Use of lanthanide oxides to reduce sintering of catalysts

Patent metadata

Field	Value
Publication number	US-9314771-B2
Application number	US-201414312105-A
Country	US
Kind code	B2
Filing date	Jun 23, 2014
Priority date	Jul 11, 2013
Publication date	Apr 19, 2016
Grant date	Apr 19, 2016

Abstract

Disclosed is a lanthanide oxide coated catalyst, and methods for its use, that includes a supported catalyst comprising a support material, a catalytic material, and a lanthanide oxide, wherein the lanthanide oxide is attached to at least a portion of the surface of the supported catalyst.

First claim

The invention claimed is:

1. A lanthanide oxide coated catalyst comprising:
(a) a supported catalyst comprising a support material and a catalytic material; and
(b) a lanthanide oxide,
wherein the lanthanide oxide is attached to at least a portion of the surface of the supported catalyst, and
wherein the coated catalyst has the structure of 10 wt % CeO 2 /2 wt % Pt/Al 2 O 3 , 8 wt % CeO 2 /2 wt % Pt/Al 2 O 3 , 5 wt % CeO 2 /2 wt % Pt/Al 2 O 3 , or 2 wt % CeO 2 /2 wt % Pt/Al 2 O 3 .

2. The lanthanide oxide coated catalyst of claim 1 , wherein the weight ratio of the lanthanide oxide to the supported catalyst is from 5:100 to 20:100.

3. The lanthanide oxide coated catalyst of claim 1 , comprising 99 to 50% by weight of the support material.

4. The lanthanide oxide coated catalyst of claim 1 , wherein the coated catalyst is in particulate form.

5. The lanthanide oxide coated catalyst of claim 4 , wherein the particle size of the coated catalyst ranges from 5 to 1000 μm.

6. The lanthanide oxide coated catalyst of claim 1 , wherein coated catalyst is in non-powdered form or has a fabricated geometry.

7. The lanthanide oxide coated catalyst of claim 6 , wherein the fabricated geometry is a pellet, foam, honeycomb, or monolith.

8. The lanthanide oxide coated catalyst of claim 1 , wherein the lanthanide oxide is dispersed on the surface of the supported catalyst.

9. The lanthanide oxide coated catalyst of claim 1 , wherein the coated catalyst is capable of reducing sintering of the catalytic metal when subjected to temperatures at a range of greater than 700° C. to 1100° C.

10. The lanthanide oxide coated catalyst of claim 1 , wherein the coated catalyst is capable of catalyzing the production of a gaseous mixture comprising hydrogen and carbon monoxide from a hydrocarbon gas.

11. The lanthanide oxide coated catalyst of claim 10 , wherein the hydrocarbon gas is methane.

12. The lanthanide oxide coated catalyst of claim 1 , wherein the supported catalyst is a calcined supported catalyst.

13. A method of reducing or preventing sintering of a supported catalyst during use, the supported catalyst comprising the lanthanide oxide catalyst of claim 1 , the method comprising grafting the lanthanide oxide to at least a portion of the surface of the supported catalyst in an amount sufficient to reduce or prevent sintering of the supported catalyst during use when compared with a supported catalyst that does not include the lanthanide oxide.

14. A method of producing a gaseous mixture comprising contacting a reactant gas mixture comprising a hydrocarbon and an oxidant with the lanthanide oxide coated catalyst of claim 1 under conditions sufficient to produce a gaseous mixture comprising hydrogen and carbon monoxide.

15. A method of catalytically reforming a reactant gas mixture comprising:
(a) providing a reactant gas mixture comprising a hydrocarbon and an oxidant;
(b) providing the lanthanide oxide coated catalyst of claim 1 ; and
(c) contacting the reactant gas mixture with the lanthanide oxide coated catalyst under conditions sufficient to produce a gaseous mixture comprising carbon monoxide and hydrogen.

16. A lanthanide oxide coated catalyst comprising:
(a) a supported catalyst comprising a support material and a catalytic material; and
(b) a lanthanide oxide,
wherein the lanthanide oxide is attached to at least a portion of the surface of the supported catalyst, and
wherein the coated catalyst has the structure of 10 wt % CeO 2 /2 wt % Pt/MgAl 2 O 4 , 8 wt % CeO 2 /2 wt % Pt/MgAl 2 O 4 , 5 wt % CeO 2 /2 wt % Pt/MgAl 2 O 4 , or 2 wt % CeO 2 /2 wt % Pt/MgAl 2 O 4 .

17. The lanthanide oxide coated catalyst of claim 16 , wherein the weight ratio of the lanthanide oxide to the supported catalyst is from 5:100 to 20:100.

18. The lanthanide oxide coated catalyst of claim 16 , comprising 99 to 50% by weight of the support material.

19. The lanthanide oxide coated catalyst of claim 16 , wherein the coated catalyst is in particulate form.

20. The lanthanide oxide coated catalyst of claim 16 , wherein coated catalyst is in non-powdered form or has a fabricated geometry.

21. The lanthanide oxide coated catalyst of claim 20 , wherein the fabricated geometry is a pellet, foam, honeycomb, or monolith.

22. The lanthanide oxide coated catalyst of claim 16 , wherein the lanthanide oxide is dispersed on the surface of the supported catalyst.

23. The lanthanide oxide coated catalyst of claim 16 , wherein the coated catalyst is capable of reducing sintering of the catalytic metal when subjected to temperatures at a range of greater than 700° C. to 1100° C.

24. The lanthanide oxide coated catalyst of claim 16 , wherein the coated catalyst is capable of catalyzing the production of a gaseous mixture comprising hydrogen and carbon monoxide from a hydrocarbon gas.

25. A lanthanide oxide coated catalyst comprising:
(a) a supported catalyst comprising a support material and a catalytic material; and
(b) a lanthanide oxide,
wherein the lanthanide oxide is attached to at least a portion of the surface of the supported catalyst, and
wherein the coated catalyst has the structure of 10 wt % CeO 2 /2 wt % Pt/kaolinite, 8 wt % CeO 2 /2 wt % Pt/kaolinite, 5 wt % CeO 2 /2 wt % Pt/kaolinite, or 2 wt % CeO 2 /2 wt % Pt/kaolinite.

26. The lanthanide oxide coated catalyst of claim 25 , wherein the weight ratio of the lanthanide oxide to the supported catalyst is from 5:100 to 20:100.

27. The lanthanide oxide coated catalyst of claim 25 , comprising 99 to 50% by weight of the support material.

28. The lanthanide oxide coated catalyst of claim 25 , wherein the coated catalyst is in particulate form.

29. The lanthanide oxide coated catalyst of claim 25 , wherein the lanthanide oxide is dispersed on the surface of the supported catalyst.

30. The lanthanide oxide coated catalyst of claim 25 , wherein the coated catalyst is capable of reducing sintering of the catalytic metal when subjected to temperatures at a range of greater than 700° C. to 1100° C.

31. The lanthanide oxide coated catalyst of claim 25 , wherein the coated catalyst is capable of catalyzing the production of a gaseous mixture comprising hydrogen and carbon monoxide from a hydrocarbon gas.

Assignees

• Sabic Global Technologies Bv

Inventors

• D Souza Lawrence
• Viswanath Vinu

Classifications

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J35/393

  Metal or metal oxide crystallite size · CPC title

• B01J23/005

  Spinels · CPC title

• C01B3/326

  characterised by the catalysts · CPC title

• B01J23/83

  with rare earths or actinides · CPC title