Reticulated ceramic foam catalysts for synthesis gas production
AssigneeConocoPhillips Company
InventorsKostantinos Kourtakis, Anne M. Gaffney, Lin Wang
Life of this patent
Estimating the term…
Abstract
Reticulated ceramic monolithic catalysts and non-poisoning catalyst supports comprising one or more metal oxides of chromium, cobalt, nickel, an alkaline earth, a rare earth, or another sinterable metal oxide that are active in any of various chemical oxidation reactions are disclosed. Methods of making the new reticulated ceramic structures comprising impregnating an organic foam or other pore-templating material are also disclosed. Processes for the catalytic conversion of light hydrocarbons to products comprising carbon monoxide and hydrogen employing reticulated ceramic catalysts are described.
Claims44
A method of converting a C1-C5 hydrocarbon to a product gas mixture containing CO and H2, the process comprising
- mixing a C1-C5 hydrocarbon-containing feedstock and an oxygen-containing feedstock to provide a reactant gas mixture;
- contacting said reactant gas mixture with a catalytically effective amount of a catalyst comprising at least one macroporous reticulated ceramic monolith containing chromium oxide;
- and
- maintaining catalytic partial oxidation reaction promoting conditions, said monolith prepared by a process comprising calcining in a non-oxidizing atmosphere.
A method of converting a C1-C5 hydrocarbon to a product gas mixture containing CO and H2, the process comprising:
- contacting a reactant gas mixture comprising a C1-C5 hydrocarbon and an oxygen-containing gas with at least one supported catalyst structure comprising an active catalytic component disposed on a non-poisoning reticulated ceramic support, said active catalytic component comprising at least one metal or metal oxide selected from the group consisting of chromium, cobalt, nickel, manganese, molybdenum, tungsten, tin, rhenium, bismuth, indium, phosphorus, alkaline earth metals, rare earth metals, and oxides thereof, and said support structure comprising magnesium oxide or chromium oxide, wherein said chromium oxide-containing support structure is prepared by a process comprising calcining said support structure under non-oxidizing conditions;
- during said contacting, maintaining said catalyst structure and said reactant gas mixture at a temperature of about 600-1,100° C.;
- during said contacting, maintaining said catalyst structure and said reactant gas mixture at a pressure of about 100-12,500 kPa;
- and
- passing said reactant gas mixture over said composition at a continuous flow rate of about 20,000 to about 100,000,000 NL/kg/h.
Dependencies are inferred from the claim text.