Method for producing catalyst fibrous structure

Patent metadata

Field	Value
Publication number	US-2017304814-A1
Application number	US-201515520640-A
Country	US
Kind code	A1
Filing date	Nov 17, 2015
Priority date	Nov 20, 2014
Publication date	Oct 26, 2017
Grant date	—

Abstract

A catalyst fibrous structure having a catalyst metal carried on a fibrous structure, wherein (a) a Log differential micropore volume distribution curve thereof obtained by measurement using a mercury intrusion technique has a peak having a maximum micropore diameter in the range of from 0.1 μm to 100 μm; (b) a Log differential micropore volume at the peak is 0.5 mL/g or more; and (c) an amount of a catalyst metal compound and a binder carried per unit volume is 0.05 g/mL or more. A production method for producing a catalyst fibrous structure having: (1) mixing a catalyst metal compound or a catalyst precursor, and an inorganic binder and a solvent; (2) grinding the mixture to obtain a coating material of the catalyst metal compound or the catalyst precursor having a median particle diameter of 2 μm or less and a viscosity of from 10 mPa·s to 200 mPa·s; (3) impregnating a fibrous structure with the coating material to fill up voids of the fibrous structure with the coating material of the catalyst metal compound or the catalyst precursor; (4) heating and drying the fibrous structure, directly as it is, at a temperature not lower than the boiling point of the solvent; and (5) heating and calcination the dried fibrous structure at a temperature not lower than the dehydration temperature of the inorganic binder to obtain a catalyst fibrous structure.

First claim

1 - 19 . (canceled)

20 . A catalyst fibrous structure having a catalyst metal carried on a fibrous structure, which satisfies all the following requirements (a), (b) and (c):
(a) a Log differential micropore volume distribution curve thereof obtained by measurement using a mercury intrusion technique has its maximum peak at a micropore diameter in the range of from 0.1 μm to 100 μm, (b) a Log differential micropore volume at the peak is 0.5 mL/g or more, and (c) an amount of a catalyst metal compound and a binder carried per unit volume is from 0.05 g/mL to 0.6 g/mL, wherein the fibrous structure is a fiber sheet, and wherein the fibrous structure comprises at least one type selected from silica fibers, alumina fibers, glass fibers and carbon fibers, or mixed fibers of a combination of two or more types selected from silica fibers, alumina fibers, glass fibers and carbon fibers.

21 . The catalyst fibrous structure according to claim 20 , wherein the peak appears in the range of from 1 μm to 70 μm.

22 . The catalyst fibrous structure according to claim 20 , wherein the Log differential micropore volume at the peak is 0.7 mL/g or more.

23 . The catalyst fibrous structure according to claim 20 , wherein the amount of the catalyst metal carried per unit volume of the catalyst fibrous structure is from 0.1 g/mL to 0.6 g/mL.

24 . A production method for a catalyst fibrous structure comprising the following steps (1) to (5):
(1) a step of mixing a catalyst metal compound or a catalyst precursor, and an inorganic binder and a solvent; (2) a step of grinding the obtained mixture to provide a coating material of the catalyst metal compound or the catalyst precursor having a median particle diameter of 2 μm or less, a viscosity of from 30 mPa·s to 200 mPa·s and a solid content of from 20% by mass to 40% by mass; (3) a step of impregnating a fibrous structure with the obtained coating material of the catalyst metal compound or the catalyst precursor to fill up voids of the fibrous structure with the coating material of the catalyst metal compound or the catalyst precursor; (4) a step of heating and drying the obtained fibrous structure filled up with the coating material of the catalyst metal compound or the catalyst precursor, at a temperature not lower than the boiling point of the solvent; and (5) a step of heating and calcination the dried fibrous structure having the catalyst metal compound or the catalyst precursor adhered thereto at a temperature not lower than the dehydration temperature of the inorganic binder to provide a catalyst fibrous structure, wherein the fibrous structure is a fiber sheet comprising at least one type selected from metal oxide fibers, glass fibers and carbon fibers.

25 . The production method according to claim 24 , wherein the catalyst metal compound or the catalyst precursor is a powdery catalyst metal carried by a porous material.

26 . The production method according to claim 24 , wherein the inorganic binder is at least one selected from alumina, silica, titania, zirconia and ceria.

27 . The production method according to claim 24 , wherein the porosity of the fibrous structure is from 30% to 99%.

28 . The production method according to claim 24 , wherein the micropore volume per unit mass of the fibrous structure is from 0.1 mL/g to 10 mL/g.

29 . The production method according to claim 24 , wherein the amount of the metal compound and the binder carried per unit volume of the catalyst fibrous structure is 0.05 g/mL or more.

30 . The production method according to claim 24 , including a step of removing the excess catalyst coating material adhering to the surface of the fibrous structure, after the impregnation.

31 . The production method according to claim 24 , wherein the fibrous structure is compressed during heating and drying and the compression ratio (apparent volume before compression/apparent volume after compression) is larger than 1.0 and 2.5 or less.

32 . The production method according to claim 24 , wherein the coating material of the catalyst metal compound or the catalyst precursor contains a surfactant.

33 . The production method according to claim 24 , wherein, in the total amount of the catalyst metal compound or the catalyst precursor and the binder, the catalyst metal compound or the catalyst precursor accounts for from 70% by mass to 90% by mass and the binder accounts for from 10% by mass to 30% by mass therein.

34 . The production method according to claim 24 , wherein the temperature in the heating and drying step is, relative to the boiling point (Tb)° C. of the solvent, (Tb+10)° C. or higher, and is (Tb+80)° C. or lower.

Assignees

• Kao Corp

Inventors

• Homma Taichi
• Kodama Satoshi
• Matsui Kunio
• Okada Nobuhiko

Classifications

• B01J37/14

  with gases containing free oxygen · CPC title

• B01J23/8926

  Copper and noble metals · CPC title

• B01J37/0248

  Coatings comprising impregnated particles · CPC title

• B01J37/0246

  Coatings comprising a zeolite · CPC title

• C10G2300/202

  Heteroatoms content, i.e. S, N, O, P · CPC title