Patents by Inventor Karl C. Kharas

Karl C. Kharas 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).

  • Patent number: 11904302
    Abstract: A microspherical fluid catalytic cracking (FCC) catalyst includes Y zeolite and a gamma-alumina.
    Type: Grant
    Filed: August 30, 2022
    Date of Patent: February 20, 2024
    Assignee: BASF CORPORATION
    Inventors: Junmei Wei, Lucas Dorazio, Karl C. Kharas, David J. Camerota, David M. Stockwell
  • Publication number: 20230365424
    Abstract: A process for preparing crystalline boehmite includes combining a stoichiometric amount of flash calcined gibbsite (AI2O3) and gibbsite (Al(OH)3) in a pressurizable reaction vessel; heating the flash calcined gibbsite and gibbsite in the reaction vessel to a temperature of about 200° C. to about 280° C. and for a time sufficient to form crystalline boehmite. A crystalline boehmite exhibiting a crystallite from about 600 ? to about 850 ? when measured in the 120 direction of the crystallographic space group Cmcm.
    Type: Application
    Filed: September 16, 2021
    Publication date: November 16, 2023
    Inventors: Karl C. Kharas, Danna Mooney
  • Publication number: 20230302432
    Abstract: A porous shaped catalyst support body comprising at least 85% by weight of alpha-alumina, wherein the support has a total pore volume in the range from 0.5 to 2.0 mL/g as determined by mercury porosimetry, and a pore structure characterized by a geometric tortuosity ? in the range from 1.0 to 2.0; and an effective diffusion parameter ? in the range from 0.060 to 1.0; wherein geometric tortuosity ? and effective diffusion parameter ? are determined by image analysis algorithms from computer-assisted 3D reconstructions of focused ion beam scanning electron microscope analyses. The structure of the support has a high total pore volume, such that impregnation with a large amount of silver is possible, while the surface area is kept sufficiently high in order to assure optimal dispersion of the catalytically active species, especially metal species. The support has a pore structure that leads to a maximum rate of mass transfer within the support.
    Type: Application
    Filed: June 25, 2021
    Publication date: September 28, 2023
    Inventors: Sung Yeun CHOI, Andrey KARPOV, Christian WALSDORFF, Patrick HUBACH, Hubert WAINDOK, Bernd HINRICHSEN, Gonzalo PRIETO GONZALEZ, Tania RODENAS TORRALBA, Karl C. KHARAS
  • Publication number: 20230271844
    Abstract: A strontium-catalyzed process for preparing boehmite includes combining a strontium material, flash calcined gibbsite, and water to obtain an aqueous suspension; contacting the aqueous suspension with a water-soluble carbonate material; and heating the aqueous suspension to a temperature, and for a time, sufficient to form at least about 5 wt. % of boehmite.
    Type: Application
    Filed: June 25, 2021
    Publication date: August 31, 2023
    Inventor: Karl C. Kharas
  • Publication number: 20230256415
    Abstract: A porous alpha-alumina catalyst support is prepared by (i) preparing a precursor material comprising a boehmitic-derived alumina having a pore volume of at least 0.6 mL/g, wherein the boehmitic-derived alumina is obtained by thermal decomposition of a boehmitic starting material and the boehmitic starting material consists predominantly of block-shaped crystals, and optionally an inorganic bond material; (ii) forming the precursor material into shaped bodies; (iii) calcining the shaped bodies to obtain the porous alpha-alumina catalyst support. The support structure has a high overall pore volume, while keeping its surface area sufficiently large so as to provide optimal dispersion of catalytically active species, in particular metal species. The support is useful for a catalyst for producing ethylene oxide by gas-phase oxidation of ethylene.
    Type: Application
    Filed: June 24, 2021
    Publication date: August 17, 2023
    Inventors: Sung Yeun CHOI, Andrey KARPOV, Christian WALSDORFF, Karl C. KHARAS
  • Publication number: 20230234030
    Abstract: A tableted catalyst support, characterized by an alpha-alumina content of at least 85 wt.-%, a pore volume of at least 0.40 mL/g, as determined by mercury porosimetry, and a BET surface area of 0.5 to 5.0 m2/g. The tableted catalyst support is an alpha-alumina catalyst support obtained with high geometrical precision and displaying a high overall pore volume, thus allowing for impregnation with a high amount of silver, while exhibiting a surface area sufficiently large so as to provide optimal dispersion of catalytically active species, in particular metal species. The invention further provides a process for producing a tableted alpha-alumina catalyst support, which comprises i) forming a free-flowing feed mixture comprising, based on inorganic solids content, at least 50 wt.-% of a transition alumina; ii) tableting the free-flowing feed mixture to obtain a compacted body; and iii) heat treating the compacted body at a temperature of at least 1100° C., preferably at least 1300° C.
