A protein template is added to a solution in which metal ions of iron and copper are dissolved to introduce the metal ions into the protein template; the protein template is separated from metal ions that have not been incorporated in the protein template; the metal ions that have been incorporated in the protein template are reduced to obtain a protein containing alloy nanoparticles of iron and copper; a sol or gel in which a co-continuous body is dispersed is frozen; the frozen sol or gel is dried in a vacuum to obtain a porous body; the porous body is allowed to support the alloy nanoparticle containing protein; and the protein is removed.

A protein template is added to a solution in which metal ions of iron and copper are dissolved to introduce the metal ions into the protein template; the protein template is separated from metal ions that have not been incorporated in the protein template; the metal ions that have been incorporated in the protein template are reduced to obtain a protein containing alloy nanoparticles of iron and copper; a sol or gel in which a co-continuous body is dispersed is frozen; the frozen sol or gel is dried in a vacuum to obtain a porous body; the porous body is allowed to support the alloy nanoparticle containing protein; and the protein is removed.

An object of the present invention is to provide a process for producing an oxide catalyst used in a vapor-phase catalytic oxidation or vapor-phase catalytic ammoxidation reaction of propane or isobutene, which enables a catalyst demonstrating favorable yield to be stably produced. According to the present invention, there is provided a process for producing an oxide catalyst used in a vapor-phase catalytic oxidation or vapor-phase catalytic ammoxidation reaction of propane or isobutane, comprising the steps of: (i) preparing a catalyst raw material mixture containing Mo, V and Nb and satisfying the relationships of 0.1≦a≦1 and 0.01≦b≦1 when atomic ratios of V and Nb to one atom of Mo are defined as a and b, respectively; (ii) drying the catalyst raw material mixture; and (iii) calcining a particle, in which a content of the particle having a particle diameter of 25 μm or less is 20% by mass or less and a mean particle diameter is from 35 to 70 μm, in an inert gas atmosphere.

An object of the present invention is to provide a process for producing an oxide catalyst used in a vapor-phase catalytic oxidation or vapor-phase catalytic ammoxidation reaction of propane or isobutene, which enables a catalyst demonstrating favorable yield to be stably produced. According to the present invention, there is provided a process for producing an oxide catalyst used in a vapor-phase catalytic oxidation or vapor-phase catalytic ammoxidation reaction of propane or isobutane, comprising the steps of: (i) preparing a catalyst raw material mixture containing Mo, V and Nb and satisfying the relationships of 0.1≦a≦1 and 0.01≦b≦1 when atomic ratios of V and Nb to one atom of Mo are defined as a and b, respectively; (ii) drying the catalyst raw material mixture; and (iii) calcining a particle, in which a content of the particle having a particle diameter of 25 μm or less is 20% by mass or less and a mean particle diameter is from 35 to 70 μm, in an inert gas atmosphere.

Disclosed are a ferrite catalyst and preparation methods thereof. The catalyst is provided with a formula below, wherein A is Mg atom, Zn atom or a mixture of both atoms at any ratio; D is one or more atoms selected from the group consisting of Ni, Co, W, Mn, Ca, Mo or V atom; Z is a catalyst carrier, which is one or more selected from the group consisting of calcium phosphate, calcium dihydrogen phosphate, aluminum phosphate, aluminum dihydrogen phosphate, ferric phosphate, magnesium phosphate, zinc phosphate, Mg—Al hydrotalcite, calcium carbonate, magnesium carbonate; a=0.01-0.6; b=0-0.30; c is a number balancing each valence; x, y represent the amounts of principal catalyst and carrier Z respectively, wherein the weight ratio y/x=0.5:1-7:1.
x(FeA.sub.aD.sub.bO.sub.c)/yZ

Disclosed are a ferrite catalyst and preparation methods thereof. The catalyst is provided with a formula below, wherein A is Mg atom, Zn atom or a mixture of both atoms at any ratio; D is one or more atoms selected from the group consisting of Ni, Co, W, Mn, Ca, Mo or V atom; Z is a catalyst carrier, which is one or more selected from the group consisting of calcium phosphate, calcium dihydrogen phosphate, aluminum phosphate, aluminum dihydrogen phosphate, ferric phosphate, magnesium phosphate, zinc phosphate, Mg—Al hydrotalcite, calcium carbonate, magnesium carbonate; a=0.01-0.6; b=0-0.30; c is a number balancing each valence; x, y represent the amounts of principal catalyst and carrier Z respectively, wherein the weight ratio y/x=0.5:1-7:1.
x(FeA.sub.aD.sub.bO.sub.c)/yZ

Effect of the type of ZPGM material composition to improve thermal stability of ZPGM catalyst systems for TWC application is disclosed. ZPGM catalyst system samples are prepared and configured with washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer including either Cu.sub.1Mn.sub.2O.sub.4 spinel or Cu.sub.1Co.sub.1Mn.sub.1O.sub.4 spinel. Testing of ZPGM catalyst samples including variations of aging temperatures and different impregnation layer materials are developed under isothermal steady state sweep test condition for ZPGM catalyst systems to evaluate performance especially NO.sub.x conversions and level of thermal stability. As a result disclosed ZPGM catalyst systems with most suitable spinel that includes Cu.sub.1Co.sub.1Mn.sub.1O.sub.4 in impregnation layer exhibit high NOx conversion and significant improved thermal stability compare to Cu.sub.1Mn.sub.2O.sub.4 spinel, which is suitable for under floor and close coupled TWC application. The effect of adding Co to Cu—Mn spinel composition to improve thermal stability confirmed by TPR measurement.

Effect of the type of ZPGM material composition to improve thermal stability of ZPGM catalyst systems for TWC application is disclosed. ZPGM catalyst system samples are prepared and configured with washcoat on ceramic substrate, overcoat including doped Zirconia support oxide, and impregnation layer including either Cu.sub.1Mn.sub.2O.sub.4 spinel or Cu.sub.1Co.sub.1Mn.sub.1O.sub.4 spinel. Testing of ZPGM catalyst samples including variations of aging temperatures and different impregnation layer materials are developed under isothermal steady state sweep test condition for ZPGM catalyst systems to evaluate performance especially NO.sub.x conversions and level of thermal stability. As a result disclosed ZPGM catalyst systems with most suitable spinel that includes Cu.sub.1Co.sub.1Mn.sub.1O.sub.4 in impregnation layer exhibit high NOx conversion and significant improved thermal stability compare to Cu.sub.1Mn.sub.2O.sub.4 spinel, which is suitable for under floor and close coupled TWC application. The effect of adding Co to Cu—Mn spinel composition to improve thermal stability confirmed by TPR measurement.

Disclosed is a method for production of synthesis gas and ethylene by a combined oxidative coupling and dry reforming of methane process. Heat generated from the oxidative coupling of methane can be used to drive the endothermic dry reforming of methane reaction.

Disclosed is a method for production of synthesis gas and ethylene by a combined oxidative coupling and dry reforming of methane process. Heat generated from the oxidative coupling of methane can be used to drive the endothermic dry reforming of methane reaction.