Catalyst, method of making, and reactions using the catalyst
AssigneeBattelle Memorial Institute
InventorsAnna Lee Y. Tonkovich, Yong Wang, Yufei Gao
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Abstract
The present invention includes a catalyst having a layered structure with, (1) a porous support, (2) a buffer layer, (3) an interfacial layer, and optionally (4) a catalyst layer. The invention also provides a process in which a reactant is converted to a product by passing through a reaction chamber containing the catalyst.
Claims42
A catalyst comprising a porous metal support, a buffer layer, an interfacial layer, and a catalytically active layer on the surface;
- wherein the porous metal support has an average pore size of from 1 μm to 1000 μm;
- wherein the porous metal support is selected from the group consisting of honeycomb, foam, felt, and wad;
- wherein the buffer layer is disposed between the porous support and the interfacial layer, and the interfacial layer is disposed between the catalytically active layer and the buffer layer;
- and wherein the interfacial layer comprises a material selected from the group consisting of nitrides, carbides, sulfides, halides and carbon.
A catalyst comprising a porous metal support, a buffer layer, and an interfacial layer;
- wherein the porous metal support has an average pore size of from 1 μm to 1000 μm;
- wherein the porous metal support is selected from the group consisting of, foam, felt, and wad;
- wherein the buffer layer is comprised of at least two compositionally different sublayers;
- and wherein the buffer layer is disposed between the porous support and the interfacial layer.
A catalyst comprising a porous metal support, a buffer layer, and an interfacial layer;
- wherein the porous metal support has an average pore size of from 1 μm to 1000 μm;
- wherein the porous metal support comprises a foam, felt, wad or combination thereof;
- wherein the buffer layer is disposed between the porous support and the interfacial layer;
- and wherein the catalyst possesses thermal cycling stability such that, if exposed to 3 thermal cycles in air, the catalyst exhibits less than 2% flaking.
A method of making a catalyst comprising the steps of:
- selecting a porous metal support selected from the group consisting of honeycomb, foam, felt, and wad;
- vapor depositing a buffer layer on said porous support;
- depositing an interfacial layer on said buffer layer;
- and
- wherein a catalytically active material is simultaneously deposited with the interfacial layer.
Dependencies are inferred from the claim text.