    Type: Application
    Filed: June 25, 2021
    Publication date: July 27, 2023
    Inventors: Sung Yeun CHOI, Andrey KARPOV, Christian WALSDORFF, Nicolas DUYCKAERTS, Kazuhiko AMAKAWA, Patrick HUBACH, Karl C. KHARAS
  • Publication number: 20230158476
    Abstract: A support comprising kaolin clay, wherein the kaolin clay comprises less than or equal to about 0.6% by weight of iron, based on total weight of the support.
    Type: Application
    Filed: April 22, 2021
    Publication date: May 25, 2023
    Inventors: Karl C. Kharas, Shen Zhao, Michael B. Sigman
  • Publication number: 20230048215
    Abstract: A microspherical fluid catalytic cracking (FCC) catalyst includes Y zeolite and a gamma-alumina.
    Type: Application
    Filed: August 30, 2022
    Publication date: February 16, 2023
    Inventors: Junmei WEI, Lucas DORAZIO, Karl C. KHARAS, David J. CAMEROTA, David M. STOCKWELL
  • Publication number: 20220331787
    Abstract: The present disclosure provides catalyst compositions capable of reducing nitrogen oxide (NOx) emissions in engine exhaust. The catalyst compositions include metal ion-exchanged zeolites having a domain size of less than about 1500 ?ngstroms (?), a crystallographic strain of less than about 0.7%, or both. Further provided are catalyst articles coated with such compositions, processes for preparing such catalyst compositions and articles, an exhaust gas treatment system including such catalytic articles, and methods for reducing NOx in an exhaust gas stream using such catalytic articles and systems.
    Type: Application
    Filed: September 24, 2020
    Publication date: October 20, 2022
    Inventors: Eduard L. KUNKES, Karl C. KHARAS
  • Patent number: 11471862
    Abstract: A microspherical fluid catalytic cracking (FCC) catalyst includes Y zeolite and a gamma-alumina.
    Type: Grant
    Filed: May 16, 2018
    Date of Patent: October 18, 2022
    Assignee: BASF CORPORATION
    Inventors: Junmei Wei, Lucas Dorazio, Karl C. Kharas, David J. Camerota, David M. Stockwell
  • Patent number: 11027264
    Abstract: A microspherical fluid catalytic cracking catalyst includes zeolite, and alkali metal ion or alkaline earth metal ion.
    Type: Grant
    Filed: December 3, 2019
    Date of Patent: June 8, 2021
    Assignee: BASF Corporation
    Inventor: Karl C. Kharas
  • Publication number: 20200101448
    Abstract: A microspherical fluid catalytic cracking catalyst includes zeolite, and alkali metal ion or alkaline earth metal ion.
    Type: Application
    Filed: December 3, 2019
    Publication date: April 2, 2020
    Inventor: Karl C. KHARAS
  • Publication number: 20200078774
    Abstract: A microspherical fluid catalytic cracking (FCC) catalyst includes Y zeolite and a gamma-alumina.
    Type: Application
    Filed: May 16, 2018
    Publication date: March 12, 2020
    Inventors: Junmei WEI, Lucas DORAZIO, Karl C. KHARAS, David J. CAMEROTA, David M. STOCKWELL
  • Patent number: 10507460
    Abstract: A microspherical fluid catalytic cracking catalyst includes zeolite, and alkali metal alkaline earth metal ion.
    Type: Grant
    Filed: November 18, 2016
    Date of Patent: December 17, 2019
    Assignee: BASF CORPORATION
    Inventor: Karl C. Kharas
  • Publication number: 20180369793
    Abstract: A micro spherical fluid catalytic cracking catalyst includes zeolite, and alkali metal alkaline earth metal ion.
    Type: Application
    Filed: November 18, 2016
    Publication date: December 27, 2018
    Inventor: Karl C. KHARAS
  • Publication number: 20170209852
    Abstract: A method for controllably producing a hematite-containing Fischer-Tropsch catalyst by combining an iron nitrate solution with a precipitating agent solution at a precipitating temperature and over a precipitation time to form a precipitate comprising iron phases; holding the precipitate from at a hold temperature for a hold time to provide a hematite containing precipitate; and washing the hematite containing precipitate via contact with a wash solution and filtering, to provide a washed hematite containing catalyst. The method may further comprise promoting the washed hematite containing catalyst with a chemical promoter; spray drying the promoted hematite containing catalyst; and calcining the spray dried hematite containing catalyst to provide a calcined hematite-containing Fischer-Tropsch catalyst.
