RU2017125557A - Способ получения катализатора - Google Patents

Способ получения катализатора Download PDF

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RU2017125557A
RU2017125557A RU2017125557A RU2017125557A RU2017125557A RU 2017125557 A RU2017125557 A RU 2017125557A RU 2017125557 A RU2017125557 A RU 2017125557A RU 2017125557 A RU2017125557 A RU 2017125557A RU 2017125557 A RU2017125557 A RU 2017125557A
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catalyst
metal
particulate
oxide
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RU2017125557A
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RU2744266C2 (ru
RU2017125557A3 (ru
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Дункан Рой КУПЛАНД
Джонатан ФИЛЛИПС
Софи УИНФИЛД
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Джонсон Мэтти Паблик Лимитед Компани
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86—Catalytic processes
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Claims (31)

1. Способ получения катализатора или прекурсора катализатора, включающий:
нанесение суспензии соединения катализатора в форме частиц в текучей среде носителе на полученную посредством аддитивного послойного производства структуру подложки с формированием пропитанной суспензией подложки, и
сушку и необязательно кальцинирование пропитанной суспензией подложки с формированием прекурсора катализатора или катализатора,
причем средний размер частиц (D50) соединения катализатора в форме частиц в суспензии находится в диапазоне 1-50 мкм, и структура подложки имеет пористость ≥ 0,02 мл/г.
2. Способ по п. 1, в котором структура подложки получена посредством стадий, включающих (i) объединение материала подложки в форме частиц со связующим веществом с формированием смеси заготовки, (ii) формирование слоя смеси заготовки, (iii) нанесение связывающего растворителя из печатающей головки на слой смеси заготовки в соответствии с заданным рисунком для связывания материала подложки в форме частиц, (iv) повторение стадий (ii) и (iii) слой за слоем, (v) удаление несвязанного материала и (vi) сушку и необязательно кальцинирование с формированием структуры подложки.
3. Способ по п. 2, в котором материал подложки в форме частиц представляет собой порошок с размером частиц в диапазоне 0,1-400 мкм.
4. Способ по п. 2 или 3, в котором материал подложки в форме частиц содержит глинозем, алюминат металла, кремнезем, алюмосиликат, кордиерит, оксид титана (IV), диоксид циркония, оксид церия (IV), оксид цинка или их смесь, цеолит, металлический порошок, карбид кремния, нитрид кремния или углерод.
5. Способ по любому из пп. 2-4, в котором материал подложки в форме частиц содержит один или более глиноземных материалов, выбираемых из гидратированных глиноземов, переходных глиноземов, альфа-глинозема и алюминатов металлов.
6. Способ по любому из пп. 2-5, в котором связующее вещество выбирают из декстрина, сахарозы и их смесей или PVA.
7. Способ по любому из пп. 2-6, в котором смесь заготовки содержит 1-10 мас.% полимерных или керамических волокон.
8. Способ по любому из пп. 2-7, в котором смесь заготовки содержит 0,5-5 мас.% одной или более спекающих добавок, выбираемых из оксида титана, оксида железа, оксида меди, оксида магния и карбоната кальция.
9. Способ по п. 8, в котором спекающая добавка является смесью оксида титана и оксида железа или меди, предпочтительно в весовых соотношениях TiO2 к Fe2O3 или CuO в диапазоне от 40:60 до 60:40.
10. Способ по любому из пп. 2-9, в котором слои материала заготовки имеют толщину в диапазоне от 0,02 до 5,0 мм, предпочтительно от 0,02 до 2,5 мм.
11. Способ по любому из пп. 2-10, в котором связывающий растворитель является органическим растворителем или водой.
12. Способ по любому из пп. 2-10, в котором печатающую головку используют при разрешении печати в направлении оси х в диапазоне от 40 мкм до 70 мкм и в направлении оси y 80-100 мкм для толщин слоя в диапазоне 50-150 мкм.
13. Способ по любому из пп. 2-12, в котором высушенную структуру подложки подвергают стадии кальцинирования при температуре в диапазоне 500-2000°C.
