OXIDATION OF CARBON MONOXIDE AND CATALYST THEREFOR

Abstract: A composition of matter comprising titania and Pt and/or Pd is prepared by a process comprising one step of heating Pt and/or Pd-impregnated titania with a reducing gas, in particular free hydrogen, at a temperature of about 300-800°C. Another composition of matter comprising titania and Pt and/or Pd is prepared by a process comprising the steps of coating a porous ceramic material (preferably a monolith) with colloidal TiO₂, drying, impregnation with Pt and/or Pd, drying/calcining, and reducing with a reducing gas, in particular free hydrogen, at a temperature of about 0-300°C. Both compositions of matter are used as a catalyst in a process for oxidizing CO to CO₂, e.g., in a CO₂ laser.

Description: This invention relates to the oxidation of carbon monoxide to carbon dioxide. In another aspect, this invention relates to the catalytic oxidation of carbon monoxide, in particular under conditions suitable for laser applications. In a further aspect, this invention relates to effective CO oxidation catalyst compositions. In still another aspect, this invention relates to a process for preparing CO oxidation catalyst compositions. The use of catalysts for the oxidation of carbon monoxide to carbon dioxide by reaction with oxygen, in particular at low temperature, is of much interest, e.g., in breathing masks designed to remove CO from inhaled air, and in CO₂ lasers for combining CO and O₂ formed by dissociation of CO₂ during discharge. In the latter application, the presence of O₂ is most undesirable because it can cause a breakdown of the electrical field in the laser cavity. Several patents, such as U.S. Patents 4,490,482 and 4,639,432, disclose compositions useful as CO oxidation catalysts in CO₂ laser applications. EP-A 0 100 267 discusses the treatment of exhaust gases from combustion engines in the presence of a catalyst comprising a noble metal and a further metal such as cobalt, zinc, manganese or chromium, amongst others. Alumina is the preferred support material. However, there is an ever present need to develop new, effective CO oxidation catalyst compositions and/or improved processes for preparing effective CO oxidation catalyst compositions. Summary of the Invention It is an object of this invention to provide a composition of matter which is effective as a catalyst for the oxidation of carbon monoxide with free oxygen. It is another object to provide a process for preparing a composition of matter which is effective as a catalyst for the oxidation of carbon monoxide. It is a further object of this invention to provide an effective process for catalytically oxidizing carbon monoxide. Other objects and advantages will be apparent from the detailed description and the claims. In accordance with this invention a process for preparing a composition of matter is provided as defined in the claims. This process comprises the steps of: (a) contacting (preferably impregnating) a support material, from which silica is not present at a level higher than 0.5 wt-%, comprising titania with a solution comprising at least one dissolved compound of at least one noble metal selected from the group consisting of platinum and palladium (preferably Pt) and at least one dissolved compound of iron; (b) heating the material obtained in step (a) under such conditions as to substantially dry said material obtained in step (a) and to at least partially (preferably substantially) convert said at least one compound of Pt and/or Pd to at least one of oxides of Pt, oxides of Pd, Pt metal and Pd metal and to convert iron to at least one iron oxide; (c) heating the material obtained in step (b) in a reducing gas atmosphere, preferably a free hydrogen containing gas, more preferably a stream of H₂, at a temperature in the range of from 300 to 800°C, under such conditions as to activate said material obtained in step (b), i.e, to make the material obtained in step (b) more active as a catalyst for CO oxidation by reaction with O₂, and to form (obtain) the composition of matter defined above. In a preferred embodiment, heating step (b) is carried out in two sub-steps: (b1) heating the material obtained in step (a) at a first temperature so as to remove substantially all liquids [i.e., the solvent of the solution used in step (a)] from said material obtained in step (a), and (b2) heating (calcining) the substantially dried material obtained in step (b1) at a second temperature, which is higher than said first temperature, so as to at least partially (preferably substantially) convert said at least one compound of Pt and/or Pd to at least one of oxides of Pt, oxides of Pd, metallic Pt and metallic Pd (i.e., Pt oxide and/or Pd oxide and/or Pt metal and/or Pd metal). In another preferred embodiment, the solution used in step (a) additionally comprises at least one dissolved compound of at least one metal selected from the group consisting of