Porous composite metal oxide, catalyst using the same, and methods for producing the porous composite metal oxide and the catalyst

Patent metadata

Field	Value
Publication number	US-9556023-B2
Application number	US-201013390254-A
Country	US
Kind code	B2
Filing date	Sep 10, 2010
Priority date	Sep 11, 2009
Publication date	Jan 31, 2017
Grant date	Jan 31, 2017

Abstract

A porous composite metal oxide, including a mixture of first ultrafine particles containing alumina and second ultrafine particles containing zirconia, wherein the first ultrafine particles and the second ultrafine particles are uniformly dispersed in such a way as to satisfy a condition that standard deviations of content ratios (% by mass) of all metal elements contained in the porous composite metal oxide at 0.1% by mass or more are each 10 or less, the standard deviations being obtained by measuring content ratios of the metal elements at 100 measurement points within a minute analysis region of 20 nm square by energy dispersive X-ray spectroscopy using a scanning transmission electron microscope equipped with a spherical aberration correction function.

First claim

The invention claimed is:

1. A porous composite metal oxide, comprising:
a mixture of first ultrafine particles containing alumina and second ultrafine particles containing zirconia, wherein
the first ultrafine particles and the second ultrafine particles are uniformly dispersed in such a way as to satisfy
a condition that standard deviations of content ratios (% by mass) of all metal elements contained in the porous composite metal oxide at 0.1% by mass or more are each 10 or less, the standard deviations being obtained by measuring content ratios of the metal elements within a minute analysis region of 20 nm square with respect to 100separate measurement points by energy dispersive X-ray spectroscopy using a scanning transmission electron microscope equipped with a spherical aberration correction function, and
a condition that standard deviations of content ratios (% by mass) of all metal elements contained in the porous composite metal oxide at 0.1% by mass or more are each 15 or less, the standard deviations being obtained by measuring content ratios of the metal elements within a minute analysis region of 10 nm square with respect to 100 separate measurement points by energy dispersive X-ray spectroscopy using a scanning transmission electron microscope equipped with a spherical aberration correction function,

a crystallite diameter determined by an X-ray diffraction method is 1 to 10 nm,
a specific surface area determined by a BET method is 65 m 2 /g or more,
an average pore diameter determined by a nitrogen adsorption method is 20 nm or less, and
a pore volume determined by a nitrogen adsorption method is 0.3 cm 3 /g or more.

2. The porous composite metal oxide according to claim 1 , wherein
at least one of the first ultrafine particles and the second ultrafine particles further contain at least one metal oxide selected from the group consisting of oxides of rare earth elements and oxides of alkaline earth metals.

3. A catalyst comprising:
the porous composite metal oxide according to claim 1 ; and
a noble metal supported on a surface of the porous composite metal oxide.

4. A catalyst comprising:
the porous composite metal oxide according to claim 1 ; and
a member selected from the group consisting of transition metals, oxides thereof, and mixtures thereof supported on a surface of the porous composite metal oxide, the transition metal being selected from the group consisting of Cu, Fe, Ni, Co, Mn, and Zn.

5. A catalyst comprising:
the porous composite metal oxide according to claim 1 ; and
CuAl 2 O 4 and CuO contained in at least one of the first ultrafine particles and the second ultrafine particles.

6. A method for producing a porous composite metal oxide, comprising the steps of:
introducing independently a raw material solution containing aluminum ions and a raw material solution containing at least one polymeric dispersant selected from the group consisting of polyalkyleneimines and (meth) acrylic acid-based polymers directly into a region in which a shear rate is 1000 to 200000 sec −1 , and homogeneously mixing the raw material solutions, thereby obtaining a first colloidal solution;
introducing independently a raw material solution containing zirconium ions and a raw material solution containing at least one polymeric dispersant selected from the group consisting of polyalkyleneimines and (meth) acrylic acid-based polymers directly into a region in which a shear rate is 1000 to 200000 sec −1 , and homogeneously mixing the raw material solutions, thereby obtaining a second colloidal solution;
mixing the first colloidal solution and the second colloidal solution with each other under a pH condition under which both the first and second colloidal solutions can maintain a state of being dispersed in a liquid, thereby obtaining a colloidal mixture liquid;
adjusting a pH of the colloidal mixture liquid to a pH condition under which the colloidal mixture liquid cannot maintain a state of being dispersed in the liquid, thereby obtaining an aggregate; and
subjecting the aggregate to a heat treatment, thereby obtaining the porous composite metal oxide according to claim 1 .

