AU598734B2 - Improved monolithic catalyst supports incorporating a mixture of alumina and silica as a high surface area catalyst support material - Google Patents

Description

9 BST7LI3 4 Patents Act LCDG'MT.D AT SBCFFO 2 3 MAY 1986 ~bour'ae COMPLETE SPECIFICATION

(ORIGINAL)

Class Int. Class Application Number: 1 Lodged: Complete Specification Lodged: Accepted; Publshed Priority "Related Art: p:i o e~ o 9 4 4,4,99 *4 0 4 0 @9 o 00 0 *4 04 0 4 .4 4 Name(s) of Applicant(s): Address(es) of Applicant(s): A ctual Inventor~s): APPLICANT'S REF,; Lachman-Nordlie 27-6 Corning Glass Works Corning, New York UNITED STATES OF AMERICA Irwin Morris Lachmnan and Lawrence AndreV Nordlie PH4bL.IPS, ORMONDE AND 'TZPATRICK Patent and Trade Mark Attorneys 367 Collins Street Melbourne, Australia, 3000 Address for Service is: Complete Specification for the invention entitled: IMPROVED MONOLITHIC CATALYST SUPPORTS INCORPORATING A MIXTURE OF ALUMINA AND SILICA AS A HIGH SURFACE AREA CATALYST7SUPPORT

MATERIAL

The following str'tement, is a full description of this invention, including the best method of performing it known to applicant(s): PI9t3/84 IMPROVED MONOLITHIC CATALYST SUPPORTS INCORPORATING A MIXTURE OF ALUMINA AND SILICA AS A HIGH SURFACE AREA CATALYST SUPPORT MATERIAL CroSS-ReferPrnre to Belatsd&-Appi .t.i.ns-- -Mh4. application is a c Atinuaio-in-FaLt Of commonly-assigned applicatio Serial No. 712,886, filed March 18, 1985, in the names of rwin M. Lachman and Carlo Golino; and commonly-assigned pplication Serial No. 712,875, filed March 18, 1985, i the names of Irwin M. Lachman, Pronob no ANordlie.i4 ."''Background of the Invention This invention is directed to monolithic catalyst l0 support structures having a sintered ceramic structural phase :::and a high surface area support phase disposed on or within the ceramic. The invention is particularly directed to catalyst support structures of this kind which are improved by using a mixture of alumina and silica \s the high surface area phase.

Conventional ceramic monolithic catalyst supports Sbonsist of a ceramic support material with a coating of high surface material upon which the catalyst is actually.

deposited. In particular, the ceramic support is normally prepared by sintering a mold of clay or other ceramic material at a high temperature to irmart density and strength. This procedure normally results in the ceramic's having a very low surface area, and consequently the ceramic is coated with another material having a higher surface area, as well as SSpecific chemical characteristics, on which to actually deposit the catalyst. This procedure of depositing a high surface area "washcoat" on the low surface area ceramic wall is disclosed, for example in U.S. Patent Nos. 2,742,437 and 3,824,196. The high surface area washcoats of these catalyst supports, however, often lose the surface area during their service lives because of the high temperatures, such as those of automotive exhaust gases, to which they are exposed.

Recently, monolithic supports in which the high surface area phase is incorporated within the ceramic structural phase itself have been developed. In these supports, (disclosed in co-pending commonly-assigned U.S.

Serial Numbers 712,875 and 712,886, both filed March 18, 1985) the high surface area material is coextruded with the S. sinterable ceramic material in a single step, and remains as a discrete phase within the ceramic matrix after the monolith is fired. Catalyst supports of this kind eliminate several mechanical and physical problems of those having an exterior S' high surface area "washcoat", but could be susceptible to St thermal degredation of the high surface area phase because of exposure to elevated service temperatures. Additionally, I because it is coextruded with the ceramic material, the high i surface area oxide phase is present during firing of the ceramic and is therefore exposed to the high temperatures involved in that process as well. It is therefore desirable to use an oxide support material that can retain high surface area despite exposure to elevated temperatures during firing or in service.

