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METAL CATALYST COMPOSITION

  • US 20140094635A1
  • Filed: 05/24/2012
  • Published: 04/03/2014
  • Est. Priority Date: 06/03/2011
  • Status: Active Grant
First Claim
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1. A method of forming a metal catalyst composition, comprising:

  • performing a plurality of atomic layer deposition cycles to form metal oxide over-coat on a supported metal catalyst, where one or more of the atomic layer deposition cycles include sequential steps;

    (a) contacting a supported metal catalyst surface with a ligand-containing metal oxide precursor for a predetermined contact time to form an intermediate layer having a plurality of metal moieties that chemically bond to the supported metal catalyst surface;

    (b) reacting the metal moieties with water for a predetermined reaction time to convert at least a portion of the ligands to hydroxyl groups thereby forming a layer of the metal oxide, metal hydroxide, or metal oxyhydroxide over-coat on the supported metal catalyst surface or a previously formed layer of the metal oxide, metal hydroxide, or metal oxyhydroxide over-coat;

    (c) prior to replicating sequential steps (a) and (b) to form an additional layer of the metal oxide over-coat, contacting the layer of the metal oxide, hydroxide, oxyhydroxide over-coat formed in step b) with an inert gas for a predetermined final stripping time to remove unreacted water; and

    (d) activating the metal oxide in the presence of a non-reducing gas at a temperature within a range from 500°

    C. to 800°

    C. for 60 minutes to 10 hours, metal hydroxide, metal oxyhydroxide over-coat, after forming a final layer of the said over-coat, to form a layer of metal oxide having a thickness of from 1 nanometer to 100 nanometers with a plurality of pores therein, where at least 80 percent of the plurality of pores have a diameter within a range of 0.3 nanometers to 5 nanometers, and where the metal catalyst composition reduces an amount of coke formed during a dehydrogenation or an oxidative dehydrogenation reaction, as compared to same supported metal catalysts without the metal oxide over-coat.

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