Preparation of monolithic catalyst supports having an integrated high surface area phase

Abstract

A method of preparing a monolithic catalyst support having an integrated high surface area phase is provided. A plasticized batch of ceramic matrix material intimately mixed with high surface area powder is formed into the desired shape for the monolith and then heated to sinter the ceramic. The resulting monolith has a strong substrate of the ceramic matrix material and a high surface area phase provided by the high surface area powder extruded with the batch.

We claim: 
     
       1. A method of preparing a monolithic catalyst support which comprises: (a) providing a substantially homogeneous body comprising an admixture of (i) a first phase sinterable ceramic matrix material, in particulate form finer than 200 mesh, selected from the group consisting of cordierite, mullite, alpha-alumina, lithium aluminosilicate, and mixtures of these, and   (ii) a second phase high surface area catalyst-support material having a crystalline size no larger than 0.2 microns and a surface area of at least 40 m 2  /g, said catalys-support material consisting of transition metal sulfide; a mixture of transition metal sulfides; porous oxide selected from the group consisting of .[.alumina,.]. zirconia, spinel, silica, zeolite, titania, .[.and.]. mixtures of these.Iadd., and mixtures of the preceeding with alumina; .Iaddend.or a mixture of said sulfide and said oxide materials;     (b) forming the resultant body into a desired shape; and   (c) heating the shaped body at a temperature sufficient to sinter the first phase matrix material.   
     
     
       2. A method of claim 1 in which mixing step (a) is performed using 50-90 parts by weight of the first phase material and 10-50 parts by weight of the second phase material. 
     
     
       3. A method of claim 2 in which mixing step (a) is performed using 1-30 part by weight of a binder material. 
     
     
       4. A method of claim 3 in which the second phase material has a surface area of at least 100 m 2  /g and is selected from the group consisting of .[.alumina,.]. silica, zeolite, .[.and.]. mixtures of these.Iadd., and mixtures of the preceeding with alumina. 
     
     
       5. A method of claim 4 in which .[.the second phase material is alumina, and.]. the binder is methyl cellulose, a silicone resin, or mixtures of these. 
     
     
       6. A method of claim 4 in which the second phase material is silica and the binder is methyl cellulose, a silicone resin, or mixture of these. 
     
     
       7. A method of claim 4 in which the second phase material is a mixture of silica and alumina and the binder is methyl cellulose, a silicone resin, or mixtures of these. 
     
     
       8. A method of claim 4 in which the second phase material is a zeolite and the binder is methyl cellulose, a silicone resin, or mixture of these. 
     
     
       9. A method of claim 3 in which the second phase material is titania and the binder is methyl cellulose, a silicone resin, or mixtures of these. 
     
     
       10. A method of claim 3 in which the second phase material is a spinel and the binder is methyl cellulose, a silicone resin, or mixtures of these. 
     
     
       11. A method of claim 3 in which the second phase material is zirconia or a transition metal sulfide. 
     
     
       12. A method of claim 5, 6, 7, 8, 9, or 10 in which the first phase sinterable material is cordierite or mullite. 
     
     
       13. A method of claim 5, 6, 7, 8, 9, or 10 in which the first phase sinterable material is alpha-alumina. 
     
     
       14. A monolithic catalyst support prepared by the method of claim 1. 
     
     
       15. A monolithic catalyst support prepared by the method of claim 12. 
     
     
       16. A monolithic catalyst support prepared by the method of claim 13. 
     
     
       17. A monlithic catalyst support comprising 50-90 parts by weight of a sintered ceramic matrix material and 10-50 parts per weight of a high surface area catalyst-support material dispersed throughout the matrix wherein (a) the ceramic matrix material consists of cordierite, mullite, alpha-alumina, lithium aluminosilicate, or mixtures of these; and   (b) the dispersed catalyst-support material has a surface area of at least 40 m 2  /g and a crystallite size no larger than about 0.5 microns, and the catalyst-support material consists of transition metal sulfide; a mixture of transition metal sulfides; porous oxide selected from the group consisting of .[.alumina,.]. zirconia, spinel, silica, zeolite, titania, .[.and.]. mixtures of these.Iadd., and mixtures of the preceeding with alumina.Iaddend.; or a mixture of said sulfide and said oxide materials.   
     
     
       18. A monolithic catalyst support of claim 17 wherein the dispersed catalyst-support material has a surface area of at least 100 m 2  /g and is .[.alumina,.]. silica, zeolite, .[.or.]. mixture of these.[...]. .Iadd., or mixtures of the preceeding with alumina. .Iaddend. .[.19. A monolithic catalyst support of claim 18 wherein the dispersed 
     
     
        catalyst-support material is a transition alumina..]. 20. A monolthic catalyst suppport of claim 18 wherein the dispersed catalyst-support 
     
     
        material is silica. 21. A monolithic catalyst support of claim 17 wherein 
     
     
        the dispersed catalyst-support material is a spinel. 22. A monlithic catalyst support of claim 17, 18, .[.19,.]. 20, or 21 in which the ceramic 
     
     
        matrix material is cordierite or mullite. 23. A monolithic catalyst 
     
     
        support of claim 22 having a surface area of at least 5 m 2  /g. 24. A method of claim 1 in which the second phase material is .[.alumina,.]. spinel, or a mixture of alumina and silica; and in which the admixture further comprises up to 20 percent by weight, based on the weight of the 
     
     
        second phase material, or rare earth oxide. 25. A monolithic catalyst support of claim 17 wherein the dispersed catalyst-support material is .[.alumina,.]. spinel, or a mixture of alumina and silica; and wherein the monolithic catalyst support further comprises up to 20 percent by weight, based on the weight of the dispersed catalyst-support material, of rare earth oxide.