Patents by Inventor James W. Kauffman

James W. Kauffman has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20200094224
    Abstract: An OCM catalyst composition characterized by general formula AaLabEcDdOx; wherein A is an alkaline earth metal; wherein E is a first rare earth element; wherein D is a redox agent or a second rare earth element; wherein the first rare earth element and second rare earth element are different; wherein a is 1.0; wherein b is 0.01-10.0; wherein c is 0-10.0; wherein d is 0-10.0; and wherein x balances the oxidation states. The alkaline earth metal is selected from the group consisting of Mg, Ca, Sr, Ba, and combinations thereof. The first rare earth element and the second rare earth element can each independently be selected from the group consisting of Sc, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Y, Tb, Dy, Ho, Er, Tm, Yb, Lu, and combinations thereof. The redox agent is selected from the group consisting of Mn, W, Bi, Sb, Sn, Ce, Pr, and combinations thereof.
    Type: Application
    Filed: March 21, 2018
    Publication date: March 26, 2020
    Inventors: Wugeng LIANG, David WEST, Luanyi LI, Vidya Sagar Reddy SARSANI, Hector PEREZ, James W. KAUFFMAN
  • Patent number: 9643171
    Abstract: The invention is for a method for making a heteropoly acid compound catalyst from compounds containing molybdenum, vanadium, phosphorus, cesium, copper, bismuth, antimony and boron in which molybdenum, vanadium, phosphorus, cesium, copper, bismuth and boron are at their highest oxidation states and antimony has a 3+ oxidation state. The catalyst contains oxides of molybdenum, vanadium, phosphorus, cesium, copper, bismuth, antimony, boron and, optionally, other metals. The catalyst has the formula: Mo12VaPbCscCudBieSbfBgOx where Mo is molybdenum, V is vanadium, P is phosphorus, Cs is cesium, Cu is copper, Bi is bismuth, Sb is antimony, B is boron, O is oxygen, a is 0.01 to 5.0, b is 0.5 to 3.5, c is 0.01 to 2.0, d is 0.0-1.5, e is 0.0-2.0, f is 0.01-3.0, g is 0.0-4.0 and x satisfies the valences. Molybdenum is reduced by antimony and reoxidized during catalyst synthesis.
    Type: Grant
    Filed: February 25, 2010
    Date of Patent: May 9, 2017
    Assignee: SAUDI BASIC INDUSTRIES CORPORATION
    Inventors: James W. Kauffman, Wugeng Liang, Lixia Cai
  • Patent number: 9415378
    Abstract: A dehydrogenation catalyst is formed by forming a mixture comprising a bayerite aluminum hydroxide (Al(OH)3), a lanthanum (La) source, a cerium (Ce) source, a barium (Ba) source, a zirconium (Zr) source, and water into a shaped body. The shaped body is calcined at a temperature of at least 750° C. to form a catalyst support. The catalyst support is treated with a dehydrogenation catalyst component to form a treated catalyst support containing the dehydrogenation catalyst component. The treated catalyst support is then calcined. The resulting catalyst composition may be used by contacting a paraffin hydrocarbon feed with a catalyst within a reactor in the presence of steam under dehydrogenation reaction conditions suitable to form dehydrogenated hydrocarbon products.
    Type: Grant
    Filed: December 2, 2013
    Date of Patent: August 16, 2016
    Assignee: SAUDI BASIC INDUSTRIES CORPORATION
    Inventors: James W. Kauffman, Patricia A. Hooks, Balamurali Krishna R. Nair, Xiankuan Zhang
  • Patent number: 9364815
    Abstract: A method of forming a dehydrogenation catalyst support is carried out by forming a mixture comprising a bayerite aluminum hydroxide (Al(OH)3) and water into a support material. The support material is particulized. The particulized support material is compressed to a pressure of at least 5,000 psig to form a shaped body. The shaped body is calcined in pure steam at a temperature of at least 750° C. for at least 0.25 hours to form a catalyst support having an average pore diameter of 200 ? or greater. The catalyst support can then be treated with a dehydrogenation catalyst component so that the catalyst support contains the dehydrogenation catalyst component to form a dehydrogenation catalyst that can then be used by contacting a hydrocarbon feed with the catalyst within a reactor in the presence of steam under dehydrogenation reaction conditions suitable to form dehydrogenated hydrocarbon products.
