MULTIMETALLIC CATALYSTS

• US 20170333878A1
• Filed: 05/17/2016
• Published: 11/23/2017
• Est. Priority Date: 05/17/2016
• Status: Active Grant

• Current Assignee: Northwestern University, UChicago Argonne LLC (University of Chicago)
• Original Assignee: UChicago Argonne LLC (University of Chicago)
• Inventors: Stair, Peter C., Bunquin, Jeffrey Camacho, Marshall, Christopher L., Hock, Adam S.
• Granted Patent: US 10,640,435 B2
• Time in Patent Office: Days
• CPC Class Codes: B01J 23/60 with zinc, cadmium or mercury
• CPC Class Codes: B01J 23/8926 Copper and noble metals
• CPC Class Codes: B01J 37/0244 Coatings comprising several layers
• CPC Class Codes: C07C 11/06 Propene
• CPC Class Codes: C07C 2521/08 Silica
• CPC Class Codes: C07C 2523/06 of zinc, cadmium or mercury
• CPC Class Codes: C07C 2523/34 Manganese
• CPC Class Codes: C07C 2523/42 Platinum
• CPC Class Codes: C07C 2523/60 with zinc, cadmium or mercury
• CPC Class Codes: C07C 2523/656 Manganese, technetium or rhenium
• CPC Class Codes: C07C 5/3337 of the platinum group
• CPC Class Codes: Y02P 20/52 using catalysts, e.g. selective catalysts

Abstract

A multimetallic catalyst having a substrate, intermediate layer and catalyst layer. The catalyst exhibits selectivity greater than 90% and a conversion rate of greater than 30%.

Claims

1. A catalyst comprising:

a substrate;

an intermediate layer comprising MO_x where M is a transition metal or main group elemental oxide, the intermediate layer deposited on the substrate;

a catalyst layer comprising a platinum group metal, the catalyst layer deposited on the metal oxide intermediate layer.

2. The catalyst of claim 1, wherein the substrate comprises silica.

3. The catalyst of claim 1, wherein M comprises a first row transition metal.

4. The catalyst of claim 1, wherein MO_x is selected from the transition metal oxides consisting of TiO₂, ZrO₂, CoO_x (x=1-1.5), ZnO, and MnOx (x=1 to 4).

5. The catalyst of claim 1, wherein the intermediate layer is a monolayer surface.

6. The catalyst of claim 1, wherein the catalyst layer consists essentially of a platinum material

7. The catalyst of claim 1, wherein the catalyst exhibits at least 95% selectivity for propene.

8. The catalyst of claim 1 further comprising an overcoat layer deposited on the catalyst.

9. The catalyst of claim 1, wherein the overcoat layer comprises multiple layers of alumina.

10. A catalyst for alkane dehydrogenation comprising:

a substrate consisting essentially of silica;

an intermediate layer consisting essentially of MO_x where M is a transition metal or main group elemental oxide, the intermediate layer deposited on the substrate;

a catalyst layer consisting essentially of a platinum group metal, the catalyst layer deposited on the metal oxide intermediate layer.

11. The catalyst of claim 10, wherein the catalyst exhibits at least 95% selectivity for propene.

12. The catalyst of claim 11, wherein the catalyst exhibits at 70% propane conversion.

13. The catalyst of claim 11, wherein the catalyst exhibits at 60% propane conversion after 50 hours.

14. The catalyst of claim 10, wherein the catalyst exhibits a turnover frequency of at least 100,000 per hour after 50 hours.

15. A method of forming a catalyst comprising:

depositing on a silica substrate by a first method selected from the group consisting of Atomic Layer Deposition (ALD), solution processes (Sol'"'"'n) and strong electrostatic adsorption (SEA), an intermediate layer comprising MO_x where M is a transition metal or main group elemental oxide; and

depositing on the intermediate layer by a method selected from the group consisting of Atomic Layer Deposition (ALD), solution processes (Sol'"'"'n) and strong electrostatic adsorption (SEA), a platinum group catalyst layer.

16. The method of claim 15, wherein the intermediate layer is deposited by atomic layer deposition.

17. The method of claim 15 wherein the catalyst layer is deposited by atomic layer deposition.

18. The method of claim 16, wherein the intermediate layer is a monolayer.

19. The method of claim 15, wherein the intermediate layer is ZnO.

20. The method of claim 15, further comprising depositing on the catalyst layer by a third method an overcoat layer.