rhenium, ruthenium, copper and silver, which are at least partially (preferably substantially) converted to metal oxides in step (b) or, alternatively, step (b2). In another preferred embodiment, compounds of chromium, manganese and zinc are substantially absent (besides silica) from the material obtained in step (c). In a further preferred embodiment, the titania support material, before its being used in step (a) has been extracted with an aqueous acidic solution (so as to remove undesirable impurities thereform), treated with an alkaline solution, washed (e.g., with water), dried, and then calcined (e.g., at 200-800°C, preferably for 0.5-10 hours). Also in accordance with this invention, there is provided a composition of matter as defined in the claims (useful and effective as a catalyst composition for the oxidation of CO with O₂), from which silica is substantially absent, comprising (i) a support material comprising (preferably consisting essentially of) titania and (ii) at least one noble metal selected from the group consisting of Pt and Pd and iron; said composition of matter having been prepared by the process, described above wherein said composition comprises 0.5 to 5.0 weight-% noble metal and 0.2 to 4.0 weight-% iron. Preferably said composition of matter comprises Pt and additionally (iii) at least one substance selected from the group consisting of rhenium oxide, ruthenium metal, ruthenium oxide, copper metal, copper oxide, silver metal, silver oxide, samarium oxide and europium oxide. In one preferred embodiment, the composition of matter of this invention consists essentially of components (i) and (ii). In another preferred embodiment, the composition of matter consists essentially of component (i), Pt metal and component (iii). Further in accordance with this invention, a process for oxidizing carbon monoxide is provided as defined in the claims, which comprises contacting a gas comprising CO and O₂ with a catalyst composition (from which silica is substantially absent) comprising titania, iron and at least one noble metal selected from the group consisting of Pt and Pd; said catalyst composition having been prepared by a process comprising steps (a), (b) and (c); or, alternatively, (aa), (bb) (aaa), (bbb) and (c) under such conditions as to at least partially (preferably substantially) convert CO and O₂ to CO₂. In the CO oxidation in the process of this invention the catalyst composition of this invention comprises iron oxide (e.g., FeO and/or Fe₂O₃ and/or Fe₃O₄). Also preferably, compounds of Cr, Mn and Zn are substantially absent from the catalyst composition (besides SiO₂). In a preferred embodiment, the CO oxidation process of this invention is carried out at a temperature of below 400°C (more preferably from -30°C to 170°C). In another preferred embodiment, the CO oxidation process is carried out in a CO₂ laser so as to recombine CO and O₂, which have been formed by decomposition of CO₂. Brief Description of the Drawings FIGURE 1 shows the CO conversion, during oxidation of CO at low temperature, as a function of the temperature during the reducing pretreatment of a Pt/TiO₂ catalyst with H₂. FIGURE 2 illustrates the effect of copromoters on the catalytic activity of a Pt/TiO₂ catalyst when used for low temperature oxidation of CO. FIGURE 3 illustrates the effect of copromoters on the catalytic activity of a Pt/Fe/TiO₂ catalyst when used for low temperature oxidation of CO. Detailed Description of the Invention Any titania-containing support material is used as the support material (i). Titania is commercially available. The method of preparation of titania is not considered critical. Titania can be prepared by flame hydrolysis of volatile titania compounds; or by precipitation from an aqueous solution of titanium compounds with an alkaline reagent, followed by washing, drying and calcining; and the like. Generally the surface area (determined by the BET/N₂ method; ASTM D3037) of titania is in the range of from 10 to 300 m²/g. Titania can have spherical, trilobal, quadrilobal or irregular shapes. When titania spheres are used, their diameter generally is in the range of from 0.5 to 5 mm. Silica should be substantially absent from the support material (i.e, silica should not be present at a level higher than 0.5, preferably 0.2, weight-% each). The impregnation of the titania support material with Pt and/or Pd (preferably Pt) in steps (a) and (c), respectively, can be carried out in any suitable manner. First, compounds of Pt and/or Pd are dissolved in a suitable solvent (preferably water) so as to prepare solutions of suitable concentration, generally containing from 0.005 to 0.20, preferably 0.01 to 0.1, g Pt and/or Pd per cm³ of solution. Non-limiting examples of suitable compounds of Pt and Pd are: PtCl₂, PtCl₄, H₂PtCl₆, PtBr₄, Pt(NH₃)₄Cl₂, Pt(NH₃)₄(NO₃)₂ and the like; PdCl₂, PdCl₄, H₂PdCl₆, Pd(NH₃)₄(NO₃)₂ and the like; preferably (at present) Pt(NH₃)₄(NO₃)₂ and Pd(NH₃)₄(NO₃)₂. The TiO₂-containing support material is then impregnated by soaking it in the solution of Pt and/or Pd compounds; or (less preferably) the Pt and/or Pd containing solution is sprayed onto the support material. The ratio of Pt and/or Pd containing solution to support material generally is such that the final catalyst obtained in step (c) contains 0.5 to 5, preferably 1 to 3, weight-% Pt or Pd. When a solution containing both Pt and Pd compounds, the level of Pt and Pd generally is 0.5 to 5, preferably 1 to 3, weight percent (Pt+Pd). The titania is also contacted with at least one compound of Fe in step (a). In a preferred embodiment, at least one compound of a metal selected from the group of Re, Ru, Cu, Ag, Sm and Eu is also present as a copromoter in the impregnating solution besides at least one Pt compound. Non-limiting examples of the above mentioned Fe compounds that can be used as solutes are FeCl₂, FeCl₃, Fe₂(SO₄)₃, Fe(NO₃)₂, Fe(NO₃)₃ and the like, preferably compounds of Fe in the valence state +3, more preferably Fe(NO₃)₃. Non-limiting examples of Mn compounds are MnCl₂, MnSO₄, Mn(NO₃)₂, KMnO₄, and the like. Non-limiting examples of Ru compounds are RuCl₃, RuF₄, Ru(NH₃)₆Cl₃, KRuO₄, and the like. Non-limiting examples of Cu compounds are CuCl₂, Cu(NO₃)₂, CuSO₄, Cu(II) acetate, ammine complexes of the above Cu salts, and the like. Non-limiting examples of Ag compounds are AgF, AgNO₃, Ag₂SO₄, Ag acetate, ammine complexes of the above Ag salts, and the like. Non-limiting examples of Sm compounds are SmCl₃, Sm(NO₃), Sm₂(SO₄)₃, and the like. Non-limiting examples of EuCl₃, Eu(NO₃)₃, Eu₂(SO₄)₃ and the like. Generally, the concentration of the copromoter compound (expressed as metal) is in the range of from 0.01 to 0.4, preferably 0.02 to 0.2, g metal (i.e., Mn or Fe or Ru or Cu or Ag or mixtures thereof) per cm³ solution. When a mixture of copromoter compounds is used, e.g., a mixture of compounds of Fe and Ru, Fe and Ag, Ru, Cu, Sm and Eu, Fe/Ru/Ag, and the like, the total concentration of copromoter metals is 0.02-0.8 g/cm³. The impregnation of the support material with Pt and/or Pd and the copromoter can be carried out either by sequential impregnation (first Pt or Pt+Pd, then copromoter; or vice versa), or by simultaneous impregnation in step (a) (i.e., using a solution containing compounds of Pt or Pt+Pd, Fe and of at least one further copromotor compound). When sequential impregnation is employed, the impregnation with a solution of at least one further copromoter compound is carried out after heating step (b) and before step (c). Thus, an impregnating step (aaa) with at least one dissolved copromoter compound and heating step (bbb) [carried out in substantially the same manner as step (b)] are performed after step (b) and before step (c). The ratio of copromoter containing solution to support material is such as to provide a level of 0.2 to 4, preferably 0.5-2, weight percent copromoter metal (i.e., Re or Fe or Ru or Cu, Ag, Sm or Eu, or mixtures of two or more metals, (e.g., FE/Ag, and the like) on the material obtained in step (c). Preferably compounds of Cr, Mn and Zn should be substantially absent from the impregnating solutions used in impregnation steps (a), (aa) since these compounds have a detrimental effect on the activity for CO oxidation of the finished catalyst. Heating step (b) is generally carried out in an inert or oxidizing atmosphere, preferably a free oxygen containing gas atmosphere (such as air), generally at a temperature ranging from 30 to 700°C. Preferably, heating step (b) is carried out in two sequential sub-steps: sub-step (b1), at 30 to 200°C (preferably at 80-130°C), generally for 0.5 to 10 hours, so as to substantially dry the impregnated material obtained in step (a) (preferably under such conditions as to reduce the level of adhered and included water to less than about 20 weight-%); and sub-step (b2), at 300 to 700°C (preferably 400 to 600°C), generally for 1 to 20 hours, under such conditions as to substantially calcine the impregnated support material so as to obtain oxides of Pt and/or Pd and Fe on titania. When compounds of Re, Ru, Cu, Ag, Sm, Eu or mixtures thereof have been present in the Pt and/or Pd-containing impregnating solution, generally oxides of Re, Ru, Cu, Ag, Sm, Eu or mixtures are formed in step (b2). Reducing step (c) can be carried out in any suitable manner at a temperature in the range of from 300 to 800°C, preferably from 350 to 500°C. Any reducing gas can be employed in reducing step (c), such as a gas comprising H₂, CO, gaseous hydrocarbons such as methane, mixtures of the above, and the like. Preferably, a free hydrogen containing gas, more preferably substantially pure H₂, is employed. Reducing step (c) can be carried out for any suitable period of time suitable to activate the calcined material obtained in the previous step, preferably from 0.5 to 20 hours. Pt and/or Pd exist