US 12,296,327 B2
Metal foam element containing cobalt and method for producing same
René Poss, Karlsruhe (DE); Meike Roos, Büdingen (DE); Monika Berweiler, Maintal (DE); and Maximilian Glaser, Obertshausen (DE)
Assigned to Evonik Operations GmbH, Essen (DE)
Appl. No. 17/762,730
Filed by EVONIK OPERATIONS GMBH, Essen (DE)
PCT Filed Sep. 25, 2020, PCT No. PCT/EP2020/076854
§ 371(c)(1), (2) Date Mar. 23, 2022,
PCT Pub. No. WO2021/058719, PCT Pub. Date Apr. 1, 2021.
Claims priority of application No. 19199651 (EP), filed on Sep. 25, 2019.
Prior Publication US 2022/0362757 A1, Nov. 17, 2022
Int. Cl. B01J 21/04 (2006.01); B01J 21/06 (2006.01); B01J 21/08 (2006.01); B01J 23/10 (2006.01); B01J 23/42 (2006.01); B01J 23/44 (2006.01); B01J 23/46 (2006.01); B01J 23/48 (2006.01); B01J 23/54 (2006.01); B01J 23/63 (2006.01); B01J 23/745 (2006.01); B01J 23/75 (2006.01); B01J 23/755 (2006.01); B01J 23/76 (2006.01); B01J 23/83 (2006.01); B01J 23/89 (2006.01); B01J 35/56 (2024.01); B01J 37/02 (2006.01); B01J 37/08 (2006.01); B01J 37/14 (2006.01); B22F 3/11 (2006.01); B22F 3/24 (2006.01); B22F 7/04 (2006.01)
CPC B01J 37/0226 (2013.01) [B01J 21/04 (2013.01); B01J 23/75 (2013.01); B01J 23/755 (2013.01); B01J 35/56 (2024.01); B01J 37/0205 (2013.01); B01J 37/0209 (2013.01); B01J 37/024 (2013.01); B01J 37/08 (2013.01); B01J 37/14 (2013.01); B22F 3/114 (2013.01); B22F 3/1143 (2013.01); B22F 3/1146 (2013.01); B22F 3/24 (2013.01); B22F 7/04 (2013.01); B22F 2003/242 (2013.01); B22F 2007/045 (2013.01); B22F 2301/052 (2013.01)] 16 Claims
 
1. A process for producing a supported catalyst, comprising the following steps:
(a) providing a metal foam body A made of metallic cobalt, an alloy of nickel and cobalt, or overlying layers of nickel and cobalt;
(b) applying an aluminum-containing powder MP to metal foam body A so as to obtain metal foam body AX;
(c) thermally treating the metal foam body AX to achieve alloy formation between metal foam body A and aluminum-containing powder MP so as to obtain metal foam body B;
wherein the maximum temperature in the thermal treatment of metal foam body AX is within a range from 680 to 715° C. for a total duration of between 5 and 240 seconds;
(d) oxidizing metal foam body B so as to obtain metal foam body C;
(e) applying a catalytically active layer comprising at least one support oxide and at least one catalytically active component to at least part of the surface of metal foam body C so as to obtain the supported catalyst;
wherein the oxidative treatment of metal foam body B in step (d) is selected from the following:
heating of metal foam body B while in contact with an oxidizing gas atmosphere without prior formation of aluminum hydroxide on the surface of the metal foam body; or
heating of metal foam body B while in contact with an oxidizing gas atmosphere after aluminum hydroxide has previously been formed on the surface of the metal foam body.