Process for the preparation of a catalytic specie using electro-deposition

Abstract

Process for the preparation of a catalytic specie consisting essentially of a metallic support, which is coated with a ceramic active phase layer, mainly compound of the general formula (I): [Rh x Ni y Mg l Al m (OH) 2 ] z+ (A n− z/n ) kH 2 O.

1 . A process for the preparation of a catalytic specie, said process comprising electro-deposition of a ceramic active phase layer on a metallic support, the ceramic active phase layer being a compound of the general formula (II):
   [A z A′ 1-z ][B 1-x-y Ni x  Rh y ]O 3-67    (II)
   
       in which A and A′ are different and are selected from the Lanthanide or the Actinide families or from the group II a  of the Mendeleev's periodical table of elements; B is selected from the transition metal groups of columns IIIb, IVb, Vb, VIb, VIIb, Ib and IIb and group VIIIb of the Mendeleev's periodical table of elements; 0≦x≦0.7; 0≦y≦0.5; 0≦x+y≦0.8; 0≦z≦1; and δ is the sub stoschiometric value of oxygen to obtain the electric neutrality of the Perovskite compound and the metallic support being selected from metallic foams that are stable at a temperature up to 1000° C. 
     
     
         2 . The process of  claim 1 , wherein the metallic support is selected from the metallic foam FeCrAlY or the metallic foam NiCrAlY. 
     
     
         3 . The process of  claim 1 , wherein the ceramic active phase layer is a compound of the general formula (II) in which A and A′ are each independently selected from La, Ce, Ca and Sr. 
     
     
         4 . The process of  claim 3 , wherein the ceramic active phase layer is a compound of the general formula (II) in which A is La. 
     
     
         5 . The process of  claim 1 , wherein the ceramic active phase layer is a compound of the general formula (II) in which B is selected from Mn, Fe and Co. 
     
     
         6 . The process of  claim 4 , wherein the ceramic active phase layer is a compound of the formula (IIa):
   [La z A′ 1-z ][Fe 1-x-y Ni x  Rh y ]O 3-δ   (IIa)
   
       in which A′, x, y, and z and δ are as defined for the formula (II); 
       or a compound of the formula (IIb):
   [La z Ce 1-z ][Fe 1-x-y Ni x  Rh y ]O 3-δ   (IIb)
 
 
       in which x, y, and z and  6  are as defined for the formula (II). 
     
     
         7 . The process of  claim 1 , wherein the ceramic active phase layer is a compound of the general formula (II) in which 0≦x≦0.5. 
     
     
         8 . The process of  1 , wherein the ceramic active phase layer is a compound of the general formula (II) in which 0≦y≦0.25. 
     
     
         9 . The process of  7 , wherein the ceramic active phase layer is a compound of the general formula (II) in which 0≦y≦0.25. 
     
     
         10 . The process of  claim 1 , wherein the ceramic active phase layer is a compound selected from:
 La Fe 0.7  Ni 0.25  Rh 0.05  O 3-δ     La 0.8  Ce 0.2  Fe 0.7  Ni 0.25  Rh 0.05  O 3-δ     La Fe 0.7  Ni 0.3  O 3-δ     La Fe 0.95 Rh   0.05  O 3-δ ; and   La 0.8  Ce 0.2  Fe 0.7  Ni 0.3  O 3-δ .   
     
     
         11 . A process for the preparation of a catalytic specie, said process comprising the steps of:
 (a) electro-deposition of a ceramic active phase layer on a metallic support, the ceramic active phase layer being a compound of the general formula (II):
   [A z A′ 1-z ][B 1-x-y Ni x  Rh y ]O 3-δ   (II)
 
   
       in which A and A′ are different and are selected from the Lanthanide or the Actinide families or from the group II a  of the Mendeleev's periodical table of elements; B is selected from the transition metal groups of columns IIIb, IVb, Vb, VIb, VIIb, Ib and IIb and group VIIIb of the Mendeleev's periodical table of elements; 0≦x≦0.7; 0≦y≦0.5; 0≦x+y≦0.8; 0≦z≦1; and δ is the sub stcechiometric value of oxygen to obtain the electric neutrality of the Perovskite compound and the metallic support being selected from metallic foams that are stable at a temperature up to 1000° C.; and
 (b) calcinatrion of the product obtained in step (a). 
 
     
     
         12 . The process of  claim 11 , wherein the metallic support is selected from the metallic foam FeCrAlY or the metallic foam NiCrAlY. 
     
     
         13 . The process of  claim 11 , wherein the ceramic active phase layer is a compound of the general formula (II) in which A and A′ are each independently selected from La, Ce, Ca and Sr. 
     
     
         14 . The process of  claim 13 , wherein the ceramic active phase layer is a compound of the general formula (II) in which A is La. 
     
     
         15 . The process of  claim 11 , wherein the ceramic active phase layer is a compound of the general formula (II) in which B is selected from Mn, Fe and Co. 
     
     
         16 . The process of  claim 14 , wherein the ceramic active phase layer is a compound of the formula (IIa):
   [La z A′ 1-z ][Fe 1-x-y Ni x  Rh y ]O 3-δ   (IIa)
   
       in which A′, x, y, and z and δ are as defined for the formula (II); 
       or a compound of the formula (IIb):
   [La z Ce 1-z ][Fe 1-x-y Ni x  Rh y ]O 3-δ   (IIb)
 
 
       in which x, y, and z and  6  are as defined for the formula (II). 
     
     
         17 . The process of  claim 11 , wherein the ceramic active phase layer is a compound of the general formula (II) in which 0≦x≦0.5. 
     
     
         18 . The process of  11 , wherein the ceramic active phase layer is a compound of the general formula (II) in which 0≦y≦0.25. 
     
     
         19 . The process of  17 , wherein the ceramic active phase layer is a compound of the general formula (II) in which 0≦y≦0.25. 
     
     
         20 . The process of  claim 11 , wherein the ceramic active phase layer is a compound selected from:
 La Fe 0.7  Ni 0.25  Rh 0.05  O 3-δ     La 0.8  Ce 0.2  Fe 0.7  Ni 0.25  Rh 0.05  O 3-δ     La Fe 0.7  Ni 0.3  O 3-δ     La Fe 0.95  Rh 0.05 ; and   La 0.8  Ce 0.2  Fe 0.7  Ni 0.3  O 3-δ .   
     
     
         21 . A process for the catalytic oxidation of gaseous hydrocarbons, said process comprising carrying out the catalytic oxidation utilizing the catalytic specie prepared by the process of  claim 1 . 
     
     
         22 . A process for the catalytic oxidation of gaseous hydrocarbons, said process comprising carrying out the catalytic oxidation utilizing the catalytic specie prepared by the process of  claim 11 . 
     
     
         23 . A process for the production of synthesis gas by oxidating a stream of gaseous hydrocarbons in the presence of a catalytic specie prepared according to the process of  claim 1 . 
     
     
         24 . A process for the production of synthesis gas by oxidating a stream of gaseous hydrocarbons in the presence of a catalytic specie prepared according to the process of  claim 11 .