substantially as Pt and/or Pd metal after reducing step (c), respectively. However, small amounts of oxides of Pt and/or Pd may also be present. The process for oxidizing a carbon monoxide containing feed gas can be carried at any suitable temperature and pressure conditions, for any suitable length of time, at any suitable gas hourly space velocity, and any suitable volume ratio of CO and O₂. The reaction temperature generally is in the range of from -50 to 400°C, preferably from -30 to 170°C, more preferably from 10 to about 50°C. The pressure during the oxidation process generally is in the range of from 6.9 kPa to 14 MPa (1 to 2,000 psia), more preferably from 34 to 138 kPa (5 to 20 psia). The volume ratio of CO to O₂ in the feed gas can range from 1:100 to 100:1, and preferably is in the range of 1:10 to 10:1. The volume percentage of CO and the volume percentage of of O₂ in the feed gas can each be in the range of from 0.05 to 50, preferably from 0.5 to 3. The gas hourly space velocity cm³ feed gas per cm³ catalyst per hour) can be in the range of from about 0.5 to about 10,000, preferably from about 1 to about 1,000. It is understood that the calculation of the gas hourly space velocity is based on the volume of the active catalyst i.e., the titania-supported Pt and/or Pd and Fe catalyst (optionally also containing copromoter), excluding the volume occupied by any additional support material, such as a monolith material. The feed gas can be formed in any suitable manner, e.g., by mixing CO, O₂ and optionally other gases such as CO₂, N₂, He and the like, such as in a carbon dioxide laser cavity. Or the feed gas can be an exhaust gas from a combustion engine, or it can be air that is to be inhaled by humans and contains undesirable levels of toxic carbon monoxide, and the like. The feed gas can be contacted in any suitable vessel or apparatus, such as in a laser cavity or in an exhaust pipe of a combustion engine, or in a gas mask used by humans, wherein the feed gas passes over the catalyst composition of this invention at the conditions described above. The CO oxidation process of this invention can be carried out in any suitable setting and for any purpose, e.g., for recombining CO and O₂ in CO₂ lasers, to oxidize CO contained in exhaust gases or air, to make isotopically labeled CO₂ from CO and the 18 / 8O isotope, and the like. The following examples are presented in further illustration of the invention and are not to be construed as unduly limiting the scope of the invention. Example I This example illustrates the experimental setup for testing the activity of noble metal and Fe catalysts for catalyzing the oxidation of carbon monoxide (so as to simulate catalytic recombination of CO and O₂ in CO₂ lasers). A gaseous feed blend comprising CO, O₂, He and N₂ was passed through a needle valve and a glass reactor in an upflow direction. The glass reactor tube had an inner diameter of about 6 mm and generally contained about 1.0 gram catalyst in a bed of about 2.5 cm height. The temperature in the catalyst bed was measured by means of a thermocouple inserted into the top layer of the catalyst bed. The CO content in the reactor effluent was determined by means of a Beckman Model 864 IR analyzer. All tests were carried out at ambient conditions. Generally the temperature in the catalyst bed rose to about 30°C because of the generation of heat during the CO oxidation tests. The feed rate of the gaseous feed stream generally was in the range of 4-300 cm³/minute. Example II This example illustrates the preparation of titania-supported catalyst compositions and their performance in CO oxidation tests. Catalyst A1 contained 1 weight-% Pt on TiO₂. It was prepared by mixing, at room temperature, 30 g of flame-hydrolyzed titania (provided by Degussa Corporation, Teterboro, NJ; having a BET/N₂ surface area of about 50 m²/g) with 31 cm³ of aqueous chloroplatinic acid solution, which contained 0.0096 g Pt/cm³ solution, and enough distilled water to form a thick paste. After impregnation, Catalyst A1 was dried at about 125°C for several hours and calcined in air at about 350°C for about 6 hours. Catalyst A1 was then pretreated with hydrogen gas for about 4 hours at various temperatures (range: 200-725°C) Samples of catalyst A1 (1% Pt/TiO₂) that had been pretreated with H₂ at different temperatures gas tested at room temperature (about 27°C) in the CO oxidation unit described in Example I. The gaseous feed blend contained 1.2 volume-% CO, 0.6 volume-% O₂, 40.7 volume-% N₂ and 57.5 volume-% He. The feed rate was 10 cm³/minute. The correlation between CO conversion and the temperature of the hydrogen pretreatment of Catalyst A1 is shown in Figure 1 . Figure 1 shows that H₂ pretreatment of the Pt/TiO₂ catalyst at temperatures in the range of 400 to 725°C resulted in a considerably more active CO oxidation catalyst than H₂ pretreatment at 200°C. Catalyst A2 contained 1 weight-% Pt and 0.3 