Monolithic zeolite coated structures and a method of manufacture
AssigneeCorning Incorporated
InventorsPaulo Marques, Christophe Remy, Charles M. Sorensen, Jr.
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Abstract
Structured zeolite coated structures comprising thick porous inorganic zeolite coatings disposed on monolithic support structures, which can be honeycomb shaped, are disclosed. The zeolite coatings have open interconnected pores of controlled pore size and are characterized by improved durability, physical integrity, and adherence sufficient to enable use as supports for catalysts in liquid phase applications under harsh reaction conditions. Methods for making zeolite coated structures are also disclosed.
Claims9
A zeolite coated monolithic article comprising:
- an uncoated monolithic support structure including walls having open porosity;
- and
- a porous inorganic zeolite coating disposed directly upon the uncoated monolithic support structure,
- wherein the zeolite coating has a permanent alumina binder component, an open, interconnected porosity characterized by a mean pore size in the range of about 0.2 to 104 nanometers, a porosity of 30% to 65%, and a thickness in excess of 100 μm.
A method of making a zeolite coated monolithic article comprising the steps of:
- (a) providing a monolithic support structure;
- (b) providing a wash-coating slurry comprising a pore-forming additive and a zeolite powder dispersed in a sol-gel binder slurry phase which contains an alumina inorganic binder precursor;
- (c) depositing the slurry directly upon on surfaces of the monolithic support structure to form a first slurry coating layer;
- (d) heating the first slurry coating layer to a temperature at least sufficient to remove the liquid phase therefrom to provide a first deposited layer;
- (e) repeating steps (a)-(d) above to form additional deposited layers to form a porous multi-layered zeolite coating incorporating an alumina binder.
A zeolite coated monolithic ceramic article comprising:
- a monolithic ceramic support structure including walls having open porosity;
- and
- a porous inorganic zeolite coating disposed directly upon the ceramic support structure,
- wherein the zeolite coating has an open, interconnected porosity characterized by a mean pore size in the range of about 0.2 to 104 nanometers and a porosity of 30% to 65%, and is formed by the method comprising the steps of:
- (a) providing a monolithic ceramic support structure;
- (b) providing a wash-coating slurry comprising a zeolite powder dispersed in slurry phase which contains an inorganic binder sol precursor;
- (c) depositing the slurry on surfaces of the monolithic support structure to form a first slurry coating layer;
- (d) heating the first slurry coating layer to a temperature at least sufficient to remove the liquid phase therefrom to provide a first deposited layer;
- (e) repeating steps (a)-(d) above to form additional deposited layers to form a multi-layered coating.
Dependencies are inferred from the claim text.