Alumina and silica mixtures have been used as the supporting material for catalysts. British Patent 1,581,628 broadly discloses the use of alumina-silica mixtures as an 1 -2- 4 h.

external washcoat support for catalysts, but discloses no specific compositions or particular preparations. U.S. Patent 4,1l9,522 discloses the preparation of hydrogel spheres of 27-75% by weight alumina; 75-25% by weight silica. These spheres are taught to be useful as catalyst supports, but neither preparation nor service temperatures above 760°C are disclosed, and the patent contains no disclosure of use in a monolithic support structure. U.S. Patent 4,151,121 discloses the use of alumina-silica mixtures containing 5-40% by weight alumina, prepared by gelation methods, as a catalyst support phase for incorporation into a granulated catalyst support.

Patent 3,637,525 discloses a monolithic catalyst support t in which an alumina-silica mixture is combined with boron phosphate to form a singular structural/supporting phase for the catalytic materials. The alumina/silica mixture is Sprepared by coprecipitation or, cogelation of alumina and silica in a weight ratio of 1.5:1 to 9:1.

It is an object of the present invention to provide an improved monolithic catalyst support having a strong structural phase of a sintered ceramic material and a second phase of a 'high surface area support material integral therewith which "resists thermal degredtion in service. It is a further object of the present Invention to provide a monolithic catalyst support of this kind in which the support phase retains high surface area even when subjected to elevated temperatures used in ceramic firing processes. These and other objects are met by the invention to be described.

-3- 3a Summary of the Invention The present invention provides a monolithic catalyst support structure comprising a substantially continuous structural phase of a sintered ceramic material and a high surface area support phase of a porous oxide integral with the structural phase, such that the overall surface area is at least 8 m 2 wherein the porous oxide supoort phase consists apart from incidental impurities of 50-93% by weight alumina and 7-50% by weight silica.

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-Summ-ary of th Tnention- -ThA preent invention provides an improved monolithic catalyst support structure comprising a struct r phase of a sintered ceramic and a high surfa ea support phase of a porous oxide integraw the structural phase, wherein the porous o d support phase consists essentially of 50-93% by Weigh±- almina..an 7- by weight- a i l i a The alumina-silica phase of the present invention retains high surface area despite being subjected to elevated temperatures of ceramic firing and catalytic service.

Surprisingly, the physical mixture of alumina and silica used .as the support phase of this invention retains higher surface Sarea than either of the components would retain if individually

I

exposed to such conditions. Catalytic activity, which is dependent on surface area, is therefore maintained to a degree greater than that heretofore attainable under similar conditions. Increased effectiveness of the catalytic activity in such catalyst support structures as automobile catalytic converters can provide such benefits as increased fuel 210' ,efficiency.

Detailed Description of the Invention The improvements embodied by the present invention relate to the finding that a physical mixture of alumina and silica can be used as the high surface area phase of a catalyst support system, and despite being subjected to conditions that normally result in thermal degredation, the mixture retains higher surface area per nit of weight than would either component individually. By intimately mixing finely divided .EJ j _411 i

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rft t t t r T V I It I Il It

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0 It t It S I S 3 0 powders of alumina and silica, it is believed that sintering of either one is impeded by the presence of the other, and the presence of silica retains the alumina substantially 'in the more desirable, higher surface area, transition forms.

According to the present invention, the high surface area catalyst support phase of a catalyst-supporting system such as a monolith consists essentially of about 50-93% by weight alumina and about 7-50% by weight sililca (that is, an alumina:silica molar ratio of about 1:1.7 to about The weight and mole proportions are determined on the basis of dry, calcined alumina and silica. The alumina and silica materials preferred for use are those which, after drying and calcining, have a surface area of at least 40 square meters per gram of 2 2 weight (m more preferably at least 100 m /g and most preferably at least 200 m 2 Preferably, the alumina and silica materials have a maximum crystallite size of micron. (As used herein, "calcining" means hea'ting a crystalline material to a temperature sufficient to eliminate water from the crystal lattice but below the temperature at which the material begins to lose substantial porosity or surface area.) The aluminas useful in the preparation of the high surface area phase of this invention are those which, upon calcining, provide gamma-alumina or other transition aluminas having the specified surface area. Colloidal gamma-alumina can be used directly, or "alumina-precursors" such as alpha-alumina monohydrate can also be used. The colloidal gamma-alumina is generally in the form of particles not exceeding one micron.

