US 11,994,345 B2
Process for the commercial production of high-quality catalyst material
Robert Schuetzle, Sacramento, CA (US); and Dennis Schuetzle, Grass Valley, CA (US)
Assigned to Greyrock Technology, LLC, Sacramento, CA (US)
Filed by GREYROCK TECHNOLOGY, LLC, Sacramento, CA (US)
Filed on Oct. 4, 2022, as Appl. No. 17/803,671.
Application 17/803,671 is a continuation of application No. 16/602,770, filed on Dec. 4, 2019, granted, now 11,493,274.
Prior Publication US 2023/0213284 A1, Jul. 6, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. F27D 3/00 (2006.01); B01J 23/755 (2006.01); B01J 35/31 (2024.01); B01J 35/63 (2024.01); B01J 35/64 (2024.01); B01J 35/66 (2024.01); B01J 37/08 (2006.01); F27D 3/16 (2006.01); F27D 5/00 (2006.01); F27D 9/00 (2006.01); F27D 19/00 (2006.01)
CPC F27D 3/0033 (2013.01) [B01J 23/755 (2013.01); B01J 35/31 (2024.01); B01J 35/63 (2024.01); B01J 35/64 (2024.01); B01J 35/66 (2024.01); B01J 37/08 (2013.01); F27D 5/0068 (2013.01); F27D 2003/0034 (2013.01); F27D 2003/166 (2013.01); F27D 2009/0002 (2013.01); F27D 2019/0056 (2013.01); F27D 2019/0093 (2013.01)] 15 Claims
OG exemplary drawing
 
1. A catalyst production process for CO2 hydrogenation catalysts, wherein catalyst materials are heated homogeneously in a calcining oven and in which the oven heating and gas flow rates are controlled, resulting in the production of catalysts that meet batch-to-batch chemical, physical and performance specifications with a high level of reproducibility, wherein the process comprises the steps of:
a. loading catalyst materials into a calcining oven, wherein the catalyst materials comprise a metal selected from Ni, Cu, Zn, Mg, Mo or Fe on a support, and wherein the weight percent of metal to support ranges from 0.01% to 20%;
b. wherein the calcining oven is connected to one or more separate reheating chambers, in which the calcining gas is heated using a thermostatically controlled heat source;
c. circulating the heated calcining gas from the reheating chambers into the calcining oven in which the gas is distributed over catalyst materials;
d. recirculating the calcining gas back into the reheating chambers at least 10 times;
e. increasing the oven temperature in increments ranging from about 0.5° F./min. to about 10° F./min such that the temperature in any area of the oven does not vary more than about 25%;
f. maintaining the oven at a final calcining temperature for a period of time;
g. cooling the oven to ambient temperature at a controlled rate ranging from about 2° F./min to about 20° F./min.