High-activity catalyst for hydrogen peroxide decomposition

Abstract

A high-activity hydrogen peroxide decomposition catalyst comprising an impregnated and calcined substrate with a catalyst mixture. The catalyst mixture comprises a hydrogen peroxide catalytically active compound containing a transition metal cation mixed with an alkaline promoter. A process for forming a high-activity hydrogen peroxide decomposition catalyst and a product of high-activity hydrogen peroxide decomposition are disclosed.

What is claimed is:  
     
       1. A high-activity hydrogen peroxide decomposition catalyst comprising: 
       an impregnated and calcined substrate with a catalyst mixture, the catalyst mixture comprising a transition metal cation mixed with an alkaline promoter, wherein the substrate comprises a porous support material selected from the group consisting of alumina, silica, aluminosilicate, polar ceramics and combinations thereof.  
     
     
       2. The catalyst of claim  1 , wherein the catalyst comprises a cation selected from the group consisting of Mn, Ag, Ru, V, Fe, Cr, Co and mixtures thereof. 
     
     
       3. The catalyst of claim  2 , wherein the catalyst comprises a cation selected from the group consisting of tetravalent manganese and tetravalent copper. 
     
     
       4. The catalyst of claim  3 , wherein the catalyst comprises tetravalent manganese. 
     
     
       5. The catalyst of claim  1 , wherein the alkaline promoter contains an ion selected from the group consisting of Li + , K + , Na + , and NH 4   + . 
     
     
       6. The catalyst of claim  5 , wherein the alkaline promoter contains an ion selected from the group consisting of K +  and Na + . 
     
     
       7. The catalyst of claim I, wherein the promoter and catalyst are mixed at a molar ratio of from about 0.5 to about 4.0. 
     
     
       8. The catalyst of claim  7 , wherein the promoter and catalyst are mixed at a molar ratio of from about 1.0 to about 2.0. 
     
     
       9. The catalyst of claim  1 , wherein the substrate comprises from about 0.01 weight percent to about 20.0 weight percent of metals. 
     
     
       10. The catalyst of claim  1 , wherein the substrate comprises a singular structure. 
     
     
       11. The catalyst of claim  10 , wherein the singular structure comprises a matrix. 
     
     
       12. The catalyst of claim  11 , wherein the matrix comprises cellular matrix. 
     
     
       13. A process for forming a high-activity hydrogen peroxide decomposition catalyst comprising the steps of: 
       providing a polar substrate comprising a porous support material selected from the group consisting of alumina, silica, aluminosilicate, polar ceramics and combinations thereof;  
       mixing, in a solvent, a soluble salt containing a transition metal cation with an alkaline promoter;  
       applying the mixture over the substrate, wherein the mixture soaks the substrate surface area, thereby impregnating the substrate;  
       drying the applied soaked mixture sufficiently causing the removal of the solvent; and,  
       calcining the dried mixture sufficient to form an activated catalyst.