weight-% Pd on TiO₂, and gas prepared by mixing 30 g Catalyst A1 with 100 cm³ of an aqueous solution containing 0.25 g tetramminepalladium(II) nitrate, drying and calcining the obtained paste as described for Catalyst A1. The calcined Catalyst A2 material was then activated by heating with H₂ at 725°C for 16 hours. CO conversion (measured as described for the tests employing Catalyst A1) was 100% for about 126 hours. Thus, Pd enhanced the CO oxidation activity of the Pt/TiO₂ catalyst. Example III This example illustrates the effects of various other copromoters on the CO oxidation activity of a Pt/TiO₂ catalyst which contained 2 weight-% Pt (labeled Catalyst B1 ) and was prepared substantially in accordance with the procedure for Catalyst A1, except that the Pt concentration in the impregnating solution was thrice as high, and the TiO₂ support material was provided by Calsicat (division of Mallinckrodt, Inc., St. Louis, MO) and had a BET surface area of about 40-170 m²/g. Catalyst B1 was then mixed with aqueous solutions containing different metal compounds so as to provide a copromoter level of 0.8 weight-% of the metal. A solution of tetramminepalladium(II) nitrate was used to make Catalyst B2 (0.8% Pd/2% Pt/TiO₂). A solution of RuCl₃·3H₂O was used to make Catalyst B3 (0.8% Ru/2% Pt/TiO₂). A solution of ReCl₃ was used to make Catalyst B4 (0.8% Re/2% Pt/TiO₂). A solution of hexamminechloroiridium(II) dichloride was used to make Catalyst B5 (0.8% Ir/2% Pt/TiO₂). A solution of Cu(NO₃)₂·2.5H₂O was used to make Catalyst B6 (0.8% Cu/2% Pt/TiO₂). A solution of Fe(NO₃)₃·9H₂O was used to make Catalyst B7 (0.8% Fe/2% Pt/TiO₂). CO conversions attained at room temperature (about 27°C) in the test unit of Example I employing a gas feed containing 1.2 volume-% CO, 0.6 volume-% O₂, 48 volume-% N₂ and He as the balance (flow rate of feed: 10 cm³/minute), are shown for Catalysts B1, B2, B3, B4, B5, B6 and B7 in Figure 2 . All catalysts had been pretreated with hydrogen gas for 3 hours at 600°C. The graphs in Figure 2 indicate that Fe, Pd, Re, Ru and Cu consistently enhanced the CO oxidation activity of the Pt/TiO₂ base catalyst, whereas Ir enhanced the CO oxidation activity of the base catalyst only up to 60 hours or stream. Additional test data (not shown in Figure 2) indicated that Rh did not affect the catalytic activity of the Pt/TiO₂ base catalyst. Fe, Pd and Re were the most effective copromoters for the Pt/TiO₂-containing CO oxidation catalyst. In another test series, a TiO₂-supported catalyst containing 0.4 weight-% Fe and 2.0 weight-% Pt, labeled Catalyst B8 , was prepared substantially in accordance with the procedure for Catalyst B7, except far a lower Fe level. Catalyst B8 was then impregnated with an aqueous solution containing a compound of a third promoter metal, so as to obtain Catalysts B9 , B10 , B11 and B12 , respectively, containing 0.1 weight-% of the following third promoter elements: Mn, Cr, Ag and Zn. Carbon monoxide conversions, attained by Catalysts B8, B9, B10 and B11 at room temperature (about 27°C) in the test unit of Example I employing the gas feed described in Example II are shown in Figure 3 . The gas feed rate was 60 cm³/minute (in lieu of 10 cm³/minute). All catalysts had been pretreated in hydrogen gas for 3 hours at about 500°C. The TiO₂ support had been heated in H₂ for about 48 hours at 500°C before impregnation with the promoters (Fe, Pt + third promoter) for removal of traces of sulfur in TiO₂. The graphs in Figure 3 indicate that Ag enhanced the activity of the Fe/Pt/TiO₂ CO oxidation catalyst, whereas the presence of Mn, Cr and Zn was detrimental. Based on these test results, it is concluded chat Ag is also an effective promoter for a Pt/TiO₂-containing catalyst (with or without Fe). Example IV This example illustrates a preferred feature of the preparation of TiO₂-supported Pt catalysts useful for CO oxidation at low temperature. Two catalysts containing 0.5 weight-% Fe, and 2.0 weight-% Pt on Calsicat TiO₂ support were tested. Catalyst C1 was prepared substantially in accordance with the preparation of Catalysts B7 and B8, using an aqueous solution of chloroplatinic acid. Catalyst C2 was prepared as described above except that the dissolved Pt compound was tetrammineplatinum(II) nitrate. The two catalysts were dried, calcined and pretreated with hydrogen gas at 500°C for about 3 hours, as has been described in Examples II and III. X-ray diffraction test results indicated that Pt existed in Catalyst C substantially as metallic Pt. The two catalysts were tested at room temperature (about 26°C) in the CO oxidation test unit described in Example I, employing the gas feed described in Example III. The gas feed rate was 120 cm³/minute. Test results are summarized in Table I . Catalyst Hours on Stream % CO Converted cm³/Minute CO Converted C1 2 60 0.84 6 56 0.78 10 56 0.78 14 55 0.77 20 55 0.77 30 50 0.70 40 44 0.62 C2 2 63 0.89 6 70 0.98 10 78 1.09 20 89 1.25 30 94 1.32 40 92 1.30 50 92 1.30 60 90 1.26 70 91 1.27 Test results in Table I clearly show that the Fe/Pt/TiO₂ catalyst prepared using a chloride-free Pt compound for impregnation (Catalyst C2) was consistently more active for CO oxidation than Catalyst C1, which had been prepared using a chloride-containing Pt compound for impregnation. Example V This example illustrates how the CO oxidation activity of a TiO₂-supported catalyst can be enhanced by pretreatment of the TiO₂ support. 