Patent US4189404A successfully refreshed from Google Patents.
US4189404A
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Catalyst and process of its preparation
Assignee: Engelhard Minerals and Chemicals Corp
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Filing: 1977-01-06
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Granted: 1980-02-19
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Expires: 1997-01-06
Abstract
Abstract Macrosized catalysts suitable for promoting chemical reactions, especially to reduce pollutants in waste gas streams such as automobile exhaust, are described. The catalysts have one or more metal components, especially a platinum group metal component, as a catalytic promoter combined with a high surface area, refractory oxide support on a relatively catalytically-inactive carrier, especially a monolithic carrier which may be of the honeycomb type. An aqueous solution of an alumina precursor is added to the macrosize catalyst to provide protection against poisoning by extraneous materials such as lead, zinc, other metals, sulfur or phosphorus with which the catalysts may come in contact during use.
Inventors
- 👤 Carl D. Keith
- 👤 John J. Mooney
- 👤 Robert E. Kenson
- 👤 Daniel L. Bair
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 07:21
CPC Classifications
B; B01; B01D; B01D53/00; B01D53/34; B01D53/92; B01D53/94; B01D53/9445; B01D53/945; B01J; B01J23/00; B01J23/38; B01J23/40; B01J33/00; Y; Y02; Y02A; Y02A50/00; Y02A50/20; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 35
Claim 1
Independent Claim
113 words
In a process of preparing a catalytic composition the steps comprising depositing on the surface of a macrosize composite an aqueous solution having dissolved therein a major amount of an aluminum compound which is a precursor of catalytically-active alumina and a minor amount of a precursor of rare earth oxide, said amounts being on a non-aqueous basis, said composite consisting essentially of a catalytically-effective amount of catalytically-promoting metal, catalytically-active, refractory oxide support and a relatively catalytically-inactive carrier, the amount of said aluminum compound in solution in said aqueous solution deposited being sufficient to increase the resistance of the catalytic composition to poisoning by extraneous materials, and drying said composition subsequent to said deposition.
Claim 2
Dependent Claim
113 words
In a process of preparing a catalytic composition the steps comprising depositing on the surface of a macrosize composite an aqueous solution having dissolved therein a major amount of an aluminum compound which is a precursor of catalytically-active alumina and a minor amount of a precursor of rare earth oxide, said amounts being on a non-aqueous basis, said composite consisting essentially of a catalytically-effective amount of catalytically-promoting metal, catalytically-active, refractory oxide support and a relatively catalytically-inactive carrier, the amount of said aluminum compound in solution in said aqueous solution deposited being sufficient to increase the resistance of the catalytic composition to poisoning by extraneous materials, and drying said composition subsequent to said deposition.
Claim 3
Dependent Claim
18 words
A process of claim 1 in which said carrier comprises a ceramic structure having fluid flow passages therethrough.
Claim 4
Dependent Claim
29 words
A process of claim 2 in which about 2 to 10 weight % (Al 2 O 3 basis) of said catalytically-active alumina precursor is deposited on the catalytic composition.
Claim 5
Dependent Claim
14 words
A process of claim 2 in which said refractory oxide support comprises catalytically-active alumina.
Claim 6
Dependent Claim
14 words
A process of claim 2 in which said promoting metal comprises platinum group metal.
Claim 7
Dependent Claim
14 words
A process of claim 5 in which said refractory oxide support comprises catalytically-active alumina.
Claim 8
Dependent Claim
29 words
A process of claim 6 in which about 2 to 10 weight % (Al 2 O 3 basis) of said catalytically-active alumina precursor is deposited on the catalytic composition.
Claim 9
Dependent Claim
17 words
A process of claim 7 in which said deposited catalytically-active, alumina precursor consists essentially of aluminum sulfate.
Claim 10
Dependent Claim
17 words
A process of claim 1 in which said deposited catalytically-active, alumina precursor consists essentially of aluminum sulfate.
Claim 11
Dependent Claim
16 words
A process in accordance with claim 1 in which said rare earth oxide comprises cerium oxide.
Claim 12
Dependent Claim
98 words
A catalytic composition consisting essentially of a macrosize composite of a catalytically-effective amount of catalytically-promoting metal and catalytically-active refractory oxide support on a relatively catalytically-inactive carrier, said macrosize composite having had deposited on the surface thereof an aqueous solution having dissolved therein a major amount of an aluminum compound which is a precursor of catalytically-active alumina and a minor amount of a precursor of rare earth oxide, said amounts being on a non-aqueous basis, said aluminum compound in said solution deposited being in an amount sufficient to increase the resistance of the catalyst to poisoning by extraneous materials.
Claim 13
Dependent Claim
98 words
A catalytic composition consisting essentially of a macrosize composite of a catalytically-effective amount of catalytically-promoting metal and catalytically-active refractory oxide support on a relatively catalytically-inactive carrier, said macrosize composite having had deposited on the surface thereof an aqueous solution having dissolved therein a major amount of an aluminum compound which is a precursor of catalytically-active alumina and a minor amount of a precursor of rare earth oxide, said amounts being on a non-aqueous basis, said aluminum compound in said solution deposited being in an amount sufficient to increase the resistance of the catalyst to poisoning by extraneous materials.
