Catalytic composition and structures made thereof

Patent metadata

Field	Value
Publication number	US-11547988-B2
Application number	US-202117514813-A
Country	US
Kind code	B2
Filing date	Oct 29, 2021
Priority date	Sep 30, 2015
Publication date	Jan 10, 2023
Grant date	Jan 10, 2023

Abstract

Methods use a catalytic composition built up from a ceramic material including a catalytic material and a first inorganic binder and a second inorganic binder and a catalytic structure made thereof. Preferably, the structure is made by a colloidal ceramic shaping technique. The structure is used for catalytic or ion exchange applications. The catalytic structures have excellent mechanical, physicochemical and catalytic properties.

First claim

The invention claimed is:

1. A method for performing methanol-to-olefins reactions, comprising:
building a bulk catalytic structure, comprising:
shaping a composition comprising a ceramic material to obtain a green structure, wherein said ceramic material comprises a catalytic material and a first inorganic binder and a second inorganic binder, the shaping comprising preparing a suspension, slurry or paste of the composition and extruding the suspension, slurry or paste as fibers by three-dimensional fiber deposition to obtain the green structure, wherein the fibers are spaced apart to form a porous layered network;
the total amount of the first and second inorganic binders in the ceramic material comprising between 10 wt % and 50 wt % by total solid weight of the formed catalytic structure;
wherein the first inorganic binder is a clay material and the second inorganic binder is selected from: colloidal silica, colloidal alumina, colloidal zirconia, colloidal yttrium oxide, or colloidal tin oxide; or the first inorganic binder is selected from: colloidal silica, colloidal alumina, colloidal zirconia, colloidal yttrium oxide and the second inorganic binder is an inorganic thermohardening compound;
drying and calcining the green structure to obtain the bulk catalytic structure, wherein the structure is monolithic and comprises first channels having a length extending in a flow direction and second channels having a length extending in a radial direction, wherein the first channels and the second channels are fluidly connected; and

using the bulk catalytic structure as a catalyst in the methanol-to-olefins reactions.

2. The method according to claim 1 , wherein the fibers extend alongside the first and the second channels.

3. The method according to claim 1 , wherein the fibers have a diameter between 0.1 mm and 2 mm.

4. The method according to claim 1 , wherein the bulk catalytic structure has a macroporous volume in the range between 0.25 cm 3 /g and 1.0 cm 3 /g.

5. The method according to claim 4 , wherein the macroporous volume is between 0.35 cm 3 /g and 0.75 cm 3 /g.

6. The method according to claim 1 , wherein the bulk catalytic structure has a pressure drop smaller than or equal to 0.3 bar/m at a superficial gas velocity of 0.04 m/s in a flow of nitrogen at about 303 K.

7. The method according to claim 6 , wherein the pressure drop is smaller than or equal to 0.2 bar/m.

8. The method according to claim 6 , wherein the pressure drop is smaller than or equal to 0.1 bar/m.

9. The method according to claim 1 , wherein the clay material is bentonite.

10. The method according to claim 1 , wherein the inorganic thermohardening compound is aluminumphosphate.

11. A method for performing catalytic applications, comprising:
building a bulk catalytic structure, comprising:
shaping a composition comprising a ceramic material to obtain a green structure, wherein said ceramic material comprises a catalytic material and a first organic binder and a second inorganic binder, the shaping comprising preparing a suspension, slurry or paste of the composition and extruding the suspension, slurry or paste as fibers by three-dimensional fiber deposition to obtain the green structure, wherein the fibers are spaced apart to form a porous layered network;
the total amount of the first and second inorganic binders in the ceramic material comprising between 10 wt % and 50 wt % by total solid weight of the formed catalytic structure;
wherein the first inorganic binder is a clay material and the second inorganic binder is selected from: colloidal silica, colloidal alumina, colloidal zirconia, colloidal yttrium oxide, or colloidal tin oxide; or the first inorganic binder is selected from: colloidal silica, colloidal alumina, colloidal zirconia, colloidal yttrium oxide and the second inorganic binder is an inorganic thermohardening compound;
drying and calcining the green structure to obtain the bulk catalytic structure, wherein the structure is monolithic and comprises first channels having a length extending in a flow direction and second channels having a length extending in a radial direction, wherein the first channels and the second channels are fluidly connected; and

using the bulk catalytic structure for catalytic applications.

12. A method for performing ion-exchange applications, comprising:
building a bulk catalytic structure, comprising:
shaping a composition comprising a ceramic material to obtain a green structure, wherein said ceramic material comprises a catalytic material and a first organic binder and a second inorganic binder, the shaping comprising preparing a suspension, slurry or paste of the composition and extruding the suspension, slurry or paste as fibers by three-dimensional fiber deposition to obtain the green structure, wherein the fibers are spaced apart to form a porous layered network;
the total amount of the first and second inorganic binders in the ceramic material comprising between 10 wt % and 50 wt % by total solid weight of the formed catalytic structure;
wherein the first inorganic binder is a clay material and the second inorganic binder is selected from: colloidal silica, colloidal alumina, colloidal zirconia, colloidal yttrium oxide, or colloidal tin oxide; or the first inorganic binder is selected from: colloidal silica, colloidal alumina, colloidal zirconia, colloidal yttrium oxide and the second inorganic binder is an inorganic thermohardening compound;
drying and calcining the green structure to obtain the bulk catalytic structure, wherein the structure is monolithic and comprises first channels having a length extending in a flow direction and second channels having a length extending in a radial direction, wherein the first channels and the second channels are fluidly connected; and

using the bulk catalytic structure for ion exchange applications.

13. The method according to claim 12 , wherein the fibers have a diameter between 0.1 mm and 2 mm.

14. The method according to claim 12 , wherein the bulk catalytic structure has a macroporous volume in the range between 0.25 cm 3 /g and 1.0 cm 3 /g.

15. The method according to claim 12 , wherein the bulk catalytic structure has a pressure drop smaller than or equal to 0.3 bar/m at a superficial gas velocity of 0.04 m/s in a flow of nitrogen at about 303 K.

16. The method according to claim 12 , wherein the clay material is bentonite.

17. The method according to claim 12 , wherein the inorganic thermohardening compound is aluminumphosphate.

Assignees

• Vito Nv Vlaamse Instelling Voor Tech Onderzoek Nv
• Univ Antwerpen

Inventors

• Mullens Steven
• Protasova Lidia
• Lefevere Jasper

Classifications

• C10G3/49

  containing crystalline aluminosilicates, e.g. molecular sieves · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title

• B01J29/084

  Y-type faujasite · CPC title

• B01J29/7007

  Zeolite Beta · CPC title

• B01J37/038

  to form slurries or suspensions, e.g. a washcoat · CPC title