25 grams of flame-hydrolyzed titania (provided by Degussa Corporation; see Example II) was stirred overnight in a mixture of 200 cm³ concentrated H₂SO₄ and 300 cm³ deionized water. The aqueous slurry of titania was then neutralized with a concentrated ammonia solution. The dispersed titania was allowed to settle, and the supernatant solution was decanted. The thus treated titania was washed four times with deionized water and dried in a circulating air oven (80-90°C; 5 hours). 5 grams of the acid-created TiO₂ was impregnated with 3 cm³ of an aqueous solution of Pt(NH₃)₄(NO₃)₂ (containing 0.033 g Pt per cm³) and then with 2.5 cm³ of an aqueous solution of Fe(NO₃)₃ (containing 0.01 g Fe per cm³). The thus impregnated material was dried, calcined and pretreated with hydrogen gas for 3 hours at 500°C. This catalyst, labeled Catalyst D , contained 2 weight-% Pt and 0.5 weight-% Fe. Catalyst D was compared to Catalyst C2 (see Example IV; also containing 2 weight-% Fe on TiO₂) which had been prepared without acid treatment of titania (provided by Degussa Corporation). The two catalysts were tested at room temperature (27-29°C) in the CO oxidation test unit described in Example I, employing the gas feed described in Example III. Test results are summarized in Table II . Catalyst Gas Feed Rate (cm³/min.) Hours on Stream % CO Converted cm³/minute CO Converted D (TiO₂ Support Acid-Treated) 160 2 58 1.09 " 4 65 1.22 " 6 68 1.28 " 10 68 1.28 " 14 68 1.28 " 18 67.5 1.26 " 22 67.5 1.26 C2 (TiO₂ Support Not Acid-Treated) 120 2 56 0.79 " 4 48 0.67 " 6 43 0.60 " 10 41 0.58 " 14 41 0.58 " 18 42 0.59 Data in Table II clearly indicate that the CO conversion was greater for Catalyst D as compared to Catalyst C2 in spite of the higher gas feed rate of the run with Catalyst D. The conversion of CO, expressed in cc CO converted per minute, attained by Catalyst D was about twice that attained by Catalyst C2. Thus, in the presently preferred catalyst preparation method of this invention, the TiO₂ support material is treated with an aqueous acid solution, followed by neutralization and washing, before the TiO₂ support material is impregnated with promoters, dried, calcined and heated in H₂ gas. Example VI A test employing a catalyst, which contained 1 weight-% Pt on SiO₂ and had been pretreated in H₂ at 660°C for about 1 hour, showed no activity for catalyzing the oxidation of CO at room temperature. Thus, SiO₂ should be substantially absent from the catalyst of this invention. Example VII This example illustrates the performance of several Pd/TiO₂ CO oxidation catalysts. Catalyst G1 (2.0 weight-% Pd on TiO₂) was prepared in accordance with the procedure for Catalyst F1 except that an aqueous solution of Pd(NH₃)₄(NO₃)₂ comprising 0.02 g Pd/cm³ solution was used in lieu of the Pt(NH₃)₄(NO₃)₂ solution Catalyst G2 (0.7 weight-% Cr and 2.0 weight-% Pd on TiO₂) was prepared by impregnating 2 grams of G1 with 2 cm³ of an aqueous solution chromium salt solution containing 0.007 g Cr per cm³ solution. Catalyst G3 (0.7 weight-% Mn and 2.0 weight-% Pd on TiO₂) was prepared by impregnating 2 grams of G1 with 1.4 cm³ of an aqueous manganese salt solution containing 0.01 g Mn per cm³ solution. Catalyst G4 (0.7 weight-% Ni and 2.0 weight-% Pd on TiO₂) was prepared by impregnating 2 grams of G1 with 2.0 cm³ of an aqueous nickel salt solution containing 0.007 g Ni per cm³ solution. Catalyst G5 (0.7 weight-% Fe and 2.0 weight-% Pd on TiO₂) was prepared by impregnating 2.0 grams of G1 with 1.2 cm³ of an aqueous iron salt solution containing 0.012 g Fe per cm³ solution. Catalyst G6 (0.7 weight-% Ag and 2.0 weight-% Pd on TiO₂) was prepared by impregnating 2 grams of G1 with 2 cm³ of an aqueous silver salt solution containing 0.007 g Ag per cm³ solution. The above-described preparation of G2 through G6 was carried out by impregnating 2 grams of G1 with 1/2 of the metal salt solution, followed by drying at 125°C for 1 hour, impregnating with the second half of the metal salt solution, and again followed by drying at 125°C for 1 hour. Catalysts G1-G6 were calcined in air at 400°C for 1 hour, and then heated in hydrogen gas at 200°C for 2 hours, before the catalysts were used in CO oxidation tests (as discussed in Example VIII). Test results are summarized in Table III . Test results summarized in Table VI show that Pd/TiO₂ was a very active CO oxidation catalyst and possessed a catalytic activity comparable to that of a Pt/TiO₂ catalyst. Test data in Table III also showed that, under the testing conditions of this example, none of the five copromoters (Cr, Mn, Ni, Fe and Ag) enhanced the catalystic activity of the Pd/TiO₂ base catalyst. The fact that Fe and Ag did not enhance the activity of Pd/TiO₂ is surprising because Fe and Ag were beneficial copromoters for Pt/TiO₂ (see Figures 2 and 3). Example VIII This example illustrates the temperature dependence of the rate of the CO oxidation in the presence of a Fe/Pt/TiO₂ catalyst (Catalyst H : containing 0.7 weight-% Fe and 2.4 weight-% Pt on TiO₂). Catalyst H was prepared as follows. 