Catalyst supports

Abstract

This invention relates to a catalyst material, and its method of making and manufacture, useful for a diversity of chemical production processes as well as various emission control processes. More specifically, it relates to a catalyst composition, preferably comprising a metal oxide felt substrate, with one or more functional surface active constituents integrated on and/or in the substrate surface, which can be used in the removal of sulfur and sulfur compounds from hot gases as well as acting to trap solid particulates and trace metals within these hot gases.

1 . A composite material comprising a support structure and a catalytic material deposited on said support structure, wherein said support structure comprises a metal oxide felt material. 
     
     
         2 . The composite material of  claim 1  wherein said metal oxide felt material is selected from the group consisting of inorganic refractory metal oxide felts selected from the group consisting of ZrO 2 , Ce 2 O 3 , CeO 2 , Y 2 O 3 , TiO 2 , HfO 2 , Al 2 O 3 , Nb 2 O 5 , La 2 O 3 , Yb 2 O 3 , and mixed oxide felts selected from the group consisting of Al 2 O 3 —SiO 2 , HfO 2 —CeO 2 , Sm 2 O 3 —CeO 2 , Yb 2 O 3 —CeO 2 . 
     
     
         3 . The composite material of  claim 2  wherein said metal oxide felt material is ZrO 2 . 
     
     
         4 . The composite material of  claim 3  wherein said metal oxide felt material further comprises yttrium. 
     
     
         5 . The composite material of  claim 1  wherein said metal oxide felt material comprises layers having a thickness from about 0.25 to about 6.35 mm. 
     
     
         6 . The composite material of  claim 1  wherein said metal oxide felt material comprises layers having a thickness from about 1.27 to about 3.81 mm. 
     
     
         7 . The composite material of  claim 1  wherein said metal oxide felt material has a bulk porosity from about 50 to 100%. 
     
     
         8 . The composite material of  claim 1  wherein said metal oxide felt material has a bulk porosity from about 88 to 96%. 
     
     
         9 . The composite material of  claim 1  wherein said metal oxide felt material has a bulk density of about 128 to 1073 grams/liter. 
     
     
         10 . The composite material of  claim 1  wherein said metal oxide felt material has a bulk density of about 160 to 400 grams/liter. 
     
     
         11 . The composite material of  claim 1  wherein said metal oxide felt material has a melting point between about 1500° and 5000° C. 
     
     
         12 . The composite material of  claim 1  wherein said catalytic material is selected from the group consisting of metals, metal oxides, metal sulfides, mixed metal oxides, mixed metal sulfides. 
     
     
         13 . The composite material of  claim 12  wherein said metals, said mixed metals and said mixed metal sulfides comprise metals selected from the group consisting of Zn, Fe, Cu, Co, Ni, Mo, Mn, Ca, Sr, Ba, Ce, Ti, V, and W. 
     
     
         14 . A method for treating a hot gas comprising exposing said hot gas to a composite material comprising a metal oxide felt substrate and a catalytic material wherein said treating includes removal of sulfur compounds, and solid particulates, and metals from said hot gas. 
     
     
         15 . The method of  claim 14  wherein said hot gas is at a temperature from about 250° to 850° C. 
     
     
         16 . The method of  claim 14  wherein said hot gas is a synthesis gas. 
     
     
         17 . The method of  claim 14  wherein said composite material both catalyzes a reaction to remove sulfur compounds and traps solid particulates and metals contained in said hot gas. 
     
     
         18 . The method of  claim 14  wherein said metal oxide felt substrate comprises a metal oxide selected from the group consisting of ZrO 2 , Ce 2 O 3 , CeO 2 , Y 2 O 3 , TiO 2 , HfO 2 , Al 2 O 3 , Nb 2 O 5 , La 2 O 3 , and Yb 2 O 3 , or a mixed metal oxide selected from the group consisting of Al 2 O 3 —SiO 2 , HfO 2 —CeO 2 , Sm 2 O 3 —CeO 2 , and Yb 2 O 3 —CeO 2 . 
     
     
         19 . The method of  claim 14  wherein said metal oxide felt substrate comprises ZrO 2 . 
     
     
         20 . The method of  claim 14  wherein said metal oxide felt substrate comprises ZrO 2  and the catalytic material comprises oxides of Mn, and said metal oxide felt substrate and catalytic material shows characteristic lines at 23.2±0.5 deg. 2-theta, 28.942±0.5 deg. 2-theta, 30.220±0.5 deg. 2-theta, 33.039±0.5 deg. 2-theta, 35.060±0.5 deg. 2-theta, 38.303±0.5 deg. 2-theta, 45.243±0.5 deg. 2-theta, 49.441±0.5 deg. 2-theta, 50.318±0.5 deg. 2-theta, 55.261±0.5 deg. 2-theta, 57.024±0.5 deg. 2-theta, 59.779±0.5 deg. 2-theta, 62.779±0.5 deg. 2-theta, 65.841±0.5 deg. 2-theta, under X-Ray Diffraction.