    Type: Grant
    Filed: November 7, 2013
    Date of Patent: June 14, 2016
    Assignee: SAUDI BASIC INDUSTRIES CORPORATION
    Inventors: James W. Kauffman, Patricia A. Hooks, Balamurali Krishna R. Nair
  • Publication number: 20150151283
    Abstract: A dehydrogenation catalyst is formed by forming a mixture comprising a bayerite aluminum hydroxide (Al(OH)3), a lanthanum (La) source, a cerium (Ce) source, a barium (Ba) source, a zirconium (Zr) source, and water into a shaped body. The shaped body is calcined at a temperature of at least 750° C. to form a catalyst support. The catalyst support is treated with a dehydrogenation catalyst component to form a treated catalyst support containing the dehydrogenation catalyst component. The treated catalyst support is then calcined. The resulting catalyst composition may be used by contacting a paraffin hydrocarbon feed with a catalyst within a reactor in the presence of steam under dehydrogenation reaction conditions suitable to form dehydrogenated hydrocarbon products.
    Type: Application
    Filed: December 2, 2013
    Publication date: June 4, 2015
    Applicant: Saudi Basic Industries Corporation
    Inventors: James W. Kauffman, Patricia A. Hooks, Balamurali Krishna R. Nair
  • Publication number: 20150126792
    Abstract: A method of forming a dehydrogenation catalyst support is carried out by forming a mixture comprising a bayerite aluminum hydroxide (Al(OH)3) and water into a support material. The support material is particulized. The particulized support material is compressed to a pressure of at least 5,000 psig to form a shaped body. The shaped body is calcined in pure steam at a temperature of at least 750° C. for at least 0.25 hours to form a catalyst support having an average pore diameter of 200 ? or greater. The catalyst support can then be treated with a dehydrogenation catalyst component so that the catalyst support contains the dehydrogenation catalyst component to form a dehydrogenation catalyst that can then be used by contacting a hydrocarbon feed with the catalyst within a reactor in the presence of steam under dehydrogenation reaction conditions suitable to form dehydrogenated hydrocarbon products.
    Type: Application
    Filed: November 7, 2013
    Publication date: May 7, 2015
    Inventors: James W. Kauffman, Patricia A. Hooks, Balamurali Krishna R. Nair
  • Publication number: 20140200384
    Abstract: A catalyst composition useful for the dehydrogenation of hydrocarbon comprises components (A)-(G). Component (A) is a catalyst substrate. (B) is platinum. (C) is at least one of germanium, tin, lead, gallium, indium, and titanium. (D) is phosphorus, the total amount of component (D) being at a level of from 1 wt. % to 3 wt. %. (E) is at least one of magnesium, calcium, strontium, barium, radium, and a lanthanide, the total amount of component (E) being at a level of from 0.1 wt. % to 5 wt. %. (F) is chloride at a level of 0.1 wt. % to 2 wt. %. Component (G) is manganese. The catalyst may be used in the conversion of hydrocarbons wherein a hydrocarbon feed is contacted with the catalyst within a reactor under hydrocarbon conversion reaction conditions to form hydrocarbon conversion products. Sources of the various components are combined in a method to form the catalyst composition.
    Type: Application
    Filed: January 16, 2013
    Publication date: July 17, 2014
    Inventors: James W. Kauffman, Patricia A. Hooks, Balamurali Krishna R. Nair
  • Patent number: 8722940
    Abstract: A catalyst for the oxidation of an olefin to an unsaturated aldehyde comprising a mixed metal oxide having the formula (I): MoaWbMcM?dM?eZfOg??(I) where M represents trivalent metals, M? represents divalent metals, M? represents monovalent metals, Z represents elements in the form of an oxide, a, b, c, d, e, f and g are numbers, and where the catalyst has an anion to cation molar (ACM) ratio greater than 1.00 and less than 2.00 and an M? to M molar ratio between 1.95 and 2.15.