1.94 grams as Fe(NO₃)₃·9H₂O were dissolved in 48 grams of an aqueous Pt(NH₃)₄(NO₃)₂ solution (containing 0.02 g Pt per cm³ solution). The above Fe/Pt nitrate solution was diluted with distilled water to a total volume of 60 cm³. 30 cm³ of this diluted solution was mixed in multiple wetting steps with 40 grams of titania, with a drying step (20 minutes at 110°C) after each wetting step. The dried impregnated material was calcined for 2 hours in air at 400°C and then for 2 hours in H₂ at 400°C. Thereafter, the thus-heated Fe/Pt impregnated titania was mixed with the second 30 cm³ of the above-described diluted Fe/Pt nitrate solution in multiple wetting steps, with a drying step (20 minutes at 110°C) after each vetting step. The thus dried, twice-impregnated material was calcined for 2 hours in air at 400°C and then four hours in hydrogen gas at 200°C. 2 grams of Catalyst H were used in CO oxidation tests, in accordance with the procedure described in Example VIII. Test results are summarized in Tables IV and V . Average Reaction Temp. (°C) Feed Rate (cm³/minute) cm³/Minute CO per g Catalyst Converted 29 463 1.5 42 463 1.7 51 463 1.9 65 930 2.5 76 930 2.8 86 930 3.1 108 930 3.6 128 930 4.1 126 1417 4.2 148 1417 4.7 169 1417 6.1 28 505 2.0 Hours on Stream Average Reaction Temp. (°C) Feed Rate (cm³/minute) % CO Conversion cm³/Minute CO Converted 1 0 300 56 1.05 2 0 300 56 1.05 3 0 300 56 1.05 4 0 300 56 1.05 5 -30 280 46 0.81 6 -30 280 46 0.80 8 -30 280 45 0.78 10 -30 280 45 0.78 15 -30 280 45 0.78 20 -30 280 45 0.78 25 -30 280 46 0.80 30 -30 280 41 0.71 Test results in Tables IV and V show that the Fe/Pt/TiO₂ CO oxidation catalyst was quite active at elevated temperatures (up to about 170°C) as well as at a low temperature (as low as -30°C).

Claims: A process for preparing a composition of matter, from which silica is not present at a level higher than 0.5 weight-%, which is useful and effective as a catalyst composition for CO oxidation, and which comprises titania and at least one noble metal selected from the group consisting of platinum and palladium, comprising the steps of: (a) contacting a support material, comprising titania, with a solution comprising at least one dissolved compound of at least one noble metal selected from the group consisting of platinum and palladium and at least one dissolved compound of iron; (b) heating the material obtained in step (a) under such conditions as to substantially dry said material obtained in step (a) and to at least partially convert said at least one compound of at least one noble metal to at least one of oxides of Pt, oxides of Pd, Pt metal and Pd metal and to at least partially convert said iron compound to at least one oxide of iron as a copromoter; and (c) heating the material obtained in step (b) in a reducing gas atmosphere at a temperature in the range of from about 300 to about 800°C, under such conditions as to activate said material obtained in step (b), wherein said composition of matter comprises 0.5 to 5.0 weight-% noble metal and 0.2 to 4 weight-% iron. A process in accordance with claim 1, wherein a sequential impregnation is employed by replacing steps (a) and (b) with the steps; aa) contacting titania with a solution comprising at least one compound of platinum, bb) heating the material obtained in step (aa) under such conditions as to substantially dry said material and to at least partially convert said compound of platinum to at least one oxide of platinum; aaa) impregnating the material obtained in step (bb) with a solution comprising at least one dissolved compound of iron; bbb)heating the material obtained in step (aaa) under such conditions as to substantially dry said material and to at least partially convert said compound of iron to at least one oxide of iron as a copromoter; and wherein step (c) is carried out with the material obtained in step (bbb). A process in accordance with claim 1 or 2, wherein said reducing gas atmosphere is a free hydrogen containing gas. A process in accordance with claims 1, 2 or 3, wherein step (b) or step (bb) respectively is carried out in two sub-steps; (b1) heating the material obtained in step (a) or step (aa) respectively at a first temperature so as to remove substantially all liquids from said material and (b2) heating the substantially dried material obtained in step (b1) at