Catalyst manufacturing method

Patent metadata

Field	Value
Publication number	US-9278338-B2
Application number	US-201113821443-A
Country	US
Kind code	B2
Filing date	Aug 22, 2011
Priority date	Sep 8, 2010
Publication date	Mar 8, 2016
Grant date	Mar 8, 2016

Abstract

A method for producing a catalyst using an additive layer method includes:
(i) forming a layer of a powdered catalyst or catalyst support material, (ii) binding or fusing the powder in said layer according to a predetermined pattern, (iii) repeating (i) and (ii) layer upon layer to form a shaped unit, and (iv) optionally applying a catalytic material to said shaped unit.

First claim

The invention claimed is:

1. A method for producing a particulate catalyst with a cross-sectional size in the range 1-50 mm and an aspect ratio in the range 0.5 to 5 using a 3D printing additive layer method comprising:
(i) forming a layer of a powdered catalyst support material comprising an alumina, metal-aluminate, silica, alumino-silicate, titania, zirconia, zinc oxide, or a mixture thereof,
(ii) binding the powder in said layer according to a predetermined pattern,
(iii) repeating (i) and (ii) layer upon layer to form a shaped unit, and
(iv) applying a catalytic material to said shaped unit.

2. A method according to claim 1 wherein the catalytic material applied to the shaped unit comprises a metal, metal compound or a zeolite.

3. A method according to claim 2 wherein the metal, metal compound or zeolite is applied to the shaped unit from a solution or dispersion of the metal, metal compound or zeolite.

4. A method according to claim 3 wherein the metal or metal compound comprises one or more metals selected from the group consisting of Na, K, Mg, Ca, Ba, Al, Si, Ti V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Ru, Rh, Pd, Ag, Sn, Sb, La, Hf, W, Re, Ir, Pt, Au, Pb, or Ce.

5. A method according to claim 1 wherein the powdered material has an average particle size, D 50 , in the range 1 to 200 micrometers.

6. A method according to claim 1 wherein the powder in each layer is bound together with a binder.

7. A method according to claim 6 wherein a burnout additive is included in the catalyst powder or binder to control the porosity of the resulting shaped unit.

8. A method according to claim 1 wherein the shaped unit is subjected to a heating step.

9. A method according to claim 1 wherein the shaped unit, comprising one or more reducible metal compounds, is subjected to a reduction step.

10. A method according to claim 1 wherein the shaped unit is a wire-frame structure or a skeletal framework containing a void space within which may have multiple internal strengthening rods.

11. A catalyst obtained by the method of claim 1 .

12. A method according to claim 1 wherein the shaped unit is a solid unit, comprising through holes.

Assignees

• Coupland Duncan Roy
• Johnson Matthey Plc

Inventors

• Coupland Duncan Roy

Classifications

• B01D2255/2092

  Aluminium · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B01J23/10

  of rare earths · CPC title

• Y10T428/2982

  Particulate matter [e.g., sphere, flake, etc.] · CPC title

• B01J37/16

  Reducing · CPC title