When alpha-alumina monohydrate is used, the particle size can be from less than one micron up to about 100 microns, but preferably the particle size does not exceed 50 microns.

Suitable commercially available materials of this kind are Kaiser SA substrate alumina, available from the Kaiser Chemical Division of Kaiser Alumina Corporation; the CATAPAL and DISPAL aluminas available from the Chemical Division of Conoco Corporation; and the HYDRAL and series of activated aluminas available from Alcoa Corporation. The high surface area silicas that can be used in the present invention are the amorphous silicas of sub-micron crystallite size such as CABOSIL colloidal silica, available from Cabot Corporation, and QUSO G-761 silica available from PQ Corporation. The most 0 preferred alumina for use is the Kaiser SA Substrate alumina,

OS

S arnd the most preferred silica for use is CABOSIL EH-5 silica.

"According to the present invention, the high surface 6* o area phase of a catalyst-support monolith is prepared by mixing the alumina and silica in the proportions (dry calcined basis) Sindicated above. Preferred alumina/silica mixtures have a molar ratio of alumina to silica of from about 3:1 to 3:4 S "(about 55-85% by weicht alumina). Most preferred is a molar ratio of about 3:2 (Ibout 72% by weight alumina, but more "generally about 65-7.% by weight alumina). As mentioned, the .aluminia and silica components are preferably in the form of a finely divided articulate, and are admixed either dry or in a dispersion, as explained more fully below, to substantial homogeneity.

The alumina/silica high surface area support phase of this invention is combined with the ceramic structural phase of a monolithic support, to integrate the support phase and structural phase, by any conventional method. In the most well-known method, the support material is applied to a preformed ceramic structure as an external washcoat. This is accomplished by providing a well-mixed slurry of compounds that are decomposable by heat to alumina and silica, and dipping the ceramic in the slurry or spraying it with the slurry, followed in either case by calcination to generate a tightly adherent coating of alumina and silica on the ceramic wall. In these methods, of course, the proportions of alumina-generating and silica-generating compounds in the slurry are such as will provide calcined alumina and silica in relative proportions within the above described ranges. Such "washcoat" procedures are described in U.S. Patents 2,742,437 and 3,824,196, the disclosures of which are hereby incorporated by reference.

%tfe In a preferred manner of practice, the alumina/silica phase is coextruded with the ceramic material of the structural phase of the monolith and, after fiing of the monolith, is embedded within the sintered ceramic material as a separate and St ttdiscrete phase of high surface area material. Two procedures fEor accomplishing this are disclosed in copending U.S.

S" Application Serial No. 712,88G and Application Serial No.

712,875, both filed March 18, 1985. The disclosures of these appL cations, commonly-assigned herewith, are incorporated by reference.

According to one procedure, the alumina/silica mixture is agglomerated and formed into coarse particles which are then coextruded with finely divided sinterable ceramic material into the desired monolithic shape. Firing the monolithic shape results in the alumina/silica mixture's being present within the sintered ceramic as discrete discernible particls, The agglomerates are prepared by mixing the alumina and silica or their "precursors' with a binder. The binder can -7be any material which will agglomerate the materials for preparation of the coarse particles, for embedding in the ceramic monolith as a separate discontinuous phase, but which will normally burn off at or before the sintering temperature of the ceramic. The binder can be any of the well-known materials for this purpose. Examples are thermosetting resins such as epoxies, polyfurfuryl alcohol, silicone resins, phenolic resins, diallyl phthalate, or polyester resins; or a thermoplastic resin such as poly(acrylonitrile),polycarbonates, polyethylene, polymerized ethylenically-unsaturated monomers such as poly(methyl methacrylate) or polystyrene, polyvinyl ",,'alcohol, or hydrated methyl cellulose. Most preferred for use *i '*as the binder are methyl cellulose, polyvinyl alcohol, or S'"polymerized furfuryl alcohol.