a second temperature, which is higher than said first temperature, so as to at least partially convert said at least one compound of at least one noble metal to at least one of oxides of Pt, oxides of Pd, metallic Pt and metallic Pd, or when present to at least partially convert said iron compound to at least one oxide of iron. A process in accordance with claim 4, wherein said first temperature is in the range of from 30 to 200°C, and said second temperature is in the range of from 300 to 700°C. A process in accordance with any of the preceding claims wherein said composition of matter comprises Pt as noble metal, Fe as copromoter metal, and additionally at least one copromoter selected from the group consisting of rhenium oxide, ruthenium metal, ruthenium oxide, copper metal, copper oxide, silver metal, silver oxide, samarium oxide and europium oxide. A process in accordance with claim 1, wherein said solution used in step (a) comprises at least one compound of Pt, at least one compound of iron and at least one compound of at least one copromoter metal selected from the group consisting of Re, Ru, Cu, Ag, Sm and Eu, and said at least one compound of at least one copromoter metal is at least partially converted to at least one oxide of said at least one copromoter metal in step (b). A process in accordance with claim 2, wherein the steps (aaa) and (bbb) are replaced respectively by the steps (aaa*) impregnating the material obtained in step (bb) with a solution comprising at least one compound of iron and at least one compound of at least one copromoter metal selected form the group consisting of Re, Ru, Co, Ag, Sm and Eu, wherein said material obtained in step (bb) comprises at least one substance selected from the group consisting of Pt metal and oxide of Pt; and (bbb*) heating the material obtained in step (aaa*) under such conditions as to substantially dry said material and to at least partially convert said at least one compound of iron to at least one oxide of iron and said at least one compound of at least one copromoter metal to at least one oxide of said at least one copromoter metal; and wherein step (c) is carried out with the material obtained in step (bbb*). A process in accordance with any of the preceding claims, wherein compounds of chromium, compounds of manganese and compounds of zinc are substantially absent in said composition of matter. A process in accordance with any of the preceding claims, wherein said composition of matter contains 0.2 to 4 weight percent of said copromoter, expressed as metal. A process in accordance with any of the preceding claims, wherein step (c) is carried out in a stream of H₂ at a temperature in the range of from 350 to 500°C, for a period of time in the range of from 0.5 to 20 hours. A process in accordance with any of the preceding claims, wherein said catalyst composition comprises from 0.5 to 5 weight percent Pt. A process in accordance with any of the preceding claims, wherein said composition of matter comprises from 0.5 to 5 weight percent Pd. A process in accordance with claim 1, wherein said support material is used in step (a) has been extracted with an aqueous acidic acid, thereafter washed, dried and calcined. A composition of matter, from which silica is not present at a level higher than 0.5 weight-% and which is useful and effective as a catalyst for CO oxidation, comprising titania as a support at least one noble metal selected form the group consisting of platinum and palladium and iron oxide, prepared by a process of any of the claims 1 to 14, wherein said composition comprises 0.5 to 5.0 weight-% noble metal and 0.2 to 4.0 weight-% iron. A process for oxidizing carbon monoxide comprising the step of: contacting a gas mixture comprising CO and O₂ with a catalyst composition comprising titania, at least one noble metal selected form the group consisting of platinum and palladium and iron oxide, under such reaction conditions as to at least partially convert said CO and O₂ to CO₂; wherein said catalyst composition is the composition of claim 15. A process in accordance with claim 16, wherein said reaction conditions comprise a reaction temperature in the range of from -50°C to 400°C, a reaction pressure in the range of from 6.9 kPa to 14 MPa (1 to 2,000 psia), and a volume ratio of CO to O₂ in the range of from 1:100 to 100:1. A process in accordance with claim 16, wherein said reaction conditions comprise a temperature in the range of from -30°C to 170°C, a reaction pressure in the range of from 34 to 138 kPa (5 to 20 psia), and a volume ratio of CO to O₂ in the range of from 1:10 to 10:1. A process in accordance with claim 16, wherein said process is carried out in the cavity of a CO₂ laser so as to recombine CO and O₂ formed by dissociation of CO₂.

Inventors: KOLTS, JOHN HENRY
Applicants: PHILLIPS PETROLEUM COMPANY
Application year: 1988
Main classification: B01J23
IPC codes: B01J23, C01B31, B01D53, H01S3