Method and system for forming plug and play metal catalysts

摘要

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.

主权项

1. A metal catalyst prepared by a method comprising:
a. forming a quantity of nanoparticles comprising:
(i) loading feed material in a powdered form, the feed material comprising a quantity of catalyst material and a quantity of carrier material in a desired ratio of catalyst material to carrier material, into a plasma reactor,(ii) vaporizing the quantity of catalyst material and the quantity of carrier material in the plasma reactor to form a vapor cloud of catalyst and carrier material, and(iii) quenching the vapor cloud of catalyst material and carrier material in a highly turbulent quench chamber to form solidified nanoparticles comprising catalyst material and carrier material, wherein the solidified nanoparticles comprise a first portion comprising the catalyst material bonded to a second portion comprising the carrier material; b. providing a quantity of supports; and c. combining the supports with the nanoparticles by suspending the nanoparticles in a solution, thereby forming a suspension, and combining the suspension with the supports.