The agglomerates are prepared by combining the alumina and silica powders with the hinder to form a homogeneous or ,substantially homogeneous mixture. The amount of binder used is such as will cause the powders to mass together. Normally 5-60 parts by weight of binder are used per 100 parts by weight of oxide powder. It is preferred to use only about 5-15 parts by weight, although when polymerized furfuryl alcohol is used, the higher levels are sometimes necessary to thoroughly wet and aggregate the powders.

The binders can be dispersed or dissolved in a suitable dilennt, such as water in the case of methyl cellulose and polyvinyl alcohol, and the powders then added to form a thick slurry. In either case, the mixture of binder and powders is preferably mulled and then extruded to effect further mixing. Extrusion is generally into a shape, preferably "noodle" shape, which will facilitate drying of the extruded -8- 1 Smass. As used herein, "drying" includes curing the binder, as may be necessary, or driving off any volatiles which may be present in the binder. Accordingly, the mass is dried at a temperature below the sintering temperature of the powders, preferably at room temperature up to about 2L0°C, and then pulverized to form the coarse particulate agglomerates. Any conventional pulverization techniques can be used, but use of a jaw crusher is preferred to attain the desired particle sizes.

The particle sizes are preferably such that the median particle diameter is 50-250 microns, more preferably 55-100 microns.

Generally, however, the particles are of a size that will not to interfere with the subsequent preparation of the ceramic monolith but will result in the presence of a discernible t discontinuous phase in the ceramic matrix.

1*S The ceramic matrix, which forms the high-strength structural phase of the monolith, is comprised of any of the o 40 well known sinterable materials capable of providing mechanical strength and good thermal properties in monolithic supports as t heretofore prepared by those skilled in the art. Preferably the ceramic is selected from covdierite, mullite, clay, talc, zirconia, zirconia-spinel, alumina, silica, lithium .0 0 i 4 aaluminosilicates, and alumina-zirconia composites. Mixtures of these can also be used to the extent that the chosen materials are compatible and will not degrade each other, as those S 25 skilled in the art will recognize.

The monolithic supports are prepared by mixing the sinterable ceramic materials with the agglomerate materials described above and, optionally, a binder. Generally about 15-50 parts by weiqh, of the agglomerate particles will be combined with 50-85 parts by weight of the ceramic material.

*Preferably, 3-20 parts by weight of binder will also be used.

Binder materials conventionally used in ceramic catalyst support manufacture are suitable. Examples are disclosed in: "Ceramics Processing Before Firing," ed. by George Y.

Onoda, Jr. L.L. Hench, John Wiley Sons, New York "Study of Several Groups of Organic Binders Under Low-Pressure Extrusion," C.C. Treischel E.W.

Emrich, Jour. Am. Cer. Soc., pp. 129-132, 194G Organic (Temporary) Binders for Ceramic Systems," S.

Levine, Ceramic Age, (75) No. 1, pp. 39+, January 1960 "Temporary Organic Binders for Ceramic Systems," S.

Levine, Ceramic Age, (75) No. 2, pp. 25+, February 1960 ret "mPreferred are methyl cellulose or a mixture of methyl cellulose and 9 Sa silicone resin, The silicone resins preferred for use are Dow t orning Corporation's Q6-2230 silicone resin or those described in t U.S. Patent 3,090,691 to Weyer. The most preferred binder is methyl ,,cellulose, available as METHOCEL A4M from the Dow Chemical Company.

Up to about 1 percent by weight, based upon total mixture weight, of a surfactant, such as sodium stearate, can also be used to 26 facilitate mixing and flow for subsequent processi"g. The mixing stop should be performed a liquid, such as water, which acts as a S further plasticizer. When the binder is silicone resin, it is preferred to use isopropyl alcohol in addition to water.

