Method for producing porous bodies with enhanced properties

• US 10,124,318 B2
• Filed: 06/02/2016
• Issued: 11/13/2018
• Est. Priority Date: 06/02/2015
• Status: Active Grant

• Current Assignee: Scientific Design Company, Inc. (Clariant AG)
• Original Assignee: Scientific Design Company, Inc. (Clariant AG)
• Inventors: Suchanek, Wojciech L., Julian, Matthew
• Primary Examiner(s): Group, Karl E
• Application Number:
  US15/171,273
• Publication Number:
  US 20160354759A1
• Time in Patent Office: 894 Days
• CPC Class Codes: B01J 19/0013 Controlling the temperature of the process
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 2219/00051 Controlling the temperature
• CPC Class Codes: B01J 23/04 Alkali metals
• CPC Class Codes: B01J 23/36 Rhenium
• CPC Class Codes: B01J 23/50 Silver
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 35/612 less than 10 m2/g
• CPC Class Codes: B01J 35/633 less than 0.5 ml/g
• CPC Class Codes: B01J 35/635 0.5-1.0 ml/g
• CPC Class Codes: B01J 35/638 more than 1.0 ml/g
• CPC Class Codes: B01J 35/66 Pore distribution
• CPC Class Codes: B01J 37/0018 Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
• CPC Class Codes: B01J 37/086 Decomposition of an organometallic compound, a metal complex or a metal salt of a carboxylic acid
• CPC Class Codes: C04B 2111/0081 as catalysts or catalyst carriers
• CPC Class Codes: C04B 35/10 based on aluminium oxide
• CPC Class Codes: C04B 38/00 Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof treating slag with gases or gas generating material C04B5/06 ; expanded graphite C04B35/536
• CPC Class Codes: C04B 38/0096 Pores with coated inner walls
• CPC Class Codes: C04B 38/08 by adding porous substances
• CPC Class Codes: C04B 41/009 characterised by the material treated
• CPC Class Codes: C04B 41/4535 : applied as a solution, emulsion, dispersion or suspension
• CPC Class Codes: C04B 41/455 : the coating or impregnating process including a chemical conversion or reaction
• CPC Class Codes: C04B 41/5116 : Ag or Au
• CPC Class Codes: C04B 41/88 : Metals
• CPC Class Codes: C07D 301/10 : with catalysts containing silver or gold
• CPC Class Codes: C07D 301/22 : by oxidation of saturated compounds with air or molecular oxygen of mixtures of unsaturated and saturated compounds C07D301/04
• CPC Class Codes: Y02P 20/52 : using catalysts, e.g. selective catalysts

Abstract

A precursor mixture for producing a porous body, wherein the precursor mixture comprises: (i) milled alpha alumina powder having a particle size of 0.1 to 6 microns, (ii) boehmite powder that functions as a binder of the alpha alumina powders, and (iii) burnout materials having a particle sizes of 1-10 microns. In some embodiments, an unmilled alpha alumina powder having a particle size of 10 to 100 microns is also included in said precursor mixture. Also described herein is a method for producing a porous body in which the above-described precursor mixture is formed to a given shape, and subjected to a heat treatment step in which the formed shape is sintered to produce the porous body.

Claims

1. A precursor mixture for producing a porous body, wherein the precursor mixture comprises:

(i) at least one milled alpha alumina powder having a particle size of 0.1 to 6 microns, (ii) boehmite powder that functions as a binder of the alpha alumina powders, and (iii) at least one burnout material having a particle size of 1-10 microns.

2. The precursor mixture of claim 1, further comprising unmilled alpha alumina powder having a particle size of 10 to 100 microns.

3. The precursor mixture of claim 2, wherein the weight ratio of milled to unmilled alpha alumina powder is in a range of 0.25:

1 to about 5;

1.

4. The precursor mixture of claim 1, wherein unmilled alpha alumina powder is excluded from the precursor mixture.

5. The precursor mixture of claim 1, further comprising an additive selected from solvents and lubricants.

6. The precursor mixture of claim 1, wherein said burnout material is selected from at least one of a polyolefin powder and graphite powder.

7. The precursor mixture of claim 1, wherein said burnout material is selected from both a polyolefin powder and graphite powder.

8. The precursor mixture of claim 7, wherein the weight ratio of polyolefin powder to graphite powder is in a range of 0.25:

1 to about 5;

1.

9. The precursor mixture of claim 1, wherein the boehmite is present in an amount of at least 10% by weight of total alumina content.

10. The precursor mixture of claim 1, wherein the boehmite is present in an amount of at least 25% by weight of total alumina content.

11. The precursor mixture of claim 1, wherein the boehmite is nano-sized powder with dispersed particle size <

100 nm.

12. The precursor mixture of claim 1, wherein said milled alpha alumina powder has a particle/crystallite size of 0.25-4 microns.

13. The precursor mixture of claim 1, wherein a silicon-containing substance is substantially excluded from the precursor mixture.

14. The precursor mixture of claim 1, wherein a sodium-containing substance is substantially excluded from the precursor mixture.