Claims:[0050] We claim:
1. A method to produce the catalyst layer on honey comb substrate for recombination of hydrogen and oxygen gases, the method comprising the steps of:
a) combining a noble metal based catalysts such as an ionized palladium salt and ionized platinum salt with a titanium oxide (Tio2) chemically using a solution combustion technique (101);
b) forming a single phase uniform titanium oxide catalyst using solution combustion technique, wherein the single phase uniform titanium oxide catalyst has the exact anatase structure representing the formula Ti1-xPtxO2-x and Ti1-xPdxO2-x (for x = 0.01 to 0.15) (102); and
c) coating the titanium oxide catalyst layer on a cordierite honey comb substrate, wherein the cordierite honey comb substrate has large surface area to provide higher rate of recombination reaction of hydrogen and oxygen gases (103).

2. The method as claimed in claim 1, wherein the surface area of cordierite honey comb substrate catalysts is determined by nitrogen desorption technique.
3. The method as claimed in claim 1, wherein the cordierite honey comb substrate has large surface area with plurality of holes.
4. The method as claimed in claim 1, wherein the cordierite honey comb substrate is made of metal or metal alloy from the group of alumina or silica.
, Description:Preamble to the Description
[0002] The following specification particularly describes the invention and the manner in which it is to be performed:
[0003] DESCRIPTION OF THE INVENTION:
[0004] Technical field of the invention
[0005] The present invention relates to a method to produce an improved catalyst layer on the cordierite honey comb substrate for recombination hydrogen and oxygen gases.
[0006] Background of the invention
[0007] A catalyst is a substance that starts or speeds up a chemical reaction. Catalysts are being used for many years to convert reactants into a specific product, which otherwise are difficult to produce. Most of the catalysts are oxides of noble metals. The catalysts are tried and tested for various industrial applications such as nuclear energy reactors for recombination of hydrogen and oxygen gases, vehicle exhaust systems, water-gas shifts reaction and the storage batteries.
[0008] Various types of conventional catalyst are known in the prior art, all, however being typically pallets or amorphous powders, which are compacted in suitable holder or enclosure to withstand working condition for the reaction. The conventional catalysts are easily poisoned and need to be replaced very often. The efficiency and productivity of the conventional catalyst is less and their replacement cost is high as well.
[0009] Hence, there is need of a method to provide an improved catalyst layer on the cordierite honey comb substrate in well-defined ionized state at all the time.

[0010] Summary of the invention
[0011] The present invention overcomes the drawbacks in the prior art and provides a method to produce a catalyst layer on a honey comb substrate for recombination of hydrogen and oxygen gases. In most preferred embodiment, the method includes the step of combining a noble metal based catalysts such as an ionized palladium salt and ionized platinum salt with a titanium oxide (Tio2) chemically using a solution combustion technique. After combining the noble metal based catalysts with the titanium oxide, a single phase uniform titanium oxide catalyst layer is formed using the solution combustion technique. The single phase uniform titanium oxide catalyst layer has the exact anatase structure representing the formula Ti1-xPtxO2-x and Ti1-xPdxO2-x (for x = 0.01 to 0.15). Finally, obtained single phase uniform titanium oxide catalyst layer is coated on a cordierite honey comb substrate, wherein the cordierite honey comb substrate has large surface area to provide higher rate of recombination reaction of hydrogen and oxygen gases.
[0012] In a preferred embodiment of the invention, the cordierite honey comb substrate has large surface area with plurality of holes.
[0013] In a preferred embodiment of the invention, the cordierite honey comb substrate is made of metal or metal alloy from the group of alumina or silica.
[0014] The prior arts use the catalysts that are typically pallets or amorphous powders. The use of such conventional catalysts involves complex design with an increased cost. The conventional catalyst gets easily poisoned and needs to be replaces quite often because of their enclosure in the suitable holder for the reaction.
[0015] The present invention overcomes draw backs in the prior art and provides a method to produce improved catalyst in an ionized state. The ionized catalyst reduces overall cost of the design and increases the productivity for recombination of hydrogen and oxygen gases. The ionized catalyst layer coated on the cordierite honey comb substrate does not poison and also does not require replacement therein.
[0016] The method is easy to implement, simple and is more suitable for applications in storage batteries, nuclear power station, and shift gas production.