    Type: Grant
    Filed: March 1, 2012
    Date of Patent: May 13, 2014
    Assignee: Saudi Basic Industries Corporation
    Inventors: James W. Kauffman, David L. Sullivan, Joe D. Dostal
  • Publication number: 20130231507
    Abstract: A catalyst for the oxidation of an olefin to an unsaturated aldehyde comprising a mixed metal oxide having the formula (I): MoaWbMcM?dM?eZfOg??(I) where M represents trivalent metals, M? represents divalent metals, M? represents monovalent metals, Z represents elements in the form of an oxide, a, b, c, d, e, f and g are numbers, and where the catalyst has an anion to cation molar (ACM) ratio greater than 1.00 and less than 2.00 and an M? to M molar ratio between 1.95 and 2.15.
    Type: Application
    Filed: March 1, 2012
    Publication date: September 5, 2013
    Inventors: James W. Kauffman, David L. Sullivan, Joe D. Dostal
  • Patent number: 8481448
    Abstract: The invention is a heteropoly acid compound catalyst composition, a method of making the catalyst composition and a process for the oxidation of saturated and/or unsaturated aldehydes to unsaturated carboxylic acids using the catalyst composition. The catalyst composition is a heteropoly acid compound containing molybdenum, vanadium, phosphorus, cesium, bismuth, copper and antimony. Thermal stability is achieved with higher cesium content (up to less than 3.0) but antimony, copper and bismuth must be present to maintain good activity. The catalyst is made by dissolving compounds of the components of each of the heteropoly acid compounds in a solution, precipitating the heteropoly acid compounds, obtaining a catalyst precursor and calcining the catalyst precursor to form a heteropoly acid compound catalyst. Unsaturated aldehydes, such as methacrolein, may be oxidized in the presence of the heteropoly acid compound catalyst to produce an unsaturated carboxylic acid, such as methacrylic acid.
    Type: Grant
    Filed: July 19, 2010
    Date of Patent: July 9, 2013
    Assignee: Saudi Basic Industries Corporation
    Inventors: Wugeng Liang, David Sullivan, James W. Kauffman, Clark Rea, Joe Linzer, Shahid Shaikh
  • Publication number: 20120016159
    Abstract: The invention is a heteropoly acid compound catalyst composition, a method of making the catalyst composition and a process for the oxidation of saturated and/or unsaturated aldehydes to unsaturated carboxylic acids using the catalyst composition. The catalyst composition is a heteropoly acid compound containing molybdenum, vanadium, phosphorus, cesium, bismuth, copper and antimony. Thermal stability is achieved with higher cesium content (up to less than 3.0) but antimony, copper and bismuth must be present to maintain good activity. The catalyst is made by dissolving compounds of the components of each of the heteropoly acid compounds in a solution, precipitating the heteropoly acid compounds, obtaining a catalyst precursor and calcining the catalyst precursor to form a heteropoly acid compound catalyst. Unsaturated aldehydes, such as methacrolein, may be oxidized in the presence of the heteropoly acid compound catalyst to produce an unsaturated carboxylic acid, such as methacrylic acid.
