초록 ▼

The present invention details a process for producing a catalyst powder. The steps of the process include preparing catalyst slurry, drying, pyrolyzing, and calcining the catalyst slurry to obtain a calcined catalyst powder. The catalyst slurry comprises a catalyst, a liquid carrier, a templating ag

The present invention details a process for producing a catalyst powder. The steps of the process include preparing catalyst slurry, drying, pyrolyzing, and calcining the catalyst slurry to obtain a calcined catalyst powder. The catalyst slurry comprises a catalyst, a liquid carrier, a templating agent, and a catalyst substrate. The catalyst slurry is dried to obtain a raw catalyst powder. The raw catalyst powder is heated in a first controlled atmosphere to obtain a pyrolyzed catalyst powder and the pyrolyzed catalyst powder is calcined in a second controlled atmosphere to obtain a calcined catalyst powder. A method of fabricating a catalyst surface and catalytic converter using the prepared catalyst powder is also illustrated.

대표청구항 ▼

1. A process for producing a catalyst powder, comprising: preparing a catalyst slurry comprising a catalyst, a liquid carrier, a templating agent, and a catalyst substrate;drying the catalyst slurry to obtain a raw catalyst powder;heating the raw catalyst powder in a first controlled atmosphere to g

1. A process for producing a catalyst powder, comprising: preparing a catalyst slurry comprising a catalyst, a liquid carrier, a templating agent, and a catalyst substrate;drying the catalyst slurry to obtain a raw catalyst powder;heating the raw catalyst powder in a first controlled atmosphere to get a pyrolyzed catalyst powder; andcalcining the pyrolyzed catalyst powder in a second controlled atmosphere to get a calcined catalyst powder. 2. The process of claim 1, wherein the first controlled atmosphere is an inert atmosphere. 3. The process of claim 2, wherein the heating comprises a first step and a second step. 4. The process of claim 3, wherein the first step is a dehydration step at a temperature lower than about 150° C. 5. The process of claim 3, wherein the second step is a pyrolyzing step at a temperature lower than about 700° C. 6. The process of claim 1, wherein the first controlled atmosphere is vacuum. 7. The process of claim 1, wherein the second controlled atmosphere comprises oxygen, and wherein the oxygen concentration is greater than about 1 mol % of the total gas content of the second controlled atmosphere. 8. The process of claim 7, wherein the oxygen concentration is greater than about 5 mol %. 9. The process of claim 7, wherein the second controlled atmosphere is air. 10. The process of claim 7, wherein calcining comprises exposing the pyrolyzed catalyst powder to the second controlled atmosphere at a temperature lower than about 100° C. 11. The process of claim 1, wherein the catalyst comprises silver. 12. The process of claim 1, wherein the catalyst substrate comprises mesoporous alumina. 13. The process of claim 1, wherein the liquid carrier comprises alcohol. 14. The process of claim 13, wherein the alcohol comprises isopropanol. 15. The process of claim 1, wherein a median particle size of the calcined catalyst powder produced is lower than about 10 microns. 16. The process of claim 1, wherein a median batch size of the prepared calcined catalyst powder is greater than about 5 kg. 17. The process of claim 1, further comprising adding water to the catalyst slurry. 18. The process of claim 17, further comprising exchanging alcohol with water before spray drying. 19. The process of claim 1, wherein the calcined catalyst powder has a specific surface area greater than about 200 m2/g. 20. A process for producing a catalytic convertor, comprising: preparing a catalyst slurry comprising a catalyst, a liquid carrier, a templating agent, and a catalyst substrate;drying the catalyst slurry to obtain a raw catalyst powder;heating the raw catalyst powder in a first controlled atmosphere to get a pyrolyzed catalyst powder;calcining the pyrolyzed catalyst powder in a second controlled atmosphere to get a calcined catalyst powder; andfabricating a catalytic surface comprising the calcined catalyst powder. 21. The process of claim 20, wherein fabricating the catalytic surface comprises disposing a calcined catalyst powder slurry on a catalyst support. 22. The process of claim 21, wherein disposing the calcined catalyst powder slurry on the catalyst support comprises wash coating. 23. The process of claim 21, wherein the catalyst support comprises a porous monolith. 24. A process for producing a NOx catalytic convertor, comprising: preparing a catalyst slurry comprising silver, alumina, an alcohol, and a templating agent;spray drying the catalyst slurry to get a raw catalyst powder;heating the raw catalyst powder in an inert atmosphere to get a pyrolyzed catalyst powder;calcining the pyrolyzed catalyst powder in a controlled oxygen atmosphere to get a calcined catalyst powder comprising silver templated mesoporous alumina (Ag-TA);mixing the calcined catalyst powder with a liquid to form a calcined catalyst powder slurry; andwashcoating the calcined catalyst powder slurry onto a monolith support.