Saudi Arabian Oil Company

Maxim Bukhovko

Michele Louisa Ostraat

Ke Zhang

Brian S Hanna

Sergio Fernandez

Timothy J Kucharski

A method of producing a catalyst comprises generating an aerosolized flow of catalyst support particles, heating a catalytically active compound precursor to produce a catalytically active compound precursor vapor, contacting the aerosolized flow of catalyst support particles with the catalytically active compound precursor vapor, and condensing the catalytically active compound precursor onto the catalyst support particles to produce the catalyst comprising catalytically active compound deposited on surfaces of the catalyst support particles. The method may further comprise aerosolizing a catalyst support precursor mixture, drying the aerosolized catalyst support precursor mixture in a first heating zone to form an aerosolized flow of catalyst support particles, and contacting the catalyst support particles with a catalytically active compound precursor vapor in a second heating zone to form the catalyst comprising the layer of the catalytically active compound deposited on surfaces of the catalyst of catalyst support particles.

Aerosol processing method for controlled coating of surface species to generate catalysts

A multi-functional composite catalyst includes a catalyst support material, a preformed catalyst material at least partially secured in the catalyst support, and at least one catalytically active compound supported by the catalyst support, the preformed catalyst material, or both. The catalyst support material may include fumed silica, alumina, fumed alumina, fumed titania, or combinations of these. A catalytic activity of the catalytically active compound may be different than a catalytic activity of the preformed catalyst material. The composite catalyst may be catalyst for producing propene from 2-butene and may include a zeolite as the preformed catalyst material and a metal oxide, such as tungsten oxide, as the catalytically active material. A method of making the composite catalyst may include aerosolizing a catalyst precursor mixture that includes a preformed catalyst material, catalyst support precursor, and catalytically active compound precursor, and drying the aerosolized catalyst precursor mixture.

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Boston, MA, United States of America

Maxim Bukhovko