Catalyst structure and method for producing same, and method for producing hydrocarbon by use of catalyst structure

Patent metadata

Field	Value
Publication number	US-12145138-B2
Application number	US-201917299646-A
Country	US
Kind code	B2
Filing date	Dec 3, 2019
Priority date	Dec 3, 2018
Publication date	Nov 19, 2024
Grant date	Nov 19, 2024

Abstract

A catalyst structure that allows prevention of aggregation of fine particles of a functional material, suppresses decrease of catalyst activity, and thus enables the extension of the lifetime of the catalyst structure. A catalyst structure is provided with: a support that is formed from a zeolite-type compound and has a porous structure; and at least one functional material present in the support. The functional material includes a first element that is at least one metallic element selected from the group consisting of cobalt, nickel, and iron. The support has paths connected to each other. The functional material including the first element is present in at least the paths of the support.

First claim

The invention claimed is:

1. A catalyst structure comprising:
a support that has a porous structure and comprises a zeolite-type compound; and
a functional material present in the support, wherein
the functional material comprises a first metal element selected from the group consisting of cobalt (Co), nickel (Ni), and iron (Fe),
a total content of the first metal element is 0.5% by mass or more with respect to the mass of the catalyst structure,
the support has channels communicating with one another,
the channels have any one of a one-dimensional pore, a two-dimensional pore, a three-dimensional pore of a framework structure of the zeolite-type compound, and an enlarged pore portion which is not defined by the framework structure of the zeolite-type compound and has a diameter greater than any one of the one-dimensional pore, the two-dimensional pore and the three-dimensional pore,
the enlarged pore portion has a greater diameter than the functional material,
the functional material has a diameter greater than any one of the one-dimensional pore, the two-dimensional pore and the three-dimensional pore,
the functional material is present at least in the channels of the support,
the functional material includes metal or metal oxide nanoparticles, and
the framework structure of the zeolite-type compound is selected from the group consisting of FAU type, MTW type, MFI type, FER type, LTA type, MWW type, MOR type, LTL type, and BEA type.

2. The catalyst structure according to claim 1 , wherein the functional material further comprises a second metal element selected from the group consisting of platinum (Pt), palladium (Pd), gold (Au), copper (Cu), ruthenium (Ru), iridium (Ir), rhodium (Rh), and osmium (Os).

3. The catalyst structure according to claim 1 , wherein the functional material is in the form of a metal oxide particle comprising at least an oxide of the first metal element.

4. The catalyst structure according to claim 1 , wherein the functional material is in the form of a metal particle comprising at least the first metal element.

5. The catalyst structure according to claim 2 , wherein the functional material comprises one or both of: alloy particles comprising the first metal element and the second metal element; and at least two types of single metal particles comprising particles of the first metal element and particles of the second metal element.

6. A catalyst structure comprising:
a support that has a porous structure and comprises a zeolite-type compound; and
a functional material present in the support, wherein
the functional material comprises a first metal element selected from the group consisting of cobalt (Co), nickel (Ni), and iron (Fe),
the support has channels communicating with one another,
the channels have any one of a one-dimensional pore, a two-dimensional pore, a three-dimensional pore of a framework structure of the zeolite-type compound, and an enlarged pore portion which is not defined by the framework structure of the zeolite-type compound and has a diameter greater than any one of the one-dimensional pore, the two-dimensional pore and the three-dimensional pore,
the enlarged pore portion has a greater diameter than the functional material,
the functional material has a diameter greater than any one of the one-dimensional pore, the two-dimensional pore and the three-dimensional pore,
the functional material is present at least in the channels of the support,
the functional material includes metal or metal oxide nanoparticles,
the framework structure of the zeolite-type compound is selected from the group consisting of FAU type, MTW type, MFI type, FER type, LTA type, MWW type, MOR type, LTL type, and BEA type,
the functional material further comprises a second metal element selected from the group consisting of platinum (Pt), palladium (Pd), gold (Au), copper (Cu), ruthenium (Ru), iridium (Ir), rhodium (Rh), and osmium (Os), and
a content of the second metal element is lower than a first metal element content.

7. The catalyst structure according to claim 2 , wherein a total content of the second metal element is 0.00005% by mass or more with respect to the mass of the catalyst structure.

8. The catalyst structure according to claim 1 , wherein the functional material is present at least in the enlarged pore portion.

9. The catalyst structure according to claim 8 , wherein the enlarged pore portion connects a plurality of pores constituting one of the one-dimensional pore, the two-dimensional pore and the three-dimensional pore.

10. The catalyst structure according to claim 8 , wherein the functional material has an average particle size larger than an average inner diameter of the channels and equal to or smaller than an inner diameter of the enlarged pore portion.

11. The catalyst structure according to claim 1 , wherein the functional material has an average particle size of 0.08 nm to 30 nm.

12. The catalyst structure according to claim 1 , wherein the ratio of the average particle size of the functional material to the average inner diameter of the channels is from 0.05 to 300.

13. The catalyst structure according to claim 1 , wherein the channels have an average inner diameter of 0.1 nm to 1.5 nm.

14. The catalyst structure according to claim 8 , wherein the enlarged pore portion has an inner diameter of 0.5 nm to 50 nm.

15. A catalyst structure comprising:
a support that has a porous structure and comprises a zeolite-type compound;
a functional material present in the support; and
an additional functional material held on an outer surface of the support, wherein
the functional material comprises a first metal element selected from the group consisting of cobalt (Co), nickel (Ni), and iron (Fe),
the support has channels communicating with one another,
the channels have any one of a one-dimensional pore, a two-dimensional pore, a three-dimensional pore of a framework structure of the zeolite-type compound, and an enlarged pore portion which is not defined by the framework structure of the zeolite-type compound and has a diameter greater than any one of the one-dimensional pore, the two-dimensional pore and the three-dimensional pore,
the enlarged pore portion has a greater diameter than the functional material
the functional material has a diameter greater than any one of the one-dimensional pore, the two-dimensional pore and the three-dimensional pore,
the functional material is present at least in the channels of the support,
the functional material includes metal or metal oxide nanoparticles, and
the framework structure of the zeolite-type compound is selected from the group consisting of FAU type, MTW type, MFI type, FER type, LTA type, MWW type, MOR type LTL type, and BEA type.

16. The catalyst structure according to claim 15 , wherein the additional functional material comprises one or more metals selected from the group consisting of cobalt (Co), nickel (Ni), and iron (Fe), or an alloy thereof.

17. The catalyst structure according to claim 15 , wherein the additional functional material comprises one or more metals selected from the group consisting of platinum (Pt), palladium (Pd), gold (Au), copper (Cu), ruthenium (Ru), iridium (Ir), rhodium (Rh), and osmium (Os), or an alloy thereof.

18. The catalyst structure according to claim 15 , wherein the content of the functional material presented in the support is higher than the content of the additional functional material held on the outer surface of the support.

19. The catalyst structure according to

Assignees

• Furukawa Electric Co Ltd

Inventors

• Nakai Yukako
• BANBA Yuichiro
• Sekine Kaori
• NISHII Mai
• Fukushima Masayuki
• Kato Sadahiro
• Masuda Takao
• Nakasaka Yuta
• Yoshikawa Takuya

Classifications

• B01J35/45

  Nanoparticles · CPC title

• B01J29/24

  Iron group metals or copper · CPC title

• B01J29/22

  Noble metals · CPC title

• B01J29/7615

  Zeolite Beta · CPC title

• B01J29/7415

  Zeolite Beta · CPC title