[0017] It is to be understood that both the foregoing general description and the following details description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
[0018] Brief description of the drawings:
[0019] The foregoing and other features of embodiments will become more apparent from the following detailed description of embodiments when read in conjunction with the accompanying drawings. In the drawings, like reference numerals refer to like elements.
[0020] FIG 1 illustrates the method for producing the catalyst layer on honey comb substrate for recombination of hydrogen and oxygen gases, according to one embodiment of the invention.
[0021] FIG 2a shows the powder XRD (X-Ray Diffraction) patterns of cordierite (Mg2Al4Si5O18) honey comb structure monolith, according to one embodiment of the invention.
[0022] FIG 2b shows the powder XRD patterns of Ti0.97Pd0.03O2-d and ?-Al2O3 coated on cordierite monolith, according to one embodiment of the invention.
[0023] FIG 2c shows the powder XRD patterns of as-prepared Ti0.97Pd0.03O2-d powder, according to one embodiment of the invention.
[0024] FIG 3a shows the Ti(2p) core level XPS (X-ray Photoelectron Spectroscopy) of Ti0.97Pd0.03O2-d coated on cordierite monolith, according to one embodiment of the invention.
[0025] FIG 3b shows the Pd(3d) core level XPS of Ti0.97Pd0.03O2-d coated on cordierite monolith, according to one embodiment of the invention.
[0026] FIG 4 shows H2 (Hydrogen) + O2 (Oxygen) recombination reaction mechanism on surface of Ti0.97Pd0.03O2-d, according to one embodiment of the invention.
[0027] FIG 5 shows the honeycomb structured ceramic body, according to one embodiment of the invention.
[0028] Detailed description of the invention:
[0029] Reference will now be made in detail to the description of the present subject matter, one or more examples of which are shown in figures. Each embodiment is provided to explain the subject matter and not a limitation. These embodiments are described in sufficient detail to enable a person skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, physical, and other changes may be made within the scope of the embodiments. The following detailed description is, therefore, not be taken as limiting the scope of the invention, but instead the invention is to be defined by the appended claims.
[0030] The term “Solution combustion method” as claimed in the embodiments refers to an effective method for the synthesis of nanoscale materials and has been used in the production of various ceramic powders for a variety of advanced applications.
[0031] The term “Nitrogen desorption technique” as claimed in the embodiments refers to an effective method to determine the pore size distribution and multilayer thickness/refractive index on the surface area of cordierite honey comb substrate.
[0032] The present invention provides a method to produce the catalyst layer on honey comb substrate for recombination of hydrogen and oxygen gases. The invention describes a catalyst layer coated on the cordierite honey comb substrate for recombination of hydrogen and oxygen gases, wherein the catalyst is in ionized form. The catalyst is made of a titanium oxide (Tio2) with the combination of ionized platinum salt and ionized palladium salt. The catalyst layer on a cordierite honey comb substrate is produced by a process known as a solution combustion technique. According to the solution combustion technique, the catalyst layer is produced by combining the ionized palladium salt and ionized platinum salt with the titanium oxide (Tio2) to form a single phase uniform titanium oxide catalyst, wherein the titanium oxide catalyst has the exact anatase structure having the formula Ti1-xPtxO2-x and Ti1-xPdxO2-x (for x = 0.01 to 0.15).
[0033] The prior arts use the catalysts that are typically pallets or amorphous powders. The use of such conventional catalysts involves complex design with an increased cost. The conventional catalyst gets easily poisoned and needs to be replaced quite often, because of their enclosure in the suitable holder for the reaction.
[0034] The present invention overcomes draw backs in the prior arts and provides a method to produce improved catalyst in an ionized state. The ionized catalyst reduces overall cost of the design and increases the productivity for recombination of hydrogen and oxygen gases. The ionized catalyst layer coated on the cordierite honey comb substrate does not poison and also does not require replacement therein.
[0035] The method is easy to implement, simple and is more suitable for applications in storage batteries, nuclear power station and shift gas production.
