000 microns and of substantially uniform wall thickness of 5.0 to 400 micron wall thickness, the walls of said microspheres comprise sintered together alumina particles which define interconnecting voids within the walls and a single central cavity in the interior of the microspheres and inner and outer microsphere wall surfaces, said interconnecting voids are continuous and extend from the outer wall surfaces to the inner wall surfaces, said walls have substantially uniform void content and said interconnecting voids are substantially uniformly distributed in the walls of the hollow microspheres, said microspheres have contained within the single central cavity a nickel catalyst and the walls of said microspheres are free of latent solid or liquid blowing gas materials and are substantially free of relatively thinned wall portions or sections and bubbles.
Dependencies are inferred from the claim text.