Porous body precursors, shaped porous bodies, processes for making them, and end-use products based upon the same

• US 8,685,883 B2
• Filed: 04/29/2009
• Issued: 04/01/2014
• Est. Priority Date: 04/30/2008
• Status: Expired due to Fees

• Current Assignee: Dow Technology Investments LLC (Dow, Inc.)
• Original Assignee: Dow Technology Investments LLC (Dow, Inc.)
• Inventors: Bryden, Todd R., Howard, Kevin E., LeBaron, Peter C., Wallin, Sten A.
• Primary Examiner(s): Nguyen, Cam N.
• Application Number:
  US12/988,317
• Publication Number:
  US 20110059844A1
• Time in Patent Office: 1,798 Days
• Field of Search: 502/355, 502/415, 502/439, 423/600
• US Class Current: 502/355
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 23/50 Silver
• CPC Class Codes: B01J 23/66 Silver or gold
• CPC Class Codes: B01J 23/688 with manganese, technetium or rhenium
• CPC Class Codes: B01J 27/055 with alkali metals, copper, gold or silver
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• 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 37/0009 Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
• 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 37/0201 Impregnation
• CPC Class Codes: B01J 37/0203 the impregnation liquid containing organic compounds
• CPC Class Codes: B01J 37/0205 in several steps
• CPC Class Codes: B01J 37/0213 Preparation of the impregnating solution
• CPC Class Codes: C07D 301/10 with catalysts containing silver or gold

Abstract

The present invention provides porous body precursors and shaped porous bodies. Also included are catalysts and other end-use products based upon the shaped porous bodies and thus the porous body precursors. Finally, processes for making these are provided. The porous body precursors comprise a precursor alumina blend capable of enhancing one or more properties of a shaped porous body based thereupon. The need to employ modifiers to achieve a similar result may thus be substantially reduced, or even avoided, and cost savings are thus provided, as well as savings in time and equipment costs.

Claims

1. A porous body precursor comprising a precursor alumina blend, wherein the blend enhances at least one property of a shaped precursor body prepared from the porous body precursor and wherein the precursor alumina blend consists essentially of (i) two or more secondary particles sizes of one precursor alumina, (ii) at least two precursor aluminas being of substantially the same particle size, or (iii) at least two secondary particle sizes of at least two precursor aluminas.

2. The porous body precursor of claim 1, wherein the blend comprises a majority component and a minority component.

3. The porous body precursor of claim 2, wherein the minority component substantially dictates the property of the shaped porous body that is enhanced, the nature of the enhancement thereof, or both.

4. The porous body precursor of claim 3, wherein the minority component comprises pseudo-boehmite.

5. The porous body precursor of claim 1, wherein the secondary particle size(s) range from about 0.25 micrometers to about 100 μ

m.

6. The porous body precursor of claim 1, wherein the precursor alumina blend comprises a blend of two secondary particles sizes of one precursor alumina.

7. The porous body precursor of claim 1, wherein the precursor alumina comprises one or more transition alumina precursors, transition aluminas and/or alpha-alumina precursors.

8. A shaped porous body prepared from a porous body precursor comprising a precursor alumina blend, wherein the blend enhances at least one property of the shaped porous body prepared from the porous body precursor and wherein the precursor alumina blend consists essentially of (i) two or more secondary particles sizes of one precursor alumina, (ii) at least two precursor aluminas being of substantially the same particle size, or (iii) at least two secondary particle sizes of at least two precursor aluminas.

9. The shaped porous body of claim 8, wherein the porous body precursor and shaped porous body are substantially additive free.