Process for preparing catalyst powder

US8476187B2 · kind B2 · utility

Assignee

• General Electric Company · US

Inventors

• Daniel George Norton · Niskayuna, US
• Larry Neil Lewis · Scotia, US
• Elliott West Shanklin · Altamont, US
• Frederic Joseph Klug · Amsterdam, US
• Venkat Subramaniam Venkataramani · Clifton Park, US
• Robert Joseph Lyons · Niskayuna, US
• Dan Hancu · Clifton Park, US
• Benjamin Hale Winkler · Albany, US
• Hrishikesh Keshavan · Clifton Park, US

Key dates

• Filing date: Jan 6, 2010
• Grant date: Jul 2, 2013
• Expiry date: Nov 25, 2030

Classification

• Technology area (CPC B): Performing Operations; Transporting
• CPC primary: B01J37/0215
• WIPO field: Chemical engineering
• WIPO sector: Chemistry

Abstract

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.