Method and system for forming plug and play oxide catalysts

• US 9,592,492 B2
• Filed: 06/19/2015
• Issued: 03/14/2017
• Est. Priority Date: 10/15/2007
• Status: Active Grant

• Current Assignee: Umicore AG & Company KG (Umicore S.A.)
• Original Assignee: SDC Materials,Inc.
• Inventors: Biberger, Maximilian A., Lehman, Stephen Edward Jr., Kevwitch, Robert Matthew, Yin, Qinghua
• Primary Examiner(s): Slifka, Sarah A
• Application Number:
  US14/745,272
• Publication Number:
  US 20160144346A1
• Time in Patent Office: 634 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 21/063 Titanium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 21/066 Zirconium or hafnium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 21/08 Silica
• CPC Class Codes: B01J 23/00 Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 B01J21/16 takes precedence
• CPC Class Codes: B01J 23/02 of the alkali- or alkaline earth metals or beryllium
• CPC Class Codes: B01J 23/10 of rare earths
• CPC Class Codes: B01J 23/40 of the platinum group metals
• CPC Class Codes: B01J 23/42 Platinum
• CPC Class Codes: B01J 23/44 Palladium
• CPC Class Codes: B01J 23/464 Rhodium
• CPC Class Codes: B01J 23/58 with alkali- or alkaline earth metals
• CPC Class Codes: B01J 23/63 with rare earths or actinides
• CPC Class Codes: B01J 23/83 with rare earths or actinides
• CPC Class Codes: B01J 27/02 Sulfur, selenium or tellurium; Compounds thereof
• CPC Class Codes: B01J 27/14 Phosphorus; Compounds thereof
• CPC Class Codes: B01J 27/20 Carbon compounds
• CPC Class Codes: B01J 27/24 Nitrogen compounds
• CPC Class Codes: B01J 31/02 containing organic compounds or metal hydrides
• CPC Class Codes: B01J 35/19 Catalysts containing parts with different compositions
• CPC Class Codes: B01J 35/23 : in a colloidal state
• CPC Class Codes: B01J 35/393 : Metal or metal oxide crystallite size
• CPC Class Codes: B01J 35/394 : Metal dispersion value, e.g. percentage or fraction
• CPC Class Codes: B01J 35/40 : characterised by dimensions, e.g. grain size in a colloidal state B01J35/23; crystallite size B01J35/77
• CPC Class Codes: B01J 37/0203 : the impregnation liquid containing organic compounds
• CPC Class Codes: B01J 37/0211 : using a colloidal suspension
• CPC Class Codes: B01J 37/0215 : Coating
• CPC Class Codes: B01J 37/0219 : the coating containing organic compounds
• CPC Class Codes: B01J 37/0236 : Drying, e.g. preparing a suspension, adding a soluble salt and drying
• CPC Class Codes: B01J 37/04 : Mixing B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: B01J 37/08 : Heat treatment B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: B01J 37/349 : making use of flames, plasmas or lasers
• CPC Class Codes: B01J 8/00 : Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
• CPC Class Codes: B82Y 40/00 : Manufacture or treatment of nanostructures
• CPC Class Codes: C07C 13/18 : with a cyclohexane ring
• CPC Class Codes: C07C 2521/04 : Alumina
• CPC Class Codes: C07C 2523/42 : Platinum
• CPC Class Codes: C07C 2601/14 : The ring being saturated
• CPC Class Codes: C07C 5/10 : of aromatic six-membered rings
• CPC Class Codes: Y02P 20/52 : using catalysts, e.g. selective catalysts
• CPC Class Codes: Y10S 977/892 : Liquid phase deposition
• CPC Class Codes: Y10T 428/2982 : Particulate matter [e.g., sphere, flake, etc.]
• CPC Class Codes: Y10T 428/2991 : Coated

Abstract

An oxide catalyst is formed by vaporizing a quantity of at least one precursor material or catalyst material thereby forming a vapor cloud. The vapor cloud is quenched forming precipitate nanoparticles. The nanoparticles are impregnated onto supports. The supports are able to be used in existing heterogeneous catalysis systems. A system for forming oxide catalysts comprises means for vaporizing a quantity of at least one precursor material or at least one catalyst material, quenching the resulting vapor cloud and forming precipitate nanoparticles. The system further comprises means for supports with the nanoparticles.

Claims

1. A supported catalyst, comprising:

a. support structures, wherein the support structure comprises a porous oxide; and

b. nanoparticles bonded to the support structures, wherein the nanoparticles comprise an oxide catalyst;

wherein the nanoparticles are attached to the support structures by an oxide-oxide bond.

2. The supported catalyst of claim 1, wherein the oxide catalyst comprises a metal oxide.

3. The supported catalyst of claim 2, wherein the oxide catalyst comprises lanthanum iron oxide.

4. The supported catalyst of claim 1, wherein the nanoparticles are prepared using plasma.

5. The supported catalyst of claim 1, wherein the support structures are macroscopic particles.

6. The supported catalyst of claim 1, wherein the nanoparticles are about 0.5 nanometers to about 200 nanometers in diameter.

7. The supported catalyst of claim 1, wherein the nanoparticles are on the surface and in the pores of the support structures.

8. The supported catalyst of claim 7, wherein the nanoparticles are deposited on the surface and in the pores of the support structures by suspending the nanoparticles in a solution to form a suspension, and mixing the suspension with the support structures.

9. The supported catalyst of claim 8, wherein the solution further comprises a dispersant.

10. The supported catalyst of claim 8, wherein the suspension of nanoparticles mixed with the support structures is dried, then exposed to heat, pressure, or a combination of heat and pressure to calcine the nanoparticles onto the support structures.

11. The supported catalyst of claim 7, wherein the nanoparticles are deposited on the surface and in the pores of the support structures by suspending the nanoparticles in a solution to form a suspension, and mixing the suspension with a slurry having the support structures suspended therein.

12. The supported catalyst of claim 11, wherein the solution further comprises a dispersant.

13. The supported catalyst of claim 1, wherein the nanoparticles comprise a metal oxide formed from a precursor material, wherein the precursor material is selected from the group consisting of a metal, a metal oxide, a metal salt, a carbon compound, a chlorine compound, a phosphorous compound, and any combination thereof.

14. The supported catalyst of claim 1, wherein the oxide-oxide bond is formed by calcination.