U.S. patent application number 13/289955 was filed with the patent office on 2012-02-23 for method and apparatus for making recyclable catalysts.
This patent application is currently assigned to SDC MATERIALS, INC.. Invention is credited to Maximilian A. Biberger.
Application Number | 20120045373 13/289955 |
Document ID | / |
Family ID | 39968475 |
Filed Date | 2012-02-23 |
United States Patent
Application |
20120045373 |
Kind Code |
A1 |
Biberger; Maximilian A. |
February 23, 2012 |
METHOD AND APPARATUS FOR MAKING RECYCLABLE CATALYSTS
Abstract
A method of producing a fixed-bed catalyst with nano-scale
structure using a nano-powder production reactor and a filter, the
method comprising: introducing a starting powder into the reactor,
wherein the starting powder comprises catalyst material; the
reactor nano-sizing the starting powder, thereby producing an
output, wherein the output comprises a nano-powder entrained in a
fluid stream, the nano-powder comprising a plurality of
nano-particles, each nano-particle comprising the catalyst
material; introducing the output from the reactor to the filter
structure, wherein the filter structure is fluidly coupled to the
reactor; the filter structure separating the nano-particles from
the fluid stream, wherein the fluid stream flows through the filter
structure, while the filter structure collects the nano-particles,
thereby forming a structured collection of catalytic nano-particles
on the filter structure; and removing the filter structure from the
reactor, wherein the structured collection of catalytic
nano-particles is maintained for use as a fixed-bed catalyst.
Inventors: |
Biberger; Maximilian A.;
(Scottsdale, AZ) |
Assignee: |
SDC MATERIALS, INC.
Tempe
AZ
|
Family ID: |
39968475 |
Appl. No.: |
13/289955 |
Filed: |
November 4, 2011 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12152098 |
May 9, 2008 |
8076258 |
|
|
13289955 |
|
|
|
|
60928946 |
May 11, 2007 |
|
|
|
Current U.S.
Class: |
422/255 ;
977/840 |
Current CPC
Class: |
F28F 27/00 20130101;
B01J 2/16 20130101; Y10T 156/15 20150115; B22F 9/12 20130101; B22F
2999/00 20130101; B22F 2999/00 20130101; B01J 19/088 20130101; B01J
2219/0805 20130101; F28D 15/00 20130101; Y10S 623/923 20130101;
A61L 2/18 20130101; B01J 25/00 20130101; B01J 2219/0879 20130101;
Y10T 137/2076 20150401; Y10T 137/0391 20150401; F28D 7/024
20130101; B22F 2203/13 20130101; B01J 37/06 20130101; B01J 19/0013
20130101; F28C 3/16 20130101; B01J 2219/0894 20130101; B01J 37/0027
20130101; F28D 7/08 20130101; B01J 25/02 20130101; B01J 35/04
20130101; Y10S 623/92 20130101; B01J 37/0018 20130101; B22F 9/12
20130101; B01J 37/349 20130101; B22F 2202/13 20130101 |
Class at
Publication: |
422/255 ;
977/840 |
International
Class: |
B01J 19/00 20060101
B01J019/00 |
Claims
1-24. (canceled)
25. A system for making a fixed-bed catalyst with nano-scale
structure, the system comprising: a nano-powder production reactor
configured to receive a catalyst material and nano-size the
catalyst material, thereby producing an output, wherein the output
comprises a nano-powder entrained in a reactor fluid stream, the
nano powder comprising a plurality of nano-particles, each
nano-particle comprising the catalyst material; and a filter
structure fluidly coupled to the nano-powder production reactor and
configured to receive the nano-powder and separate the
nano-particles from the reactor fluid stream, wherein the filter
structure collects the nano-particles, thereby forming a structured
collection of catalytic nano-particles on the filter structure.
26. The system of claim 25, wherein the filter structure is further
configured to be de-coupled from the nano-powder production
reactor, wherein the structured collection of catalytic
nano-particles is maintained on the filter structure for use as a
fixed-bed catalyst.
27. The system of claim 26, further comprising an airlock structure
configured to: enable selective air-tight isolation of the
structured collection of catalytic nano-particles for the
de-coupling of the filter structure from the nano-powder production
reactor; and enable selective exposure of the structured collection
of catalytic nano-particles to a catalysis fluid stream after the
de-coupling of the filter structure from the nano-powder production
reactor.
28. The system of claim 27, wherein the airlock structure comprises
at least one valve disposed on the filter structure.