Claim 14
Dependent Claim
18 words
A composition of claim 11 in which said carrier comprises a ceramic structure having fluid flow passages therethrough.
Claim 15
Dependent Claim
28 words
A composition of claim 12 in which said deposited catalytically-active alumina precursor is about 2 to 10 weight % (Al 2 O 3 basis) of the catalytic composition.
Claim 16
Dependent Claim
14 words
A composition of claim 13 in which said refractory oxide support comprises catalytically-active alumina.
Claim 17
Dependent Claim
14 words
A composition of claim 13 in which said promoting metal comprises platinum group metal.
Claim 18
Dependent Claim
14 words
A composition of claim 15 in which said refractory oxide support comprises catalytically-active alumina.
Claim 19
Dependent Claim
28 words
A composition of claim 16 in which said deposited catalytically-active alumina precursor is about 2 to 10 weight % (Al 2 O 3 basis) of the catalytic composition.
Claim 20
Dependent Claim
17 words
A composition of claim 17 in which said deposited catalytically-active alumina precursor consists essentially of aluminum sulfate.
Claim 21
Dependent Claim
17 words
A composition of claim 11 in which said deposited catalytically-active alumina precursor consists essentially of aluminum sulfate.
Claim 22
Dependent Claim
16 words
A catalyst in accordance with claim 11 in which said rare earth oxide comprises cerium oxide.
Claim 23
Dependent Claim
30 words
A catalyst according to claim 11 wherein the catalytic metal consists essentially of platinum, rhodium and nickel, said nickel being present in an amount greater than said platinum group metals.
Claim 24
Dependent Claim
151 words
A catalyst for purifying exhaust gas from vehicles which comprises a monolithic carrier having a plurality of exhaust gas passages penetrating through the carrier, a layer of catalytically-active alumina containing a catalytic metal of the platinum group deposited as a first layer on the inside surfaces of said plurality of passages, and further comprising catalytically-active alumina formed by depositing on said first layer an aqueous solution having dissolved therein a major amount of an aluminum compound which is a precursor of catalytically-active alumina and a minor amount of a precursor of rare earth oxide, said amounts being on a non-aqueous basis, said aqueous solution deposited having an amount of said aluminum compound sufficient to increase the resistance of the catalyst to poisoning by extraneous materials, said aqueous solution being free from said catalytic metal, and heating resulting aluminum and rare earth containing composite to form catalytically-active alumina and rare earth oxide.
Claim 25
Dependent Claim
151 words
A catalyst for purifying exhaust gas from vehicles which comprises a monolithic carrier having a plurality of exhaust gas passages penetrating through the carrier, a layer of catalytically-active alumina containing a catalytic metal of the platinum group deposited as a first layer on the inside surfaces of said plurality of passages, and further comprising catalytically-active alumina formed by depositing on said first layer an aqueous solution having dissolved therein a major amount of an aluminum compound which is a precursor of catalytically-active alumina and a minor amount of a precursor of rare earth oxide, said amounts being on a non-aqueous basis, said aqueous solution deposited having an amount of said aluminum compound sufficient to increase the resistance of the catalyst to poisoning by extraneous materials, said aqueous solution being free from said catalytic metal, and heating resulting aluminum and rare earth containing composite to form catalytically-active alumina and rare earth oxide.
Claim 26
Dependent Claim
20 words
A catalyst according to claim 22 wherein the catalytic metal comprises at least two metals of the platinum group elements.
Claim 27
Dependent Claim
19 words
A catalyst according to claim 22 including also at least one oxide of nickel, iron, cobalt, copper and chromium.
Claim 28
Dependent Claim
32 words
A catalyst according to claim 22 wherein about 0.01 to 40% by weight of the catalytic metal is contained in the first layer on the basis of the weight of the catalyst.
Claim 29
Dependent Claim
12 words
A catalyst according to claim 25 wherein the catalytic metal is platinum.
Claim 30
Dependent Claim
28 words
A catalyst according to claim 25 wherein the amount of the catalytically-active alumina deposited as an outermost layer is about 0.5 to 20 weight % of the catalyst.
Claim 31
Dependent Claim
17 words
A catalyst according to claim 22 wherein the catalyst metal is a mixture of platinum and ruthenium.
Claim 32
Dependent Claim
30 words
A catalyst according to claim 21 wherein the catalytic metal consists essentially of platinum, rhodium and nickel, said nickel being present in an amount greater than said platinum group metals.
Claim 33
Dependent Claim
22 words
A catalyst according to claim 22 wherein the catalytic metal is a mixture of platinum and another metal of the platinum group.
Claim 34
Dependent Claim
27 words
A catalyst according to claim 22 wherein the catalytic metal is a mixture of platinum and at least one oxide of nickel, iron, cobalt, copper or chromium.
Claim 35
Dependent Claim
16 words
A catalyst in accordance with claim 22 in which said rare earth oxide comprises cerium oxide.
References Cited (Backward Citations)
US3741725A
Cited
US3931050A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-02-18 | 1983-08-20 | 1984-02-19 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-02-18 | 1987-08-20 | 1988-02-19 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-02-18 | 1991-08-20 | 1992-02-19 | $7700.00 | Window Closed / Lapsed |