Method for large-scale production of combustion deposited metal-metal oxide catalysts

Abstract

A process and system for producing industrial-scale quantities of highly dispersed, thermally stable catalysts is disclosed. The process, which may be continuous production or batch production, includes mixing together the desired catalyst precursor materials, a combustible organic material and a solvent; evaporating the solvent, combusting the catalyst intermediate; and shaping final catalyst.

What is claimed is:  
     
         1 . A method of producing a catalyst, the method comprising: 
 combining in a mixing vessel 
 at least one decomposable precursor compound of a catalytically active metal or metal oxide,  
 optionally, at least one decomposable precursor compound of a refractory metal oxide support,  
 at least one combustible organic compound,  
 optionally, a liquid mixing agent, such that a mixture is formed;  
   in an evaporator, evaporating said liquid mixing agent, if present, and/or a portion of said combustible organic compound to produce a catalyst intermediate;    in a furnace, heating said catalyst intermediate to the point of autoignition, and allowing said catalyst intermediate to combust, such that a combustion product is produced;    optionally, calcining said combustion product;    optionally, in a shaping unit, forming said combustion product into a predetermined shape; and    optionally, in an activation unit, heating said combustion residue under activating conditions, to provide an activated catalyst.    
     
     
         2 . The method of  claim 1  comprising at least one step for automatically performing at least one of the following operations: 
 adding predetermined amounts of said precursor compound(s), combustible organic compound and liquid mixing agent, if present, to a mixing vessel;  
 mixing said precursor compound(s), combustible organic compound and liquid mixing agent, if present, in said mixing vessel;  
 introducing said mixture into an evaporator;  
 heating said liquid mixing agent, if present, and/or a portion of said combustible organic compound within said evaporator, to produce a catalyst intermediate;  
 introducing said catalyst intermediate into a furnace;  
 heating said catalyst intermediate within said furnace to the point of autoignition;  
 igniting the catalyst intermediate in the furnace with an igniter;  
 venting combustion exhaust gas from said furnace;  
 calcining said combustion product;  
 introducing said combustion product into a shaping unit;  
 forming said combustion product into a predetermined shape;  
 introducing said combustion product into an activation unit;  
 heating said combustion residue under activating conditions, to provide an activated catalyst; and  
 collecting a final catalyst product.  
 
     
     
         3 . The method of  claim 1  wherein said calcining comprises heating said residue according to a predetermined heating program in an O 2 -containing atmosphere.  
     
     
         4 . The method of  claim 3  wherein said predetermined heating program includes heating the combustion residue at rate up to about 10° C./min to a temperature in the range of 300-700° C.  
     
     
         5 . The method of  claim 1  wherein said optional calcining comprises heating the combustion residue to a temperature in the range of 400-1,500° C.  
     
     
         6 . The method of  claim 1  comprising evaporating said liquid mixing agent from said mixture prior to said ignition.  
     
     
         7 . The method of  claim 1  further comprising adding a phase separation reducing agent to said mixture.  
     
     
         8 . The method of  claim 1  wherein heating said combustion residue under activating conditions to provide an activated catalyst comprises reducing conditions.  
     
     
         9 . The method of  claim 1  wherein heating said combustion residue under activating conditions to provide an activated catalyst comprises oxidizing conditions.  
     
     
         10 . The method of  claim 1  wherein said catalytically active metal or metal oxide comprises at least one transition metal or metal oxide chosen from the group consisting of Rh, Ru, Pd, Pt, Au, Ag, Os and Ir, and oxides thereof.  
     
     
         11 . The method of  claim 10  wherein said at least one transition metal or metal oxide is chosen from the group consisting of Co, Ni, Mn, V and Mo, and oxides thereof.  
     
     
         12 . The method of  claim 1  wherein said at least one decomposable precursor compound of a refractory metal oxide support comprises at least one metal chosen from the group consisting of Mg, Ca, Al and Si.  
     
     
         13 . The method of  claim 1  wherein said metal or metal oxide comprises a rare earth metal or metal oxide chosen from the group consisting of La, Yb, Sm, Ce and oxides thereof.  
     
     
         14 . The method of  claim 1  wherein said combustible organic compound is chosen from the group consisting of amines, hydrazides, urea and glycol.  
     
     
         15 . The method of  claim 1  comprising producing a catalyst continuously.  
     
     
         16 . The method of  claim 1  comprising producing catalyst intermittently or semi-continuously.  
     
     
         17 . A catalyst comprising the product of the process of  claim 1 .  
     
     
         18 . An system for producing a catalyst, the apparatus comprising: 
 means for mixing said predetermined amounts of said at least one precursor compound, said at least one combustible organic compound and said liquid mixing agent, if present;    means for adding said predetermined amount of said at least one precursor compound, said at least one combustible organic compound and said liquid mixing agent, if present, to said mixing means;    means for evaporating said liquid mixing agent, if present, and/or a portion of said combustible organic compound, to produce a catalyst intermediate;    means for introducing said mixture into said evaporating means;    means for heating said catalyst intermediate to the point of autoignition, such that a combustion product is produced;    optionally, means for calcining said combustion product;    optionally, means for shaping said catalyst; and    optionally, means for activating said catalyst.    
     
     
         19 . The apparatus of  claim 18  comprising means for filtering combustion furnace exhaust.  
     
     
         20 . The apparatus of  claim 18  wherein said shaping means comprises means for sizing said catalyst.