Method of using a sulfur-tolerant catalyst

Patent metadata

Field	Value
Publication number	US-11839868-B2
Application number	US-202117459984-A
Country	US
Kind code	B2
Filing date	Aug 27, 2021
Priority date	Sep 22, 2015
Publication date	Dec 12, 2023
Grant date	Dec 12, 2023

Abstract

Disclosed in certain embodiments is a sulfur tolerant catalytic system that includes a catalytic material coated onto a substrate. Certain embodiments are directed to a method of preparing a sulfur-tolerant catalyst.

First claim

What is claimed is:

1. A method comprising:
providing a catalytic system, wherein the catalytic system comprises:
a catalytic material comprising:
an active precious metal component comprising platinum; and
a sulfur-tolerant support material comprising silica and zirconia mixture; and

a substrate having the catalytic material coated thereon;

placing the catalytic system in a stream containing carbon monoxide and high sulfur levels of at least 0.1 ppm of sulfur; and
aging the stream containing the high sulfur levels with the catalytic system, wherein the aging results in a carbon monoxide conversion greater than 80% after aging the stream for 1500 hours.

2. The method of claim 1 , wherein at least 50% of the sulfur-tolerant support material is amorphous.

3. The method of claim 1 , wherein the carbon monoxide conversion is greater than 80% after aging the stream for 3300 hours.

4. The method of claim 1 , wherein the substrate comprises a ceramic or a metal foil.

5. The method of claim 1 , wherein the stream containing high sulfur levels comprises from 0.1 to 500 ppm of sulfur.

6. The method of claim 1 , wherein the platinum is present in an amount from 0.4 wt % to 5.0 wt % of a total weight of the catalytic material.

7. The method of claim 1 , wherein the active precious metal component further comprises palladium, wherein the palladium is present in an amount of from about 0.1 wt % to 5.0 wt % of a total weight of the catalytic material.

8. The method of claim 1 , wherein the sulfur-tolerant support is present in an amount from 90 wt % to 98 wt % of a total weight of the catalytic material.

9. The method of claim 1 , wherein the silica to zirconia ratio in the sulfur-tolerant support material ranges from 1:4 to 1:98.

10. The method of claim 1 , wherein the catalytic system further comprises bulk ceria.

11. The method of claim 10 , wherein the bulk ceria is present in an amount from 0.5 wt % to 10 wt % of a total weight of the catalytic material.

12. The method of claim 1 , wherein the catalytic material is in a form of particles, and wherein 90% of the particles have a particle size ranging from about 6 micrometers to about 14 micrometers.

13. A method comprising:
providing a catalytic system, wherein the catalytic system comprises:
a catalytic material comprising:
an active precious metal component comprising platinum; and
a sulfur-tolerant support material comprising silica and zirconia mixture, wherein the silica to zirconia ratio in the sulfur-tolerant support material ranges from 1:4 to 1:98; and

a substrate having the catalytic material coated thereon;

placing the catalytic system in a stream containing carbon monoxide and high sulfur levels of at least about 0.1 ppm of sulfur; and
aging the stream containing the high sulfur levels with the catalytic system, wherein the aging results in a carbon monoxide conversion greater than 80%.

14. A method comprising:
providing a catalytic system, wherein the catalytic system comprises:
a catalytic material comprising:
an active precious metal component comprising platinum; and
a sulfur-tolerant support material comprising silica and zirconia mixture, wherein the catalytic material is in the form of particles, and wherein 90% of the particles have a particle size ranging from about 6 micrometers to about 14 micrometers; and

a substrate having the catalytic material coated thereon;

placing the catalytic system in a stream containing carbon monoxide and high sulfur levels of at least about 0.1 ppm of sulfur; and
aging the stream containing the high sulfur levels with the catalytic system, wherein the aging results in a carbon monoxide conversion greater than 80%.

Assignees

• Basf Corp

Inventors

• Lapadula Gerard D
• Pham Tiep M
• Durilla Michael
• Tran Pascaline Harrison

Classifications

• B01J2235/00

  Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties · CPC title

• B01J23/63 Primary

  with rare earths or actinides · CPC title

• B01D53/944

  Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts (three-way-catalysts [TWC] B01D53/9445) · CPC title

• B01J21/04

  Alumina · CPC title

• B01J21/066

  Zirconium or hafnium; Oxides or hydroxides thereof · CPC title