Metal foam supported catalyst and method for the production thereof

Patent metadata

Field	Value
Publication number	US-2022395816-A1
Application number	US-202017762732-A
Country	US
Kind code	A1
Filing date	Sep 25, 2020
Priority date	Sep 25, 2019
Publication date	Dec 15, 2022
Grant date	—

Abstract

The invention relates to methods for producing supported catalysts, comprising: providing a metal foam element A made of nickel; applying an aluminum-containing powder MP to metal foam element A, such that metal foam element AX is obtained; thermally treating metal foam element AX in order to form an alloy between metal foam element A and the aluminum-containing powder MP, such that metal foam element B is obtained; oxidatively treating metal foam element B, such that metal foam element C is obtained; and applying a catalytically active layer, comprising at least one carrier oxide and at least one catalytically active component, to at least one part of the surface of metal foam element C, such that a supported catalyst is obtained. The invention also relates to the supported catalysts obtained according to the method, and to the use thereof 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 consisting of metallic nickel; (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 the range from 680 to 715° C. and the total duration of thermal treatment in the 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 a 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 680° 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 680° 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 680° 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 680° 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 19 , 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 680° 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

• B22F2003/242

  Coating · CPC title

• B22F3/114

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

• B22F7/04

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

• B22F3/1143

  involving an oxidation, reduction or reaction step · CPC title

• B22F2007/045

  accompanied by fusion or impregnation · CPC title