    Type: Application
    Filed: July 19, 2010
    Publication date: January 19, 2012
    Applicant: Saudi Basic Industries Corporation
    Inventors: Wugeng Liang, David Sullivan, James W. Kauffman, Clark Rea, Joe Linzer, Shahid Shaikh
  • Publication number: 20110207600
    Abstract: The invention is for a method for making a heteropoly acid compound catalyst from compounds containing molybdenum, vanadium, phosphorus, cesium, copper, bismuth, antimony and boron in which molybdenum, vanadium, phosphorus, cesium, copper, bismuth and boron are at their highest oxidation states and antimony has a 3+ oxidation state. The catalyst contains oxides of molybdenum, vanadium, phosphorus, cesium, copper, bismuth, antimony, boron and, optionally, other metals. The catalyst has the formula: Mo12VaPbCscCudBieSbfBgOx where Mo is molybdenum, V is vanadium, P is phosphorus, Cs is cesium, Cu is copper, Bi is bismuth, Sb is antimony, B is boron, O is oxygen, a is 0.01 to 5.0, b is 0.5 to 3.5, c is 0.01 to 2.0, d is 0.0-1.5, e is 0.0-2.0, f is 0.01-3.0, g is 0.0-4.0 and x satisfies the valences. Molybdenum is reduced by antimony and reoxidized during catalyst synthesis.
    Type: Application
    Filed: February 25, 2010
    Publication date: August 25, 2011
    Applicant: Saudi Basic Industries Corporation
    Inventors: James W. Kauffman, Wugeng Liang, Lixia Cai, Joseph Linzer
  • Patent number: 7999133
    Abstract: Methods for making unsaturated acids using catalysts for oxidation of unsaturated and/or saturated aldehyde to unsaturated acids is disclosed where the catalyst including at least molybdenum (Mo) and phosphorus (P), where the catalyst has a pore size distribution including at least 50% medium pores and if bismuth is present, a nitric acid to molybdenum mole ratio of at least 0.5:1 or at least 6.0:1 moles of HNO3 per mole of Mo12.
    Type: Grant
    Filed: May 31, 2010
    Date of Patent: August 16, 2011
    Assignee: Sabic Basic Industries Corporation
    Inventors: Scott A. Stevenson, Wugeng Liang, James W. Kauffman, Lixia Cai, Angie McGuffey, Joseph R. Linzer
  • Patent number: 7923404
    Abstract: Methods of making catalysts for oxidation of unsaturated and/or saturated aldehyde to unsaturated acids is disclosed where the catalyst including at least molybdenum (Mo) and phosphorus (P), where the catalyst has a pore size distribution including at least 50% medium pores and if bismuth is present, a nitric acid to molybdenum mole ratio of at least 0.5:1 or at least 6.0:1 moles of HNO3 per mole of Mo12.
    Type: Grant
    Filed: May 31, 2010
    Date of Patent: April 12, 2011
    Assignee: Saudi Basic Industries Corporation
    Inventors: Scott A. Stevenson, Wugeng Liang, James W. Kauffman, Lixia Cai, Angie McGuffey, Joseph R. Linzer
  • Publication number: 20100323882
    Abstract: Methods of making catalysts for oxidation of unsaturated and/or saturated aldehyde to unsaturated acids is disclosed where the catalyst including at least molybdenum (Mo) and phosphorus (P), where the catalyst has a pore size distribution including at least 50% medium pores and if bismuth is present, a nitric acid to molybdenum mole ratio of at least 0.5:1 or at least 6.0:1 moles of HNO3 per mole of Mo12.
    Type: Application
    Filed: May 31, 2010
    Publication date: December 23, 2010
    Applicant: SAUDI BASIC INDUSTRIES CORPORATION
    Inventors: Scott A. Stevenson, Wugeng Liang, James W. Kauffman, Lixia Cai, Angie McGuffey, Joseph R. Linzer
  • Publication number: 20100240925
    Abstract: Methods for making unsaturated acids using catalysts for oxidation of unsaturated and/or Saturated aldehyde to unsaturated acids is disclosed where the catalyst including at least molybdenum (Mo) and phosphorus (P), where the catalyst has a pore size distribution including at least 50% medium pores and if bismuth is present, a nitric acid to molybdenum mole ratio of at least 0.5:1 or at least 6.0:1 moles of HNO3 per mole of Mo12.
