US4760044A — Catalyst for minimizing the H2 S emissions from a…

Claim 1

Independent Claim 125 words

A catalytic composite for treating a hot exhaust stream from an internal combustion engine which comprises a mixture of (1) a primary refractory inorganic oxide support having dispersed thereon at least one of a first active component selected from the group consisting of rare earth oxides and (2) a secondary support selected from the group consisting of zirconia, titania, ceria, silica, magnesia, natural and synthetic zeolites having dispersed thereon at least one of a second active component which is an oxide of a metal, the metal selected from the group consisting of metals which form a stable sulfide under fuel rich conditions, said mixture having at least one main catalytic metal selected from the group consisting of platinum, palladium, rhodium, ruthenium and iridium deposited thereon.

Claim 2

Dependent Claim 125 words

A catalytic composite for treating a hot exhaust stream from an internal combustion engine which comprises a mixture of (1) a primary refractory inorganic oxide support having dispersed thereon at least one of a first active component selected from the group consisting of rare earth oxides and (2) a secondary support selected from the group consisting of zirconia, titania, ceria, silica, magnesia, natural and synthetic zeolites having dispersed thereon at least one of a second active component which is an oxide of a metal, the metal selected from the group consisting of metals which form a stable sulfide under fuel rich conditions, said mixture having at least one main catalytic metal selected from the group consisting of platinum, palladium, rhodium, ruthenium and iridium deposited thereon.

Claim 3

Dependent Claim 19 words

The catalytic composite of claim 1 where the catalytic composite is formed in the shape of spheres or pellets.

Claim 4

Dependent Claim 22 words

The catalytic composite of claim 1 where said catalytic composite is deposited on a low surface area solid ceramic or metallic carrier.

Claim 5

Dependent Claim 19 words

The catalytic composite of claim 1 where said primary refractory inorganic oxide support is a high surface area alumina.

Claim 6

Dependent Claim 34 words

The catalytic composite of claim 3 where said main catalytic metal is platinum which is present in a concentration in the range of about 0.15 to about 8.8 g per liter of carrier volume.

Claim 7

Dependent Claim 57 words

The catalytic composite of claim 3 where said main catalytic metal is a mixture of platinum and rhodium, said platinum is present in a range of about 0.15 to about 8.8 g per liter of monolith carrier volume and said rhodium is present in a range of about 0.03 to 2.5 g per liter of carrier volume.

Claim 8

Dependent Claim 55 words

The catalytic composite of claim 3 where said catalytic metal is a mixture of palladium and rhodium, said palladium is present in a range of about 0.15 to 8.8 g per liter of carrier volume and said rhodium is present in a range of about 0.03 to about 2.5 g per liter of carrier volume.

Claim 9

Dependent Claim 32 words

The catalytic composite of claim 3 where said rare earth oxide is cerium oxide and is present in a range of about 3.5 to about 55 g per liter of carrier volume.

Claim 10

Dependent Claim 22 words

The catalytic composite of claim 1 where said catalytic composite remains effective after exposure to a temperature of at least 850° C.

Claim 11

Dependent Claim 32 words

The catalytic composite of claim 3 where said rare earth oxide is lanthanum oxide and is present in a range of about 3.5 to about 55 g per liter of carrier volume.

Claim 12

Dependent Claim 49 words

The catalytic composite of claim 3 where the second active component is an oxide of a metal, the metal selected from the group consisting of metals which form a stable sulfide such that the equilibrium constant, Kp, is less than 2×10 -3 at temperatures as high as 700° C.

Claim 13

Dependent Claim 27 words

The catalytic composite of claim 11 where the metal is cobalt present in a concentration of about 0.7 to about 15 g per liter of carrier volume.

Claim 14

Dependent Claim 27 words

The catalytic composite of claim 11 where the metal is nickel present in a concentration of about 0.7 to about 15 g per liter of carrier volume.

Claim 15

Dependent Claim 27 words

The catalytic composite of claim 11 where the metal is zinc present in a concentration of about 0.7 to about 15 g per liter of carrier volume.

Claim 16

Dependent Claim 27 words

The catalytic composite of claim 11 where the metal is copper present in a concentration of about 0.7 to about 15 g per liter of carrier volume.

Claim 17

Dependent Claim 30 words

The catalytic composite of claim 3 where said secondary support is zirconia which is present in a range of from 0.7 to about 35 g per liter of carrier volume.

Claim 18

Dependent Claim 30 words

The catalytic composite of claim 3 where said secondary support is ceria which is present in a range of from 0.7 to about 35 g per liter of carrier volume.

Claim 19

Dependent Claim 30 words

The catalytic composite of claim 3 where said secondary support is titania which is present in a range of from 0.7 to about 35 g per liter of carrier volume.

Claim 20

Independent Claim 162 words

A method of manufacturing a catalytic composite for the treatment of an exhaust gas which comprises the steps of: (a) dispersing at least one first active component selected from the group consisting of the rare-earth oxides onto a primary refractory inorganic oxide; (b) dispersing at least one second active component which is an oxide of a metal, the metal selected from the group consisting of metals which form a stable sulfide under fuel rich conditions onto a secondary support selected from the group consisting of zirconia, titania, ceria, silica, magnesia, natural and synthetic zeolites; (c) preparing a slurry with the mixture of said supports formed in the steps (a) and (b); (d) coating a metallic or ceramic solid honeycomb support with the slurry of step (c) and calcining said coated support; (e) dispersing at least one main catalytic metal selected from the group consisting of platinum, palladium, rhodium, ruthenium and iridium onto said coated support, calcining and recovering the resultant catalytic composite.