14. Способ по любому из пп. 1-13, в котором суспензия имеет содержание твердых веществ в диапазоне 5-80 мас.%.
15. Способ по любому из пп. 1-14, в котором соединение катализатора в форме частиц, наносимое на структуру подложки, содержит металлический порошок, соединение металла или цеолит.
16. Способ по любому из пп. 1-15, в котором соединение катализатора в форме частиц содержит порошок благородного металла, выбираемого из одного или более из Pt, Pd, Rh, Ir, Ru и Re.
17. Способ по любому из пп. 1-15, в котором соединение катализатора в форме частиц выбирают из одного или более соединений переходного металла, включая соединения лантаноидов и соединения актиноидов.
18. Способ по п. 17, в котором соединение переходного металла содержит один или более металлов, выбираемых из группы, состоящей из Na, K, Mg, Ca, Ba, Al, Si, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Ru, Rh, Pd, Ag, Sn, Sb, La, Hf, W, Re, Ir, Pt, Au, Pb или Ce.
19. Способ по п. 17 или 18, в котором соединение металла является оксидом металла, гидроксидом металла, карбонатом металла, гидрокарбонатом металла или их смесью.
20. Способ по любому из пп. 17-19, в котором соединение катализатора в форме частиц представляет собой объемную частицу катализатора, в которой каталитический металл распределен по всей частице, или представляет собой покрытую частицу катализатора, в которой каталитический металл присутствует в виде поверхностного слоя на поверхностях частицы.
21. Способ по любому из пп. 17-20, в котором соединение катализатора в форме частиц содержит один или более из Pt, Pd, Rh и Ir, нанесенных на материал подложки.
22. Способ по любому из пп. 17-20, в котором соединение катализатора в форме частиц является покрытым или объемным катализатором, содержащим один или более каталитических металлов, выбираемых из Ni, Co, Mo, W, Cu и Fe.
23. Способ по любому из пп. 17-20, в котором соединение катализатора в форме частиц выбирают из LaCoO3, в котором А-центр частично замещен Sr или Ce, La2CoO4, Co3O4 на глиноземе, оксиде церия, диоксиде циркония или их смесях, а также Co3O4, активированного редкоземельными элементами.
24. Катализатор или прекурсор катализатора, получаемый по способу по любому из пп. 1-23.
25. Способ, использующий катализатор по п. 24 или катализатор, полученный в соответствии со способом по любому из пп. 1-23, содержащий контактирование смеси реагентов с катализатором или прекурсором катализатора при условиях протекания катализируемой реакции.
26. Способ по п. 25, включающий катализируемую реакцию, выбираемую из гидрообработки, включая гидродесульфуризацию, гидрирование, паровой риформинг, включая предварительный риформинг, каталитический паровой риформинг, автотермический риформинг и вторичный риформинг, а также способов преобразования, используемых для прямого восстановления железа, каталитического неполного окисления, конверсии водяного газа, включая изотермическую конверсию, кислую конверсию, низкотемпературную конверсию, конверсию с промежуточной температурой, среднетемпературную конверсию и высокотемпературную конверсию, конверсию оксидов углерода водородом в метан, синтез углеводородов посредством реакции Фишера-Тропша, синтез метанола, синтез аммиака, VOC или окисление метана, реакции окисления аммиака и разложения закиси азота, или окисления, тройного катализа или реакций селективного восстановления выхлопных газов двигателя внутреннего сгорания или электростанции.
27. Способ по п. 26, включающий реакции окисления аммиака и разложения закиси азота, в котором катализатор используют в комбинации с сетчатым катализатором на основе благородного металла.
28. Способ по п. 26, включающий сорбцию, выбираемую из извлечения сернистых соединений или тяжелых металлов, таких как ртуть и мышьяк, из загрязненных газообразных или жидких потоков, или твердых примесей из выхлопных газов двигателей внутреннего сгорания или электростанций.
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