7. The method for producing a porous composite metal oxide according to claim 6 , wherein
at least one of the raw material solution containing aluminum ions and the raw material solution containing zirconium ions further contains ions of at least one metal selected from the group consisting of rare earth elements and alkaline earth metals.

8. The method for producing a porous composite metal oxide according to claim 6 , wherein
each of the polymeric dispersants is at least one polyalkyleneimine,
the pH condition under which both the first and second colloidal solutions can maintain the state of being dispersed in the liquid is 0.5 to 5.5, and
the pH condition under which the colloidal mixture liquid cannot maintain the state of being dispersed in the liquid is 9.0 to 12.0.

9. The method for producing a porous composite metal oxide according to claim 6 , wherein
each of the polymeric dispersants is at least one (meth) acrylic acid-based polymer,
the pH condition under which both the first and second colloidal solutions can maintain the state of being dispersed in the liquid is 5.0 to 10.0, and
the pH condition under which the colloidal mixture liquid cannot maintain the state of being dispersed in the liquid is 0.5 to 4.0.

10. A method for producing a catalyst, comprising the step of:
supporting a noble metal on a surface of a porous composite metal oxide obtained by the production method according to claim 6 .

11. A method for producing a catalyst, comprising the step of:
supporting at least one selected from the group consisting of transition metals, oxides thereof, and mixtures thereof on a surface of a porous composite metal oxide obtained by the production method according to claim 6 , the transition metal being selected from the group consisting of Cu, Fe, Ni, Co, Mn, and Zn.

12. A method for producing a catalyst, comprising the step of:
causing the porous composite metal oxide comprising the mixture of the first ultrafine particles containing alumina and the second ultrafine particles containing zirconia to further contain CuAl 2 O 4 and CuO as additional components, in the production method according to claim 6 .

13. The porous composite metal oxide according to claim 1 , wherein the porous composite metal oxide is obtained by a method comprising:
introducing independently a raw material solution containing aluminum ions and a raw material solution containing at least one polymeric dispersant selected from the group consisting of polyalkyleneimines and (meth) acrylic acid-based polymers directly into a region in which a shear rate is 1000 to 200000 sec −1 , and homogeneously mixing the raw material solutions, thereby obtaining a first colloidal solution;
introducing independently a raw material solution containing zirconium ions and a raw material solution containing at least one polymeric dispersant selected from the group consisting of polyalkyleneimines and (meth) acrylic acid-based polymers directly into a region in which a shear rate is 1000 to 200000 sec −1 , and homogeneously mixing the raw material solutions, thereby obtaining a second colloidal solution; and
mixing the first colloidal solution and the second colloidal solution with each other under a pH condition under which both the first and second colloidal solutions can maintain a state of being dispersed in a liquid, thereby obtaining a colloidal mixture liquid.

14. The porous composite metal oxide according to claim 13 , wherein
the metho

Assignees

• Sato Kimitoshi
• Yamamura Kae
• Morikawa Akira
• Suda Akihiko
• Toyota Chuo Kenkyusho Kk

Inventors

• Sato Kimitoshi
• Yamamura Kae
• Morikawa Akira
• Suda Akihiko

Classifications

• C01P2006/12

  Surface area · CPC title

• B01J23/83

  with rare earths or actinides · CPC title

• B01J21/066

  Zirconium or hafnium; Oxides or hydroxides thereof · CPC title

• B01J21/04

  Alumina · CPC title

• C01P2006/14

  Pore volume · CPC title