    Type: Application
    Filed: May 31, 2010
    Publication date: September 23, 2010
    Applicant: SAUDI BASIC INDUSTRIES CORPORATION
    Inventors: Scott A. Stevenson, Wugeng Liang, James W. Kauffman, Lixia Cai, Angie McGuffey, Joseph R. Linzer
  • Patent number: 7732367
    Abstract: A catalyst for oxidation of unsaturated and/or saturated aldehyde to unsaturated acids is disclosed where the catalyst including at least molybdenum (Mo), phosphorus (P), vanadium (V), bismuth (Bi), and a first component selected from the group consisting of potassium (K), rubidium (Rb), cesium (Cs), thallium (Tl), or mixtures or combinations thereof, where the catalyst has at least 57% medium pores and a nitric acid to molybdenum mole ratio of at least 0.5:1 or at least 6.0:1 moles of HNO3 per mole of Mo12. Methods for making and using such catalysts are also disclosed.
    Type: Grant
    Filed: July 25, 2005
    Date of Patent: June 8, 2010
    Assignee: Saudi Basic Industries Corporation
    Inventors: Scott A. Stevenson, Wugeng Liang, James W. Kauffman, Lixia Cai, Angie McGuffey, Joseph R. Linzer
  • Patent number: 7501377
    Abstract: A catalyst for production of unsaturated aldehydes, such as methacrolein, by gas phase catalytic oxidation of olefins, such as isobutylene, contains oxides of molybdenum, bismuth, iron, cesium and, optionally, other metals. The catalyst has a certain relative amount ratio of cesium to bismuth, a certain relative amount ratio of iron to bismuth and a certain relative amount ratio of bismuth, iron, cesium and certain other metals to molybdenum and, optionally, tungsten. For a catalyst of the formula: Mo12BiaWbFecCodNieSbfCsgMghZniPjOx wherein a is 0.1 to 1.5, b is 0 to 4, c is 0.2 to 5.0, d is 0 to 9, e is 0 to 9, f is 0 to 2.0, g is from 0.4 to 1.5, h is 0 to 1.5, i is 0 to 2.0, j is 0 to 0.5 and x is determined by the valences of the other components, c:g=3.3-5.0, c:a=2.0-6.0 and (3a+3c+2d+2e+g+2h+2i)/(2×12+2b)=0.95-1.10.
    Type: Grant
    Filed: May 24, 2007
    Date of Patent: March 10, 2009
    Assignee: Saudi Basic Industries Corporation
    Inventors: Wugeng Liang, Scott A. Stevenson, James W. Kauffman, John S. Ledford, Joseph R. Linzer
  • Patent number: 7494952
    Abstract: The present invention is for a process for making a catalyst for production of unsaturated aldehydes, such as methacrolein, by gas phase catalytic oxidation of olefins, such as isobutylene, said catalyst containing oxides of molybdenum, bismuth, iron, cesium, tungsten, cobalt, nickel, antimony, magnesium and zinc. The process is a synthesis of the catalyst with aging or digestion of the reaction slurry with little or no agitation. A catalyst precursor is formed from the water insoluble and water soluble components and is dried. The metal oxide catalyst is formed by calcination of the catalyst precursor.
    Type: Grant
    Filed: January 17, 2006
    Date of Patent: February 24, 2009
    Assignee: Saudi Basic Industries Corporation
    Inventors: James W. Kauffman, Angela McGuffey
  • Patent number: 7485596
    Abstract: The present invention is for a process for making a heteropoly acid compound catalyst for oxidation of unsaturated aldehydes, such as methacrolein, to unsaturated carboxylic acids, such as methacrylic acid, said catalyst containing oxides of molybdenum, phosphorus, and M?, wherein M? is cesium, potassium, rubidium, or sodium, and bismuth. The process is a synthesis of the catalyst with specific process conditions for addition of the bismuth compound as an aqueous slurry without nitric acid. A catalyst precursor is formed by removing the water and drying the solid particles. The heteropoly acid compound catalyst is formed by calcination of the catalyst precursor.
    Type: Grant
    Filed: December 28, 2005
    Date of Patent: February 3, 2009
    Assignee: Saudi Basic Industries Corporation
    Inventors: James W. Kauffman, Lixia Cai, Wugeng Liang