Metal foam element containing cobalt and method for producing same

Patent metadata

Field	Value
Publication number	US-2022362757-A1
Application number	US-202017762730-A
Country	US
Kind code	A1
Filing date	Sep 25, 2020
Priority date	Sep 25, 2019
Publication date	Nov 17, 2022
Grant date	—

Abstract

The present invention relates to a method for producing supported catalysts, comprising: providing a metal foam element A, which consists of metallic cobalt, an alloy of nickel and cobalt, or an arrangement of layers of nickel and cobalt, lying one over the other; applying an aluminum-containing powder MP to metal foam element A in order to obtain metal foam element AX; thermally treating metal foam element AX to achieve alloy formation between metal foam element A and aluminum-containing powder MP, in order to obtain metal foam element B; oxidatively treating metal foam element B, in order to obtain metal foam element C; and applying a catalytically active layer, comprising at least one support oxide and at least one catalytically active component, to at least part of the surface of metal foam element C, in order to obtain a supported catalyst. The present invention further relates to the supported catalysts that can be obtained using the method and to the use of said supported catalysts in chemical transformations.

First claim

1 - 12 . (canceled)

13 . A process for producing a supported catalyst, comprising the following steps:
(a) providing a metal foam body A made of metallic cobalt, an alloy of nickel and cobalt, or overlying layers of nickel and cobalt; (b) applying an aluminum-containing powder MP to metal foam body A so as to obtain metal foam body AX; (c) treating metal foam body AX thermally to achieve alloy formation between metal foam body A and aluminum-containing powder MP so as to obtain metal foam body B;
wherein the maximum temperature in the thermal treatment of metal foam body AX is within a range from 680 to 715° C. and the total duration of thermal treatment in a temperature range from 680 to 715° C. is between 5 and 240 seconds;
(d) oxidatively treating metal foam body B so as to obtain metal foam body C; (e) applying a catalytically active layer comprising at least one support oxide and at least one catalytically active component to at least part of the surface of metal foam body C so as to obtain the supported catalyst.

14 . The process of claim 13 , wherein the oxidative treatment of metal foam body B in step (d) is selected from the following:
heating of metal foam body B while in contact with an oxidizing gas atmosphere without prior formation of aluminum hydroxide on the surface of the metal foam body; heating of metal foam body B while in contact with an oxidizing gas atmosphere after aluminum hydroxide has previously been formed on the surface of the metal foam body.

15 . The process of claim 13 , wherein, for the oxidative treatment of metal foam body B in step (d), metal foam body B is heated while in contact with an oxidizing gas atmosphere without prior formation of aluminum hydroxide on the surface of the metal foam body.

16 . The process of claim 15 , wherein the heating while in contact with an oxidizing gas atmosphere is carried out for a period of 1 to 60 minutes at a temperature of 200° C. to 700° C. in air.

17 . The process of claim 13 , wherein, for the oxidative treatment of metal foam body B in step (d), metal foam body B is heated while in contact with an oxidizing gas atmosphere after aluminum hydroxide has been formed on the surface of the metal foam body.

18 . The process of claim 17 , wherein aluminum hydroxide is formed on the surface by contacting the metal foam body with an aqueous alkali solution.

19 . The process of claim 18 , wherein the aqueous alkali solution contains sodium hydroxide, potassium hydroxide, lithium hydroxide or combinations thereof, and the metal foam body is contacted with the aqueous alkali solution for a period of not more than 30 minutes.

20 . The process of claim 17 , wherein the heating while in contact with an oxidizing gas atmosphere is carried out for a period of 1 to 60 minutes at a temperature of 200° C. to 700° C. in air.

21 . The process of claim 13 , wherein the support oxide of the catalytically active layer applied in step (e) is selected from the group consisting of: aluminum oxide, silicon dioxide, titanium oxide, and mixtures thereof.

22 . The process of claim 13 , wherein the catalytically active component is a transition metal or transition metal compound, the transition metal being selected from the group consisting of: iron, ruthenium, osmium, cobalt, rhodium, iridium, nickel, palladium, platinum, cerium, copper, silver, gold, and mixtures thereof.

23 . The process of claim 14 , wherein, for the oxidative treatment of metal foam body B in step (d), metal foam body B is heated while in contact with an oxidizing gas atmosphere without prior formation of aluminum hydroxide on the surface of the metal foam body.

24 . The process of claim 23 , wherein the heating while in contact with an oxidizing gas atmosphere is carried out for a period of 1 to 60 minutes at a temperature of 200° C. to 700° C. in air.

25 . The process of claim 14 , wherein, for the oxidative treatment of metal foam body B in step (d), metal foam body B is heated while in contact with an oxidizing gas atmosphere after aluminum hydroxide has been formed on the surface of the metal foam body.

26 . The process of claim 25 , wherein aluminum hydroxide is formed on the surface by contacting the metal foam body with an aqueous alkali solution.

27 . The process of claim 26 , wherein the aqueous alkali solution contains sodium hydroxide, potassium hydroxide, lithium hydroxide or combinations thereof, and the metal foam body is contacted with the aqueous alkali solution for a period of not more than 30 minutes.

28 . The process of claim 27 , wherein the heating while in contact with an oxidizing gas atmosphere is carried out for a period of 1 to 60 minutes at a temperature of 200° C. to 700° C. in air.

29 . The process of claim 28 , wherein the support oxide of the catalytically active layer applied in step (e) is selected from the group consisting of: aluminum oxide, silicon dioxide, titanium oxide, and mixtures thereof.

30 . The process of claim 29 , wherein the catalytically active component is a transition metal or transition metal compound, the transition metal being selected from the group consisting of: iron, ruthenium, osmium, cobalt, rhodium, iridium, nickel, palladium, platinum, cerium, copper, silver, gold, and mixtures thereof.

31 . The process of claim 18 , wherein:
a) the heating while in contact with an oxidizing gas atmosphere is carried out for a period of 1 to 60 minutes at a temperature of 200° C. to 700° C. in air; b) the support oxide of the catalytically active layer applied in step (e) is selected from the group consisting of: aluminum oxide, silicon dioxide, titanium oxide, and mixtures thereof; and c) the catalytically active component is a transition metal or transition metal compound, the transition metal being selected from the group consisting of: iron, ruthenium, osmium, cobalt, rhodium, iridium, nickel, palladium, platinum, cerium, copper, silver, gold, and mixtures thereof.

32 . A supported catalyst obtainable by the process of claim 13 .

Assignees

• Evonik Operations Gmbh

Inventors

• Poss René
• Roos Meike
• Berweiler Monika
• Glaser Maximilian

Classifications

• B22F3/1146

  After-treatment maintaining the porosity (B22F3/114 takes precedence) · CPC title

• B01J37/024

  Multiple impregnation or coating · CPC title

• B22F7/04

  with one or more layers not made from powder, e.g. made from solid metal · CPC title

• B01J37/0205

  in several steps · CPC title

• B22F3/114

  the porous products being formed by impregnation (B22F3/1137, B22F3/26 take precedence) · CPC title