Method and system for forming plug and play metal compound catalysts

• US 9,597,662 B2
• Filed: 10/19/2015
• Issued: 03/21/2017
• 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, Kingsley, Jesudos J.
• Primary Examiner(s): Slifka, Sarah A
• Application Number:
  US14/887,187
• Publication Number:
  US 20160184802A1
• Time in Patent Office: 519 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

A metal compound catalyst is formed by vaporizing a quantity of catalyst material and a quantity of carrier thereby forming a vapor cloud, exposing the vapor cloud to a co-reactant and quenching the vapor cloud. The nanoparticles are impregnated onto supports. The supports are able to be used in existing heterogeneous catalysis systems. A system for forming metal compound catalysts comprises means for vaporizing a quantity of catalyst material and a quantity of carrier, quenching the resulting vapor cloud, forming precipitate nanoparticles comprising a portion of catalyst material and a portion of carrier, and subjecting the nanoparticles to a co-reactant. The system further comprises means for impregnating the of supports with the nanoparticles.

Claims

1. A supported catalyst, comprising:

a. a support structure comprising an oxide,

b. a nanoparticle wherein the nanoparticle has been reacted with a co-reactant, comprising;

i) a catalyst portion, and

ii) a carrier portion, said carrier portion comprising an oxide;

wherein the carrier portion is bonded to the support structure through an oxide-oxide bond.

2. The supported catalyst of claim 1 wherein the catalyst portion comprises a material selected from the group consisting of a metal, a metal compound, a metal alloy, and any combination thereof.

3. The supported catalyst of claim 1 wherein the oxide carrier portion comprises a material selected from the group consisting of silica, alumina, yttria, zirconia, titania, ceria, baria, and any combination thereof.

4. The supported catalyst of claim 1, wherein the oxide carrier portion comprises alumina.

5. The supported catalyst of claim 1, wherein the oxide carrier portion comprises ceria.

6. The supported catalyst of claim 1, wherein the catalyst portion comprises a transition metal.

7. The supported catalyst of claim 1, wherein the catalyst portion comprises a platinum group metal.

8. The supported catalyst of claim 1, wherein the catalyst portion comprises platinum.

9. The supported catalyst of claim 1, wherein the catalyst portion comprises palladium.

10. The supported catalyst of claim 1, wherein the catalyst portion comprises rhodium.

11. The supported catalyst of claim 1, wherein the co-reactant comprises a reactant selected from the group consisting of a carbon compound, a nitrogen compound, a phosphorus compound, an oxygen compound, a hydrogen compound, a sulfur compound, and any combination thereof.

12. The supported catalyst of claim 1, wherein the support structure comprises a porous oxide.

13. The supported catalyst of claim 1, wherein the support structure comprises alumina.

14. The supported catalyst of claim 1, wherein the catalyst portion comprises a platinum group metal, the oxide carrier portion comprises alumina, and the support structure comprises alumina.

15. The supported catalyst of claim 1, wherein the catalyst portion comprises platinum, the oxide carrier portion comprises alumina, and the support structure comprises alumina.

16. The supported catalyst of claim 1, wherein the catalyst portion comprises palladium, the oxide carrier portion comprises alumina, and the support structure comprises alumina.

17. The supported catalyst of claim 1, wherein the catalyst portion comprises rhodium, the oxide carrier portion comprises alumina, and the support structure comprises alumina.