[0036] FIG 1 illustrates the method flow involved in producing the catalyst layer on honey comb substrate for recombination of hydrogen and oxygen gases, according to one embodiment of the invention. In the preferred embodiment, the method (100) comprising at step (101), the noble metal based catalysts such as an ionized palladium salt and ionized platinum salt are combined with a titanium oxide (Tio2) chemically using a solution combustion technique. After combining the noble metal based catalysts with the titanium oxide, at step (102), a single phase uniform titanium oxide catalyst layer is formed using the solution combustion technique. The single phase uniform titanium oxide catalyst layer has the exact anatase structure representing the formula Ti1-xPtxO2-x and Ti1-xPdxO2-x (for x = 0.01 to 0.15). Finally, after obtaining the single phase uniform titanium oxide catalyst layer, at step (103), the single phase uniform titanium oxide catalyst layer is coated on a cordierite honey comb substrate. The cordierite honey comb substrate has large surface area to provide higher rate of recombination reaction of hydrogen and oxygen gases.
[0037] In the preferred embodiment, the ionized catalyst layer achieves high yield rate on surface area of the cordierite honey comb substrate. The honeycomb design gives large surface area contact for gases to recombine very efficiently. The single phase uniform titanium oxide catalyst layer is coated with a micron layer on the honeycomb surface using solution combustion technique. Consequently a higher surface area is available for the reaction and which yields higher rate of recombination reaction. The palladium salt activates and accelerates the exothermic reaction at temperature greater than 35 degree Celsius for recombination of hydrogen and oxygen gases. The platinum salt functions well at lower temperatures.
[0038] FIG 2a shows the powder XRD (X-ray powder diffraction) patterns of cordierite (Mg2Al4Si5O18) honey comb structure monolith, according to one embodiment of the invention. The different peaks in the waveform indicate the intensities for various degrees.
[0039] FIG 2b shows the powder XRD patterns of Ti0.97Pd0.03O2-d and ?-Al2O3 coated on cordierite monolith, according to one embodiment of the invention.
[0040] FIG 2c shows the powder XRD patterns of as-prepared Ti0.97Pd0.03O2-d powder, according to one embodiment of the invention.
[0041] FIG 3a shows the Ti(2p) core level XPS (X-ray Photoelectron Spectroscopy) of Ti0.97Pd0.03O2-d coated on cordierite monolith, according to one embodiment of the invention. The waveform indicates the intensities for different binding energies.
[0042] FIG 3b shows the Pd (3d) core level XPS of Ti0.97Pd0.03O2-d coated on cordierite monolith, according to one embodiment of the invention.
[0043] FIG 4 shows H2 (Hydrogen) and O2 (Oxygen) recombination reaction mechanism on surface of Ti0.97Pd0.03O2-d, according to one embodiment of the invention.
[0044] FIG 5 shows the honeycomb structured ceramic body, according to one embodiment of the invention. In the preferred embodiment, the honeycomb structured ceramic body (500) includes multiple parallel channels (501). The parallel channels (501) permit the gases to escape therein and bound by thin ceramic wall (502). The ceramic wall (502) material has high surface area with excellent thermal stability. The composition of the honeycomb structured ceramic body (500) includes cordierite value greater than or equal to 90 percent (cordierite = >90%), SiO2 (Silicon dioxide) ranging from 47 to 52 percent, Al2O3 (Aluminium oxide) ranging from 31 to 35 percent, MgO (Magnesium oxide) ranging from 12 to 17 percent, water absorption ranging from 20 to 25 percent, coefficient of thermal expansion ranging from normal to 800°C < 1.8 x 10?6, density ranging from 0.45 to 0.55 gm/cc and thermal stability is greater or equal 1. The honeycomb structured ceramic body (500) has pore density equal to 400 pores/inch².
[0045] The prior arts use the catalysts that are typically pallets or amorphous powders. The use of conventional catalysts that are typically pallets or amorphous powders involves complex design with an increased cost. The conventional catalyst gets easily poisoned and needs to be replaced quite often, because of their enclosure in the suitable holder for the reaction.
[0046] The present invention overcomes draw backs in the prior arts and provides a method to produce improved catalyst in an ionized state. The ionized catalyst reduces overall cost of the design and increases the productivity for recombination of hydrogen and oxygen gases. The ionized catalyst layer coated on the cordierite honey comb substrate does not poison and also does not require replacement therein.
[0047] The process is easy to implement, simple and is more suitable for applications in storage batteries, nuclear power station, and shift gas production.
[0048] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only.