Patent ID: 6677270
Filing Date: 2004-01-13
Classification: B01J,C01B,Y02P

Abstract:
A process of making a carbided metal catalyst for catalyzing the partial oxidation of a C1-C5 hydrocarbon to form a product gas mixture comprising CO and H2, the process comprising:combining a first metal compound comprising an oxide, alkoxide or nitrate of a first metal chosen from the group consisting of Mo, W and Cr, said first metal comprising at least about 50 wt % of the metal content of said carbided metal catalyst, and at least one second metal compound, containing a different metal than said first metal, chosen from the group consisting of metal compounds comprising oxides, ailcoxides and nitrates of Mo, W, V, Cr, Fe, Nb, Ta, Re, Co, Cu, Sn and Bi, the metal component of said at least one second metal compound comprising about 0.1-10 wt % of the metal content of said carbided metal catalyst, to provide a catalyst intermediate composition; optionally, loading a porous support with said intermediate composition; combining a promoter chosen from the group consisting of metals and metal oxides of rare earth, alkali and alkaline earth elements of the periodic table of the elements, and combinations thereof, with said first and second metal compounds, and reacting said intermediate composition with a gaseous hydrocarbon of the formula CnH2n+2 wherein n is an integer from 1 to 4, at a gas flow rate up to about 500 sccm, to provide a catalyst consisting essentially of: a carbided metal composition containing Mo, W or Cr, and at least one other metal chosen from the group consisting of Mo, W, V, Cr, Fe, Nb, Ta, Re, Co, Cu, Sn and Bi, a promoter chosen from the group consisting of rare earth, alkali and alkaline earth elements, and optionally, a support.