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US 5,733,842 AGranted
Method of making porous catalyst carrier without the addition of pore forming agents
AssigneeNorton Checmical Process Products Corporation
InventorsWilliam H. Gerdes, Donald J. Remus, Thomas Szymanski
Life of this patent
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Abstract
An improved catalyst carrier is formed by a process that comprises the use of ceramic particle components with particle sizes chosen to ensure that a desired degree of porosity is obtained without recourse to the use of organic burnout materials.
Claims12
A process for the production of a catalyst carrier which comprises:
- a) providing a mixture consisting essentially of:
- i) ceramic components comprising at least 80% by weight of alpha alumina, from 0.01 to about 10% by weight (measured as the oxide, MO,) of an alkaline earth metal oxide, from 0.01 to about 10% by weight (measured as silica) of a silicon oxide, and from zero to about 15% by weight (measured as the dioxide) of zirconium in the form of an oxide;
- ii) a liquid carrier medium in an amount to render the mixture shapable;
- and
- iii) a total amount from zero to 15% by weight based on the ceramic components of ceramic bond, lubricant and/or forming aids;
- b) shaping the mixture to form a carrier precursor;
- c) drying the carrier precursor to remove the liquid carrier medium;
- and then
- d) firing the precursor to form a carrier with an essentially uniform porosity of from about 15 to about 60%,
- wherein the particle sizes of the ceramic components are chosen such that the packing density of the dried precursor is not greater than that of the fired carrier.
7 more elements
A process for the production of a catalyst carrier which comprises:
- a) providing a mixture consisting essentially of:
- i) ceramic components comprising at least 90% by weight of alpha alumina, from 0.01 to about 10.0% by weight (measured as the oxide, MO,) of an alkaline earth metal oxide, from 0.01 to about 10.0% by weight (measured as silica) of a silicon oxide, and from zero to about 10% by weight (measured as the dioxide) of zirconium in the form of an oxide;
- ii) a liquid carrier medium in an amount to render the mixture shapable;
- and
- iii) a total of from zero to 10% by weight based on the ceramic components of ceramic bond, lubricant and/or forming aids;
- b) shaping the mixture to form a carrier precursor;
- c) drying the carrier precursor to remove the liquid carrier medium;
- and then
- d) firing the precursor to form a carrier with an essentially uniform porosity of from about 15 to about 60%,
- wherein the loss in weight upon firing the dried precursor is less than 15%.
7 more elements
Dependencies are inferred from the claim text.