Catalyst, structures, reactors, and methods of forming same
Structures, catalysts, and reactors suitable for use for a variety of applications, including gas-to-liquid and coal-to-liquid processes and methods of forming the structures, catalysts, and reactors are disclosed. The catalyst material can be deposited onto an inner wall of a microtubular reactor and/or onto porous support structures using atomic layer deposition techniques.
1. A catalyst structure comprising:
a support structure having a surface comprising one or more crystalline regions; and
a crystalline catalyst layer formed overlying the one or more crystalline regions,
wherein the support structure has a surface area greater than or equal to 50 m 2 /g, and
wherein the support structure comprises:
delta alumina, theta alumina, and/or alpha alumina, or
a nitride.
2. The catalyst structure of claim 1 , wherein the crystalline catalyst layer is deposited onto the support structure using ALD.
3. The catalyst structure of claim 1 , wherein the support structure comprises an oxide.
4. The catalyst structure of claim 1 , wherein the support structure comprises heat-conductive material.
5. The catalyst structure of claim 1 , wherein the support structure comprises one or more of delta alumina, theta alumina, and alpha alumina.
6. The catalyst structure of claim 1 , wherein the support structure comprises ALD deposited material terminated with organic material.
7. The catalyst structure of claim 1 , wherein the catalyst structure comprises a carbon-containing protective layer.
8. The catalyst structure of claim 1 , wherein the support structure comprises a surface comprising a metal terminated with nitrogen or nitrogen groups.
9. The catalyst structure of claim 1 , wherein the support structure comprises a metal nitride.
10. The catalyst structure of claim 1 , wherein the crystalline catalyst layer comprises cobalt.
11. A catalyst structure comprising:
a support structure comprising an oxide and a heat-conductive layer adjacent the oxide;
a catalyst layer formed overlying the oxide; and
a protective layer overlying the catalyst layer.
12. The catalyst structure of claim 11 , wherein the support structure comprises crystalline regions.
13. The catalyst structure of claim 11 , wherein the catalyst layer comprises crystalline planes and nanoparticles.
14. The catalyst structure of claim 13 , wherein the crystalline planes have a dimension parallel a surface of the support structure ranging from about 2 nm to about 200 nm.
15. The catalyst structure of claim 11 , wherein a thickness of the crystalline catalyst layer ranges from about 1 to about 8 monolayers.
16. The catalyst structure of claim 11 , wherein the protective layer comprises a carbon chain or ring that can substitutionally react to give off the chain or ring and not form an oxide.
17. The catalyst structure of claim 16 , wherein the protective layer comprises the carbon ring.
18. The catalyst structure of claim 16 , wherein the protective layer comprises organic material derived from an ALD precursor.