The most preferred ceramic materials are the pre-reacted cordierite and mullite. The ceramic material should be in i, particulate form, preferably of a size finer than 200 mesh Standard) and most preferably finer than 325 mesh Standard).

The ceramic particles can be coarser than 200'mesh, but pshotld b. a least as fine as the agglomerate particles.

The monoliths are prepared by combilm st bto form a homogeneous or substantially homogeno -16- L A *Conventional mixing equipment can be used, the use of a mix muller is preferred. To effect further the batch can subsequently be extruded through a "noodling" die one or more times. Ultimately, the batch is formed into the desired monolith shape, preferably by extrusion through a die.

According to the second procedure for incorporating the alumina/silica mixture into the monolith as a discrete discernable support phase, the alumina/silica mixture and a ceramic matrix material (as described above) are separately formed into moldable bodies by admixture with a substance that will bind those materials into a plasticized mass. This binder substance can be any of those described earlier in connection with preparation of the, agglomerate/ceramic extrusion batch. A preferred binder is methyl S cellulose, S The constituent materials (alumina and silica for the support bodies; ceramic material for the structural bodies) are separately mixed with sufficient binder to form a moldable mass.

Generally, about 1-20 percent by weight, based on the alumina/silica or ceramic material weight, of the binder is used. Up to about 1 percent by weight, based upon the total body weight, of surfactant or lubricant such as sodium stearate can also be used to facilate mixing. The mixing step should be performed in a liquid, preferably <,,Jwater, which acts as a further plasticizer. When the binder is a silicone resin, it is preferred to use isopropyl alcohol in addition Sa~I 25 to water. Conventional mixing equipment can be used, but the use of a mix muller is preferred.

The plasticized masses of alumina/silica and those of ceramic material are separately molded or formed into discrete bodies which are then intermingled for coextrusion through a die to form the final desired shape of the monolithis catalyst support 4 ,k -V1 SNormally, the support bodies and structural bodies will be intermingled to form a composite body thereof in which the support bodies constitute a distinct, preferably discontinuous, phase throughout. The support bodies should also be uniformly or substantially uniformly distributed throughout the composite. To provide the proper distribution, there will normally be a ratio of ceramic structural bodies to alumina/silica support bodies of at least about 1.3:1, preferably at least 1.5:1. It is preferred, that the size aod shape of the structural bodies and support bodies be about the same. Following this and the above-mentioned ratios, the monoliths formed from such a composite contain, as is preferred, about 10-40 percent by weight of the high surface area phase.

The composite can be of any size or shape so long as the Ssupport bodies are uniformly or substantially uniformly distributed throughout and are present therein in a distinct phase and so long Sas the composite can be extruded through a dio to form the final monolith shape. It is also to be understood that "the manner of forming the composite can be by any means by which these criteria Sare substantially met.

2 In a preferred embodiment of this procedure, the plasticized masses of alumina/silica and those of ceramic material ;,0*are separately extruded through a rod die into bodies of elongate shape, preferably of rectangular, hexagonal, or circular cross-section. The extruded bodies are then assembled into a single S 25 composite body by intermingling the rods axially or longitudinally.

SMost preferably, this will be done so that the rods are substantially parallel. The support bodies are positioned to be uniformly or substantia'ly uniformly distributed through the composite. To provide the proper distribution, there will normally be a ratio of ceramic structural bodies to alumina silica support -12n

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'bodies of at least 1.5:1, preferably at least about 2:1 in the composite. After firing, monoliths formed from such a composite will contain, as is preferable, about 10-40 percent by weight of the high surface area alumina/silica phase. Ultimately, the composite is extruded through a die to form the desired shape of the final monolith.

Both this procedure and the one described above relating to the use of agglomerates are well suited for the preparation of monoliths in the shape of honeycombs. The "green" monolith shapes formed by either of these procedures are heated to a temperature and for a time sufficient to sinter the ceramic material. Optionally, this heating/sintering step can b preceded by drying the monolith o' shapes at about 100-120 0 C. The heating/sintering step generally S takes place at 800 0 -12000C, although preferably the temperature does not exceed about 1100-1150°C. Despite the temperatures used to S"sinter the ceramic, the embedded alumina/silica support phase of this invention contains high surface area and preferably provides the monolithic support with an overall surface area of at least 8-10 I t l m2 more preferably at least 15-20 m2/g.

