Patent ID: 6107238
Filing Date: 2000-08-22
Classification: B01J,Y10S

Abstract:
Process for manufacturing of an attrition resistant catalyst having an oxide-rich surface layer comprising the steps of:a) forming a slurry comprising:i) catalyst or catalyst precursor, wherein the catalyst or catalyst precursor contains one or more transition metal oxide,ii) a colloidal oxide sol wherein oxide particles in the sol having an average size between 10 and 100 nm; andiii) a solution of a solvent and solute wherein the solute consist essentially of a precursor of said oxide-rich surface with particle size no greater than 5 nm; and wherein 25 to 50% of the total dry catalyst weight is from the colloidal oxide sol (ii), 5% to 15% of the total dry catalyst weight is from the soluble oxide precursor (iii), and the remainder is from the catalyst or catalyst precursor (i);b) spray drying the slurry from step (a) to form porous microspheres of attrition resistant catalyst; and,c) calcining the spray dried microspheres of step (b) at an elevated temperature which is below the temperature which is substantially deleterious to the catalyst or catalyst precursor.