Catalyst particles and methods for making same

Patent metadata

Field	Value
Publication number	US-11624023-B2
Application number	US-202017001665-A
Country	US
Kind code	B2
Filing date	Aug 24, 2020
Priority date	Mar 15, 2017
Publication date	Apr 11, 2023
Grant date	Apr 11, 2023

Abstract

Catalyst particles and methods for making same are disclosed herein. The catalyst particles can include a ceramic support containing silica and alumina. The ceramic support can have a macropore concentration of about 15% to about 45%, a mesopore concentration of about 20% to 50%, and a micropore concentration of about 8% to about 30% based on the total pore volume of the ceramic support. The ceramic support can also have a surface area of about 0.5 m 2 /g to about 50 m 2 /g. The catalyst particles can have a long term permeability at 7,500 psi of at least about 10 D in accordance with ISO 13503-5.

First claim

What is claimed is:

1. A catalyst particle, comprising:
a ceramic support comprising silica and alumina, the ceramic support having
a macropore concentration of about 15% to about 45%,
a mesopore concentration of about 20% to 50%, and
a micropore concentration of about 8% to about 30% based on the total pore volume of the ceramic support, and
a surface area of about 0.5 m 2 /g to about 50 m 2 /g; and

a catalytic metal deposited on the ceramic support.

2. The catalyst particle of claim 1 , wherein the catalyst support has a long term permeability at 7,500 psi of at least about 10 D in accordance with ISO 13503-5.

3. The catalyst particle of claim 1 , wherein the catalytic metal comprises any one or more of the elements selected from Groups 4-10 of the IUPAC Periodic Table.

4. The catalyst particle of claim 3 , wherein the catalytic metal is a base metal selected from the group consisting of vanadium, molybdenum, tungsten, cobalt, nickel, platinum, and palladium and any combination thereof.

5. The catalyst particle of claim 4 , wherein the catalytic metal is deposited onto walls of pores and channels contained in the ceramic support.

6. The catalyst particle of claim 1 , wherein the ceramic support further comprises: a density of about 1.7 to about 2.7 g/cc; a porosity of about 15% to about 35%; and an average largest pore size of less than about 25.

7. The catalyst particle of claim 1 , wherein the ceramic support has a silica to alumina ratio of about 0.8:1 to about 1.2:1.

8. The catalyst particle of claim 1 , wherein:
the catalytic metal is selected from the group consisting of vanadium, molybdenum, tungsten, cobalt, nickel, platinum, and palladium and any combination thereof, and
the ceramic support has a density of about 1.7 to about 2.7 g/cc.

9. The catalyst particle of claim 1 , wherein:
the catalytic metal is selected from the group consisting of vanadium, molybdenum, tungsten, cobalt, nickel, platinum, and palladium and any combination thereof, and
the ceramic support has an average largest pore size of less than about 25.

10. The catalyst particle of claim 1 , wherein:
the catalytic metal is selected from the group consisting of vanadium, molybdenum, tungsten, cobalt, nickel, platinum, and palladium and any combination thereof, and
the ceramic support has a silica to alumina ratio of about 0.8:1 to about 1.2:1.

11. A catalyst particle, comprising:
a ceramic support comprising silica and alumina, the ceramic support having
a macropore concentration of about 15% to about 45%,
a mesopore concentration of about 20% to 50%, and
a micropore concentration of about 8% to about 30% based on the total pore volume of the ceramic support, and
a surface area of about 0.5 m 2 /g to about 50 m 2 /g; and

a zeolitic material deposited on the ceramic support.

12. The catalyst particle of claim 11 , wherein the catalyst particle has a long term permeability at 7,500 psi of at least about 10 D in accordance with ISO 13503-5.

13. The catalyst particle of claim 11 , wherein the zeolitic material comprises ZSM-5, zeolite X, zeolite Y, or SAPO-41.

14. The catalyst particle of claim 11 , wherein the zeolitic material comprises mordenite.

15. The catalyst particle of claim 11 , wherein the catalyst particle has a surface area of about 100 m 2 /g to about 300 m 2 /g.

16. The catalyst particle of claim 11 , wherein the ceramic support has:
a density of about 1.7 to about 2.7 g/cc;
a porosity of about 15% to about 35%; and
an average largest pore size of less than about 25 μm.

17. The catalyst particle of claim 11 , wherein the ceramic support has a silica to alumina ratio of about 0.8:1 to about 1.2:1.

18. The catalyst particle of claim 11 , wherein:
the zeolitic material comprises ZSM-5, zeolite X, zeolite Y, or SAPO-41, and
the catalyst particle has a surface area of about 100 m 2 /g to about 300 m 2 /g.

19. The catalyst particle of claim 11 , wherein:
the ceramic support has a silica to alumina ratio of about 0.8:1 to about 1.2:1, and
the catalyst particle has a surface area of about 100 m 2 /g to about 300 m 2 /g.

Assignees

• Carbo Ceramics Inc

Inventors

• Savoy Steve
• Mitchell Daniel R
• Zollars Byron
• Cannan Chad
• Roper Todd

Classifications

• C09K8/62

  Compositions for forming crevices or fractures · CPC title

• C09K8/805 Primary

  Coated proppants · CPC title

• B01J21/12

  Silica and alumina · CPC title

• E21B43/04

  Gravelling of wells · CPC title

• E21B43/267

  reinforcing fractures by propping · CPC title