.2q:44 The improvements of the present invention are also applicable to monolithic support structures in which the ceramic .phase is formed from a precursor of alumina, silica, titania, or ,zirconia. In the preparation of such monolithic supports, the alumina/silica mixture of the present invention is mixed with one or more of the aforementioned precursor materials (which are normally in the forr of a dispersion, suspension, or solution in a liquid diluent) and a temporary binder to form a substantially homogeneous body which is shaped and fir'd to form the support. The precursors generate the actual ceramic material at or below the firing temperature of the shaped body. The alumita/silica mixture is -13i i dispersed throughout the sintered and densified ceramic phase generatedby the precursors and provides a second phase of high surface area support material.

The improvement provided by the present invention is particularly important in the preparation of monolithic supports in which the high surface area support phase is exposed to the elevated temperatures necessary to sinter the ceramic material. One particularly preferred alumina/silica mixture contains Kaiser SA substrate alumina and CABOSIL silica in an alumina:silica molar ratio of 3:2. When this mixture is heated to 1200°C for a six hour period, it retains a surface area of 53m In contrast, the silica subjected individually to those conditions retains a surface 1 ft .area of 0.4 m 2 and the alumina individually subjected to those ,'conditions retains a surface area of 8.4m /g.

I The improved monolithic supports of this invention may have "some catalytic activity of their own by virtue of the chemistry and structure of the high surface area alumina/silica phase. The It ,support may further carry additional catalytically active ingredients on the surface area provided by the alumina/silica 2d, tsupport phase. These additional catalytic ingredients can be incorporated into the monolith by methods known in the art. The i'improved monolithic supports are useful in most applications in S. t hich it is nece'ssary to catalytically convert undesirable components in a gas stream prior to the stream's further processing or exhaustion to the atmosphere. The alumina/silica support phase of this invention is also useful in biological applications, such as enzyme processes, in which high surface area substrates are desirable, and in carrying out catalytically activated reactions for the manufacture of chemicals.

-14- I The following examples are illustrative, but not limiting, of the invention.

EXAMPLE 1 Compositions of alumina and silica were prepared from the ingredients indicated in Table 1A. Figures in Table IA are in parts by weight. The ingredients were intimately dry-mixed, then wet-mixed with water, followed by drying and reduction to particulate form. The resultant powder formulations were fired at

S.'

f 1000C, 11000C, and 1200 C for six hours. Some of the formulations were also fired at 10000C or 1200°C for 300 hours to determine the t effect of extended exposure to elevated temperatures. The surface area of the fired powder formulations is indicated in Table 1B. The Salumina materials used in this example were hydrated aluminas having a weight loss-on-ignition of about 24-28%. Accordingly, the weight VIl'i of alumina generated by the materials after firing is less than the indicated weight of the alumina ingredient itself. Examples 1A and r IB are included as controls, the composition being either 100% ".alumina (1A) or 100% silica(lB). It can be seen that examples ID through 1G, which are compositions of the alumina used in control S 20 example 1A and the silica used in control example 1B, retain Sj considerably higher surface area after exposure to 1200°C for six hours than does either the alumina or silica alone when subjected to the same conditions. A particularly preferred embodiment of the invention is depicted in Example 1F.

L TABLE 1A Example Number Ingredient Ka~iser SA hydrated A1 2 0 3 Conoco DISPAL M hydrated A1 2 0 3 Cabot CABOSIL EH-5 Amophous SiO 2 Crystallite Size 0.007 micron 1A 18 IC 1D IE IF 1G 1H 11 100 93.3 87.4 77.7 *63.5 93.3 63.5 100 36.5 6.7 12.6 22.3 6.5 16.9 PQ Corp QUSO G-761 hydrophlic SiO 2 mean crystallite size 0.015 micron 6.7 it S 0 *0

S.