Claim 21

Independent Claim 162 words

A method of manufacturing a catalytic composite for the treatment of an exhaust gas which comprises the steps of: (a) dispersing at least one first active component selected from the group consisting of the rare-earth oxides onto a primary refractory inorganic oxide; (b) dispersing at least one second active component which is an oxide of a metal, the metal selected from the group consisting of metals which form a stable sulfide under fuel rich conditions onto a secondary support selected from the group consisting of zirconia, titania, ceria, silica, magnesia, natural and synthetic zeolites; (c) preparing a slurry with the mixture of said supports formed in the steps (a) and (b); (d) coating a metallic or ceramic solid honeycomb support with the slurry of step (c) and calcining said coated support; (e) dispersing at least one main catalytic metal selected from the group consisting of platinum, palladium, rhodium, ruthenium and iridium onto said coated support, calcining and recovering the resultant catalytic composite.

Claim 22

Dependent Claim 32 words

The method of claim 19 where said primary refractory inorganic oxide is alumina and which is present in a concentration of about 28 to about 355 g per liter of carrier volume.

Claim 23

Dependent Claim 33 words

The method of claim 19 where said main catalytic metal is platinum which is present in a concentration in the range of about 0.15 to about 8.8 g per liter of carrier volume.

Claim 24

Dependent Claim 56 words

The method of claim 19 where said main catalytic metal is a mixture of platinum and rhodium, said platinum is present in a range of about 0.15 to about 8.8 g per liter of monolith carrier volume and said rhodium is present in a range of about 0.03 to 2.5 g per liter of carrier volume.

Claim 25

Dependent Claim 55 words

The method of claim 19 where said main catalytic metal is a mixture of palladium and rhodium, said palladium is present in a range of about 0.15 to 8.8 g per liter of carrier volume and said rhodium is present in a range of about 0.03 to about 2.5 g per liter of carrier volume.

Claim 26

Dependent Claim 31 words

The method of claim 19 where said rare earth oxide is cerium oxide and is present in a range of about 3.5 to about 55 g per liter of carrier volume.

Claim 27

Dependent Claim 31 words

The method of claim 19 where said rare earth oxide is lanthanum oxide and is present in a range of about 3.5 to about 55 g per liter of carrier volume.

Claim 28

Dependent Claim 31 words

The method of claim 19 where the metal which forms a stable sulfide is cobalt present in a concentration of about 0.7 to about 15 g per liter of carrier volume.

Claim 29

Dependent Claim 31 words

The method of claim 19 where the metal which forms a stable sulfide is nickel present in a concentration of about 0.7 to about 15 g per liter of carrier volume.

Claim 30

Dependent Claim 31 words

The method of claim 19 where the metal which forms a stable sulfide is copper present in a concentration of about 0.7 to about 15 g per liter of carrier volume.

Claim 31

Dependent Claim 29 words

The method of claim 19 where said secondary support is zirconia which is present in a range of from 0.7 to about 35 g per liter of carrier volume.

Claim 32

Dependent Claim 28 words

The method of claim 19 said secondary support is ceria which is present in a range of from 0.7 to about 35 g per liter of carrier volume.

Claim 33

Independent Claim 147 words

A method of manufacturing a catalytic composite which comprises the steps of: (a) dispersing at least one first active component selected from the group consisting of the rare-earth oxides and at least one main catalytic element selected from the group consisting of platinum, palladium, rhodium, ruthenium and iridium onto a primary refractory inorganic oxide; (b) dispersing at least one second active component which is an oxide of a metal, the metal selected from the group consisting of metals which form a stable sulfide under fuel rich conditions onto a secondary support selected from the group consisting of zirconia, titania, ceria, silica, magnesia, natural and synthetic zeolites; (c) preparing a slurry with the mixture of said supports formed in steps (a) and (b); (d) coating a metallic or ceramic solid honeycomb support with the slurry of step (c), calcining said coated support, and recovering the resultant catalytic composite.

Claim 34

Independent Claim 147 words

A method of manufacturing a catalytic composite which comprises the steps of: (a) dispersing at least one first active component selected from the group consisting of the rare-earth oxides and at least one main catalytic element selected from the group consisting of platinum, palladium, rhodium, ruthenium and iridium onto a primary refractory inorganic oxide; (b) dispersing at least one second active component which is an oxide of a metal, the metal selected from the group consisting of metals which form a stable sulfide under fuel rich conditions onto a secondary support selected from the group consisting of zirconia, titania, ceria, silica, magnesia, natural and synthetic zeolites; (c) preparing a slurry with the mixture of said supports formed in steps (a) and (b); (d) coating a metallic or ceramic solid honeycomb support with the slurry of step (c), calcining said coated support, and recovering the resultant catalytic composite.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1991-07-26	1992-01-25	1992-07-26	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1995-07-26	1996-01-25	1996-07-26	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1999-07-26	2000-01-25	2000-07-26	$7700.00	Window Closed / Lapsed

Catalyst for minimizing the H2 S emissions from automotive exhaust and method of its manufacture

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