Preparation of monolithic catalyst supports having an integrated high surface area phase
AssigneeCorning Glass Works
InventorsThomas P. DeAngelis, Irwin M. Lachman
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Abstract
A method of preparing a monolithic catalyst support having an integrated high surface area phase is provided. A plasticized batch of ceramic matrix material intimately mixed with high surface area powder is formed into the desired shape for the monolith and then heated to sinter the ceramic. The resulting monolith has a strong substrate of the ceramic matrix material and a high surface area phase provided by the high surface area powder extruded with the batch.
Claims25
A method of preparing a monolithic catalyst support which comprises:
- (a) providing a substantially homogeneous body comprising an admixture of
- (i) a first phase sinterable ceramic matrix material, in particulate form finer than 200 mesh, selected from the group consisting of cordierite, mullite, alpha-alumina, lithium aluminosilicate, and mixtures of these, and
- (ii) a second phase high surface area catalyst-support material having a crystalline size no larger than 0.2 microns and a surface area of at least 40 m.sup.2 /g, said catalyst-support material consisting of transition metal sulfide;
- a mixture of transition metal sulfides;
- porous oxide selected from the group consisting of alumina, zirconia, spinel, silica, zeolite, titania, and mixtures of these;
- or a mixture of said sulfide and said oxide materials;
- (b) forming the resultant body into a desired shape;
- and
- (c) heating the shaped body at a temperature sufficient to sinter the first phase matrix material.
A monlithic catalyst support comprising 50-90 parts by weight of a sintered ceramic matrix material and 10-50 parts per weight of a high surface area catalyst-support material dispersed throughout the matrix wherein
- (a) the ceramic matrix material consists of cordierite, mullite, alpha-alumina, lithium aluminosilicate, or mixtures of these;
- and
- (b) the dispersed catalyst-support material has a surface area of at least 40 m.sup.2 / g and a crystallite size no larger than about 0.5 microns, and the catalyst-support material consists of transition metal sulfide;
- a mixture of transition metal sulfides;
- porous oxide selected from the group consisting of alumina, zirconia, spinel, silica, zeolite, titania, and mixtures of these;
- or a mixture of said sulfide and said oxide materials.
Dependencies are inferred from the claim text.