0 S S #0 0

*S*

C SC t I 4 145 4 44 I 4 54,4 ~t

S

S II; S 4 5,4 44 4

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4 4 4 Alcoa HYDRAL 710 83.1 -16- -4 TABLE 1B Surface Area (m2/g) Firing Data (*C/hours) 1000/6 1100/6 1200/6 1000/300 1200/300 Example 63 104 99 105 92 79 8.4 0.4 21 61 57 54 43 22 36 117 l18 118 104 110

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41 4 6 £5 £4

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*4 t t t** *r 1. ~t 4 4 4£ 4 44 t~t 4 C 4 4 51 11 '2 -17- EXAMPLE 2 This example illustrates the preparation of high surface area agglomerates based on alumina and silica. The alumina ingredient was Kaiser SA Substrate Alumina, a hydrated alumina which, after heat treatment at 600 0 C. for one hour, has a weight loss-on-ignition of 27 percent and provides gamma-alumina having a surface area of about 300m2/g. The silica ingredient was CABC, 'L silica (Cabot Corp.), an amorphous silica having a surface area ,of 400m 2 /g and a median crystallite size of 0.007 micron.

i0t**, 93.3 parts by weight of the alumina and 6.72 parts by '"weight of the si,ica were pre-mixed in a plastic jar on a roller for two hours, About 6 percent by weight of methyl cellulose, based on the alumina-silica total weight, was dispersed separately in distilled water which had been heated to 80 0 C. When the methyl .cellulose was sufficiently dispersed, the alumina-silica mixture was added. The resultant mixture was stirred by hand and additional 1 water was added, bringing the total water content to 90 parts by weight, until a thick slurry was prodsced. The slurry was dried S.overnight at 175 0 C. to form a hard cake. The cake was crushed into 'particles of various dimensions for use in Examples 3-5, following.

EXAMPLES In these examples, compositions of the following ingredients were prepared, as described in the table below, for the fabrication of honeycomb monolithic supports. Fig:. es represent S 25 parts by weight.

-18j" j f 'INGREDIENT EXAMPLE 3 EXAMPLE 4 EXAMPLE Methyl Cellulose Sodium Stearate Distilled Water Pre-reacted Cordierite 7.9 microns 6.8 microns Example 2A Agglomnerates 80.5-84 microns 62 microns 4 0.5 43.8 50. 0 10.0 40.0 4 0.5 40.6 60.0 40.0 4 41.3 60.0 'A I 6 4 04 4 hi *median particle size -19- 7 For each example, the compositions were formulated by combining all ingredients but the water in a plastic jar. The jar contained 1-inch diameter balls from a standard ball mill, 6 balls per 800 grams of material. The jar was rotated until the ingredients were well mixed, after which the ingredients were placed in a mix muller with the water and further mixed until a plasticized batch was attained. The batch was extruded several times through a noodle die to distribute the agglomerate particles throughout the mixture. The compositions of Examples 3 and 4 were extruded through a die to produce honeycomb shapes having 200 square openings per square inch with a wall thickness of 12 mils. The composition of Example 5 was extruded through a die to produce honeycomb shapes ,V having 400 square openings per square inch with a wall thickness of mils. Honeycomb shapes of each example/composition were heated at various temperatures between 1000 0 -1200 0 C. for four hours to sinter Sthe ceramic material. Agglomerate particles of Example 2 were also separately heated so that their characteristics could be Sascertained. The physical characteristics, according to heating 4t 1 temperatures of the monoliths and agglomerates above, are shown in r t the table below.

3 EXAMPLE Heating Temp, (OC.) 4 Hours Porosity Percent Thermal Expansion Coefficient 2 25-10000C.

WOOC

Axial Crushing Strength

(PSI)

BET Surface Area (U2/g) 1000 1100 1150 1200 1000 1100 1150 1200 1000 1100 1200 1100 1150 1200 30 x 1- 27 29 350 450 840 1,080 2020 33 17 7 55.5 39 19 57 35.5 10.5 350 550 100 so 54 IMeasured with a Mercury Porosimeter.

