Process for the preparation of a catalyst or catalyst precursor

• US 6,562,749 B1
• Filed: 11/26/1996
• Issued: 05/13/2003
• Est. Priority Date: 11/27/1995
• Status: Expired due to Fees

• Current Assignee: Shell Oil Company (Shell Plc)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: Searcy-Roberts, Katherine, Lednor, Peter William
• Primary Examiner(s): Bell, Mark L.
• Assistant Examiner(s): Hailey, Patricia L
• Application Number:
  US08/755,844
• Time in Patent Office: 2,359 Days
• Field of Search: 502/66, 502/74, 502/201, 502/217, 502/218, 502/221, 502/223, 502/224, 502/229, 502/230, 502/243, 502/246, 502/247, 502/258, 502/259, 502/260, 502/261, 502/262, 502/300, 502/325, 502/326, 502/327, 502/344, 502/347, 502/349, 502/350, 502/353, 502/354
• US Class Current: 502/66
• 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 37/0201 Impregnation
• CPC Class Codes: Y02P 20/52 using catalysts, e.g. selective catalysts

Abstract

A process for the preparation of a ceramic foam supporting one or more catalytically active components or precursors thereof, which component is active in a form other than an inorganic oxide, the process comprising impregnation of the foam with an impregnating phase comprising the catalytically active component or a precursor thereof and drying, wherein the impregnating phase has a viscosity greater than 1 cps, wherein drying is performed without substantial prior draining of impregnating phase from the ceramic foam, and wherein the catalytically active component or precursor thereof is present throughout the process in one or more forms other than the inorganic oxide thereof. The ceramic foams prepared by this process find use in catalytic conversion processes, in particular the catalytic partial oxidation of a hydrocarbon feed.

Claims

1. A process for the preparation of a ceramic foam support supporting at least one catalytically active component or precursor thereof, which component is active in a form other than an inorganic oxide, the process comprising impregnation of the ceramic foam containing pores with an impregnating phase comprising the catalytically active component or a precursor thereof and drying, wherein the impregnating phase has a viscosity, of from 5 to 80 cps, wherein drying is performed without substantial prior draining of impregnating phase from the ceramic foam, and wherein the catalytically active component or precursor thereof is present throughout the preparation process in one or more forms other than the inorganic oxide thereof.

2. The process of claim 1 wherein the drainage of the impregnating phase from the foam prior to drying is 0 to 40% of that introduced.

3. The process of claim 1 wherein the pores of the foam are filled by at least 60% with impregnating phase.

4. The process of claim 1 wherein catalytically active component is selected from the group consisting of cobalt, iron, nickel, ruthenium, rhodium, palladium, osmium, iridium, platinum, vanadium, titanium, silver, and a mixture thereof.

5. The process of claim 4 wherein precursor for the catalytically active component is employed and is selected from chlorides, bromides, iodides, nitrates, sulphates and phosphates.

6. The process of claim 1 wherein the ceramic foam has a tortuosity in the range of from 1.1 to 5.0.