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