2 Measured with a sapphire dilatometer 4.00 4.

-21- EXAMPLE 6 In this example, the following materials were used to form ceramic matrix structural bodies and alumina/silica support bodies for co-extrusion into monolith form..

Alumina-silica Ceramic Material Mixture Pre-reacted cordierite, 3:1 mole ratio, dry particle size finer basis, using Kaiser than 200 mesh SA alumina and CABOSIL EH-5 silica i The alumina/silica material and ceramic material were tr mixed separately in a mix muller with an additional 6% by weight t of METHOCEL A4M methyl cellulose and 0.5% by weight of sodium Sstearate as lubricant. Distilled water was added to further plasticize the mass. The two mixtures were extruded separately through a noodle die and then, still segregated, through a hexagonal die, to form rods having a hexagonal cross-section with 0.25-inch sides.

The extruded rods were assembled in a jig in the form of a single composite hexagon, using 24 ceramic material rods and 13 alumina/silica rods. The composite was extruded several times through a hexagonal rod die to reduce the cross-sectional area of the alumina/silica phase and to distribute it through the ceramic material phase. The composite was then extruded through a die to produce a honeycomb shape having 400 square openings per square inch with a wall thickness of 7 mils.

The honeycomb shapes were wrapped in aluminum foil and steam dried at 110°C for 16 hours, and then heated at various temperatures for 4 hours to sinter the ceramic matrix phase.

-22- Hexagonal rods of the alumina/silica support material were also heated under similar conditions so that their, separate characteristics could be ascertained. The surface areas of the honeycomb monoliths and the rods, according to heating temperature, are shown in the following Table.

Heating Temp.

(0 C)

BET

Surface Area (M 2 /g) alumina/ silica rods

P

P

'PP..

PP

P 0 Pt

PP

P

OPo P P PP. P 1000 1100 1150 1200 1250 1000 1100 1150 1200 1250 94.6 75.0 64.4 52.1 31.8 22.8 13.8 6.9 1.4 honeycomb P PP P P Pip.

P.

00 P P 94

P.

PP P

P

it t~ 4 4 t1

C'

-23-

Claims (5)

1. A monolithic catalyst support structure comprising a subtantially continuous structural phase of a sintered ceramic material and a high surface area support phase of a porous oxide integral with the structural phase, such that t'e overall surface area is at least 8 m wherein the porous oxide suboort phase consists apart from incidental impurities of 50-93% by weight alumina and 7-50% by weight silica.

2. A monolithic support according to claim 1 in which the sintered ceramic phase is substantially continuous and in which the high surface area support phase is a substantially discontinuous, discrete, discernible phase embedded in the ceramic phase.

3. A monolithic support according to claim 1 or claim 2 in which the monolith has a surface area of at least m2/g.

4. A monolithic support according to any one of claims 1 to 3 in the shape of a honeycomb. A monolithic support according to any one of claims 1 to 4 wherein the support phase consists apart from incidental impurities of 55-85% by weight of alumina and

15-45% by weight of silic 6. A monolithic support according to any one of claims 1 to 4 wherein the support phase consists apart from SincideRtal impurities of 65-75% by weight alumina and 25-35% be weight silica. 7. A monolithic support dccording to any one of claims 1 to 6 wherein the alumina is formed from a hydrated alumina, said hydrated alumina characterized in that it i,,converts to a transition alumina having a surface area of at 20 fl^ 1 25 least about 300 m /g after calcination at a temperature of 600 0 C for one hour; and the silica is formed from an amorphous silica having a crystallite size no larger than 2 0.02 micron and a surface area of at least 200 m /g. 8. A monolithic support substantially as herein described with reference to any one of the examples. DATED: 24 April, 1990 PHILLIPS ORMONDE FITZPATRICK Attorneys for: CORNING GLASS WORKS, w- ff J h I II I I I I I I ID ~D iI Il II 1028v i f i P-~ -1 t I: or: eel; i, te C- I r 2( i f I- C ci /v