Method and system for forming plug and play metal catalysts

• US 9,737,878 B2
• Filed: 02/26/2016
• Issued: 08/22/2017
• Est. Priority Date: 10/15/2007
• Status: Active Grant

• Current Assignee: SDC Materials,Inc., Umicore AG & Company KG (Umicore S.A.)
• Original Assignee: SDC Materials,Inc.
• Inventors: Biberger, Maximilian A., Lehman, Jr., Stephen Edward, Kevwitch, Robert Matthew, Yin, Qinghua, Kingsley, Jesudos J.
• Primary Examiner(s): Slifka, Sarah A
• Application Number:
  US15/055,085
• Publication Number:
  US 20170028393A1
• Time in Patent Office: 543 Days
• Field of Search: None
• 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 catalyst is formed by vaporizing a quantity of metal and a quantity of carrier forming a vapor cloud. The vapor cloud is quenched forming precipitate nanoparticles comprising a portion of metal and a portion of carrier. The nanoparticles are impregnated onto supports. The supports are able to be used in existing heterogeneous catalysis systems. A system for forming metal catalysts comprises means for vaporizing a quantity of metals and a quantity of carrier, quenching the resulting vapor cloud and forming precipitate nanoparticles comprising a portion of metals and a portion of carrier. The system further comprises means for impregnating supports with the nanoparticles.

Claims

1. A method of making a metal catalyst comprising:

a. providing a quantity of nanoparticles, wherein at least some of the nanoparticles comprise a first portion comprising catalyst material bonded to a second portion comprising a carrier;

b. providing a quantity of supports; and

c. combining the supports with the nanoparticles.

2. The method of claim 1 wherein the supports comprise pores and voids.

3. The method of claim 1 wherein the catalyst material comprises any among a list of at least one metal, at least one metal alloy, and any combination thereof.

4. The method of claim 1 wherein providing a quantity of nanoparticles comprises:

a. loading a quantity of catalyst material and a quantity of carrier into a plasma gun in a desired ratio;

b. vaporizing the quantity of catalyst material and quantity of carrier thereby forming a vapor cloud; and

c. quenching the vapor cloud, thereby forming a quantity of nanoparticles.

5. The method of claim 1 wherein the carrier comprises an oxide.

6. The method of claim 5 wherein the oxide comprises silica, alumina, yttria, zirconia, titania, ceria, baria, and any combination thereof.

7. The method of claim 1 wherein combining the supports with the nanoparticles comprises:

a. suspending the nanoparticles in a solution, thereby forming a suspension; and

b. mixing the suspension with a quantity of the supports.

8. The method of claim 7 wherein the suspension further comprises any among a dispersant and surfactant.

9. The method of claim 1 wherein combining the supports with the nanoparticles comprises:

a. suspending the nanoparticles in a solution, thereby forming a suspension; and

b. mixing the suspension with a slurry having supports suspended therein.

10. The method of claim 9 wherein the suspension further comprises any among a dispersant and a surfactant.

11. The method of claim 9 wherein the slurry comprises any one of organic solvent, aqueous solvent, and a combination thereof.

12. The method of claim 1 further comprising drying the supports.

13. The method of claim 1 further comprising exposing the supports to heat, pressure, or a combination thereof, thereby bonding the nanoparticles onto the supports.