    Type: Application
    Filed: April 10, 2017
    Publication date: July 27, 2017
    Inventors: Dawid J. Duvenhage, Christine Schmidt, Mark Still, Khalid Azzam, Karl C. Kharas, Sara Hunegnaw, Olga Ionkina, Ray J. Huang, Harold A. Wright
  • Patent number: 9669390
    Abstract: A method for controllably producing a hematite-containing Fischer-Tropsch catalyst by combining an iron nitrate solution with a precipitating agent solution at a precipitating temperature and over a precipitation time to form a precipitate comprising iron phases; holding the precipitate from at a hold temperature for a hold time to provide a hematite containing precipitate; and washing the hematite containing precipitate via contact with a wash solution and filtering, to provide a washed hematite containing catalyst. The method may further comprise promoting the washed hematite containing catalyst with a chemical promoter; spray drying the promoted hematite containing catalyst; and calcining the spray dried hematite containing catalyst to provide a calcined hematite-containing Fischer-Tropsch catalyst.
    Type: Grant
    Filed: February 11, 2014
    Date of Patent: June 6, 2017
    Assignee: RES USA, LLC
    Inventors: Dawid J. Duvenhage, Christine Schmidt, Mark Still, Khalid Azzam, Karl C. Kharas, Sara Hunegnaw, Olga Ionkina, Ray J. Huang, Harold A. Wright
  • Publication number: 20160001267
    Abstract: A method for controllably producing a hematite-containing Fischer-Tropsch catalyst by combining an iron nitrate solution with a precipitating agent solution at a precipitating temperature and over a precipitation time to form a precipitate comprising iron phases; holding the precipitate from at a hold temperature for a hold time to provide a hematite containing precipitate; and washing the hematite containing precipitate via contact with a wash solution and filtering, to provide a washed hematite containing catalyst. The method may further comprise promoting the washed hematite containing catalyst with a chemical promoter; spray drying the promoted hematite containing catalyst; and calcining the spray dried hematite containing catalyst to provide a calcined hematite-containing Fischer-Tropsch catalyst.
    Type: Application
    Filed: February 11, 2014
    Publication date: January 7, 2016
    Inventors: Dawid J. Duvenhage, Christine Schmidt, Mark Still, Khalid Azzam, Karl C. Kharas, Sara Hunegnaw, Olga Ionkina, Ray J. Huang, Harold A. Wright
  • Patent number: 8809225
    Abstract: An iron-based Fischer-Tropsch catalyst comprising magnetite and characterized by integrable X-ray diffraction reflections corresponding to (311), (511), (440), and (400), such that the relative intensity of the (400) reflection to the (300) reflection is less than about 39%. A method of preparing an activated iron-based Fischer-Tropsch catalyst by providing a precipitated catalyst comprising oxides including at least iron oxide; and activating the precipitated catalyst to provide the activated iron-based Fischer-Tropsch catalyst, wherein activating the precipitated catalyst comprises exposing the precipitated catalyst to an activation gas and increasing the temperature from a first temperature to a second temperature at a ramp rate, whereby the ratio of the intensity of the (400) reflection of the activated iron-based Fischer-Tropsch catalyst to the intensity of the (311) reflection thereof is less than 38%.
    Type: Grant
    Filed: October 15, 2012
    Date of Patent: August 19, 2014
    Assignee: Rentech, Inc
    Inventor: Karl C. Kharas
  • Publication number: 20130109561
    Abstract: An iron-based Fischer-Tropsch catalyst comprising magnetite and characterized by integrable X-ray diffraction reflections corresponding to (311), (511), (440), and (400), such that the relative intensity of the (400) reflection to the (300) reflection is less than about 39%. A method of preparing an activated iron-based Fischer-Tropsch catalyst by providing a precipitated catalyst comprising oxides including at least iron oxide; and activating the precipitated catalyst to provide the activated iron-based Fischer-Tropsch catalyst, wherein activating the precipitated catalyst comprises exposing the precipitated catalyst to an activation gas and increasing the temperature from a first temperature to a second temperature at a ramp rate, whereby the ratio of the intensity of the (400) reflection of the activated iron-based Fischer-Tropsch catalyst to the intensity of the (311) reflection thereof is less than 38%.
    Type: Application
    Filed: October 15, 2012
    Publication date: May 2, 2013
    Applicant: Rentech, Inc.
    Inventor: Karl C. KHARAS