Catalyst – solid sorbent – or support therefor: product or process – Catalyst or precursor therefor – Inorganic carbon containing
Patent
1985-08-06
1987-10-27
Shine, W. J.
Catalyst, solid sorbent, or support therefor: product or process
Catalyst or precursor therefor
Inorganic carbon containing
502177, 502200, 502202, 502240, 502355, 502439, B01J 2102, B01J 2104, B01J 2106
Patent
active
047030283
DESCRIPTION:
BRIEF SUMMARY
The present invention concerns itself with a carrier for the manufacture of abrasion-resistant catalysts, a manufacturing method for this carrier as well as its application in the manufacture of shell catalysts.
Shell catalysts are used for catalytic reactions and, in particular, for use in oxidizing reactions of hydrocarbons, cracking reactions of low octane paraffin cuts to flammable gases of high octane number and hydrocracking reactions. These catalysts consist of carriers, for example in the shape of spheres, tablets or other moulded elements, the surface of which has a dish-shaped catalytically active layer. The application of the catalytically active layer onto the carrier is effected using wet chemical methods. A process is described, for example, in the DE-OS No. 31 25 062 in which a suspension of the base material for the shell is sprayed onto an agitated bed, dried and tempered. According to the methods suggested in the DE-OS No. 28 14 262 and DE-OS No. 29 09 671, the pre-moistened carrier particles are sprayed with a catalytically active material and suspended in water. All these methods have the disadvantage of unsatisfactory adhesive strength of the dish, and the surface structure and layer thickness cannot be freely determined.
The task underlying the present invention is to produce a catalyst carrier with defined surface structure, pore distribution and surface characteristics which can be reproduced in a manufacturing process, and which allows for an abrasion-resistant arrangement of the catalytic layer.
The invention solves this task by providing the surface of an inert carrier with a layer, applied by a physical coating method, which is made up of individual structures producing porosity which in their turn consist essentially of high-fusion oxides, nitrides and/or carbides of at least one transition element, of boron, aluminum and/or of silicon or of combinations of these compounds.
Metallic or non-metallic, low-porous and also compact inert materials are used for the carrier e.g. silicic acid compounds such as silicates, in particular magnesium silicate, calcium aluminum silicate, clays, zeolites and similar, kaolin, aluminum silicate, aluminum oxide and hydroxide, silicon dioxide, furthermore titanium dioxide, zirconium dioxide and similar. There is a wide selection with regard to shape and size of the carrier e.g. tabletted, grained and lumpy carriers, pellets or spheres can be used.
It was ascertained that layers which are suitable for use with these usual types of carrier material consist of oxides, nitrides and/or carbides of transition elements, preferably of elements of the IV to VI auxiliary groups of the periodic systems, in particular of titanium, vanadium, chromium, zircon, molybdenum or tungsten. Oxides, nitrides or carbides of boron, aluminum or silicon are also suitable. Combinations of such compounds can also be used, e.g. carbonitrides. The type and/or composition of the catalytically active material is not specific for the invented carrier. Basically, any catalytically active material can be used. The invention also forsees the possibility of the catalytically active layer corresponding to the carrier coating.
The porosity of the carrier coating is preferably in the micrometer range and is responsible for the good adhesion of the catalytically active mass. According to the present invention, porosity of the layer is to be understood as a non-coherent structure with continuous spaces between those parts coated with the layer up to the carrier surface region. In other words, the layer consists of several individual elevations whose diameter and height lie in the micrometer range. Similarly, the diameters of the spaces between the individual elevations lie within the micrometer range. These elevations are preferably stem-shaped or columnar having a height ranging from 0.5 to 20 .mu.m, preferably from 1 to 10 .mu.m. The layers produced in this way are hard and also abrasion-resistant due to suitable texturing and frequently contain other elements such as metals in low conc
REFERENCES:
patent: 3966645 (1976-06-01), Cairns et al.
patent: 4297247 (1981-10-01), Krabetz et al.
patent: 4536482 (1985-08-01), Carcia et al.
Above References Land M, were Cited in the International Search Report.
Battelle - Institut e.V.
Shine W. J.
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