Catalyst – solid sorbent – or support therefor: product or process – Having foreign or diverse function – With structure having utility in addition to support or carrier
Patent
1991-09-05
1993-04-20
Dees, Carl F.
Catalyst, solid sorbent, or support therefor: product or process
Having foreign or diverse function
With structure having utility in addition to support or carrier
502 1, 502 5, 502527, B01J 3500, B01J 3734
Patent
active
052043029
ABSTRACT:
A multi-layered catalyst on a metal substrate and a method for its preparation is provided. The catalyst includes a substrate, an adhesive sublayer whose improved adhesion to the substrate is obtained by the formation of a diffusion layer between the substrate and adhesive layer, a catalytically active layer deposited on the adhesive sublayer characterized by a smooth compositional gradient of the catalytically active component such that the catalytically active layer ranges from substantially 0.0 wt % at the adhesive sublayer interface to substantially 100 wt % at the outermost portion of the catalytically active layer and a porous layer containing at least the catalytically active component. An activator coating can be applied to the porous layer. The catalyst is prepared by plasma spraying a thermally reactive powder onto the substrate to form the adhesive sublayer, whereby the heat generated by the thermally reactive powders causes diffusion of the sublayer into the substrate and a diffusion bonded layer is formed resulting in a strong adhesion of the sublayer to the substrate, subsequently introducing at least alumina and a second powder into a plasma torch at separately controllable variable feed rates and co-depositing alumina and the second powder, adjusting the relative feed rates of alumina and second powder into the plasma torch such that a catalytically active layer with a smooth compositional gradient is achieved, whereby the alumina content of the catalytically active layer ranges from substantially 0 wt % at the adhesive sublayer interface to substantially 100 wt % at the uppermost portion of the catalytically active layer, subsequently introducing at least alumina and an additional metal carbonate or hydroxide into the plasma torch; and co-depositing a porous layer of at least alumina and the additional metal carbonate or hydroxide, whereby the metal carbonate or hydroxide decomposes with a release of gas or vapor resulting in an outer coating with a high surface area.
REFERENCES:
patent: 3264226 (1966-08-01), Johnson
patent: 3492148 (1970-01-01), Hervert
patent: 4252690 (1981-02-01), Kanya et al.
patent: 4455281 (1984-06-01), Ishida et al.
patent: 4465654 (1984-08-01), Faschinghauer
patent: 4702897 (1987-10-01), Onal
patent: 4703028 (1987-10-01), Steininger
patent: 4752599 (1988-06-01), Nakamura et al.
patent: 4778649 (1988-10-01), Niino et al.
E. S. Lox et al., "Development of Scavenger-Free Three-Way Automotive Emission Control Catalysts with Reduced Hydrogen Sulfide Formation", SAE Technical Paper Series, pp. 1-11, presented at the International Congress and Exposition, Detroit, Michigan (Feb. 27-Mar. 3, 1989).
E. Koberstein et al., "Catalytic Automotive Exhaust Purification-The European Situation 1985", SAE Technical Paper Series, pp. 1-9, presented at the International Fuels and Lubricants Meeting and Exposition, Tulsa, Oklahoma (Oct. 21-Oct. 24, 1985).
Elizabeth A. Bretz, "Lower Limits on Engine Emissions Force Post-Combustion Treatment", Power, pp. 65-68 (May 1989).
Farmakovsky Boris V.
Gorynin Igor V.
Kalogina Karina V.
Khinsky Alexander P.
Saluja Navtej S.
Dees Carl F.
Technalum Research, Inc.
LandOfFree
Catalyst composition and a method for its preparation does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Catalyst composition and a method for its preparation, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Catalyst composition and a method for its preparation will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-1526029