Method and system for forming plug and play metal compound catalysts
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.
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.