29. The system of claim 26, further comprising: a gas dispensing
device fluidly coupled to the nano-powder production reactor and
configured to provide a motive gas to the nano-powder production
reactor, wherein the reactor fluid stream comprises the motive gas;
and a powder dispensing device fluidly coupled to the nano-powder
production reactor and configured to provide the catalyst material
in powder form to the nano-powder production reactor.
30. The system of claim 26, further comprising an exhaust fluidly
coupled downstream from the filter structure and configured to
receive the filtered reactor fluid stream.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to co-pending U.S.
patent application Ser. No. 11/110,341, filed on Apr. 19, 2005,
entitled, "HIGH THROUGHPUT DISCOVERY OF MATERIALS THROUGH VAPOR
PHASE SYNTHESIS" and to co-pending U.S. Provisional Application
Ser. No. 60/928,946, filed May 11, 2007, entitled "MATERIAL
PRODUCTION SYSTEM AND METHOD," both of which are hereby
incorporated by reference as if set forth herein.
FIELD OF THE INVENTION
[0002] The present invention relates to catalysts, primarily metal
catalysts used in fixed bed catalysis of fluid flows, and to
methods of reusing catalytic materials.
BACKGROUND OF THE INVENTION
[0003] Catalysts play many important roles in industry. One such
role is fluid conditioning, including decontamination of flowing
fluid. For example, a catalytic system might be employed to remove
oxygen content from an inert gas flow. The "catalytic converter"
employed in automobiles (circa. 2007 and earlier) removes certain
pollutants from an exhaust flow produced by the engine. "Solid"
catalysts--so-called because the catalytic compound exists in solid
phase during use--are often employed in this role, as fluid
decontamination typically involves removal of the contaminant from
fluid phase, aerosol state, solution, or entrainment.
[0004] "Raney nickel", a solid phase catalyst formed of nickel
grains bonded in a skeletal structure along with aluminum grains,
performs many industrial roles, including fluid conditioning. A
variety of similar catalysts employ other active materials,
including iron or copper, instead of nickel, and other alloying
components, such as zinc or silicon, instead of aluminum.
Currently, all of these "Raney-style" catalysts are formed via
processes essentially similar to the original recipe for Raney
nickel.
[0005] A Raney-style process describes a multi-step method of
forming a porous, active metal catalyst. First, a precursor is
formed of at least a binary alloy of metals where one of the metals
can be extracted. Second, the precursor is activated by extracting
an alloy constituent leaving a porous residue comprising a metal
that has catalytic activity. Such processes are described in, e.g.
Raney, M. Catalysts from Alloys, Ind. Eng. Chem., 1940, 32, 1199;
as well as U.S. Pat. Nos. 1,628,190; 1,915,473; 2,139,602;
2,461,396 and 2,977,327 to M. Raney. Commercial catalysts made by
these type of processes are sold by W. R. Grace & Co. under the
trademark RANEY.RTM. catalyst.
[0006] Often, additional materials are added and process parameters
are varied to achieve a desired catalytic activity or function.
Typically, the process parameters and additional materials included
depend both on the active material employed and the catalytic
function desired. Some added materials called "promoters" serve to
enhance catalytic activity. A typical process parameter that is
varied according to specific needs is the precursor alloy
composition. For example, the precursor used for Raney nickel
typically consists of equal amounts of nickel and aluminum by
volume.
[0007] The traditional Raney-style process results in a collection
of granular pieces, each with an internal porosity. Depending on
their grain size, these particles are used in slurry or in
packed-column systems as heterogeneous catalysts. Generally, larger
particle sizes are required for use in packed-column systems.
Traditionally, there is a tradeoff between surface area and
particle size, with larger-sized particles having less surface area
per unit volume. See, e.g. the background section of U.S. Pat. No.
4,895,994.
[0008] Although small powder catalysts have desirable surface area
to volume characteristics, they are only suitable for batch
processing and must be isolated after use. In order to avoid these
disadvantages, a variety of processing regimes have been proposed
to permit use of Raney particles in fixed-bed catalysis. For
example, U.S. Pat. No. 4,895,994 describes a fixed bed catalyst
shaped from Raney precursor mixed with a polymer, cured, and then
activated via a leaching process. U.S. Pat. No. 5,536,694 describes
a fixed-bed catalyst prepared from powders of Raney precursor mixed
with a powder of its catalytically active component as a binder.
However, these processes involve high sintering temperatures and
thus cannot accommodate small, high surface-to-volume-ratio
precursor particles (the sintering temperatures are sufficient to
destroy the grain structure of the precursor alloy in small
particles). Thus, lacking the high surface to volume ratio provided
by the smallest precursor sizes, these approaches instead rely on
macroporosity of the fixed bed structure to achieve high internal
diffusion, making the most of their surface area.
[0009] Therefore, the smallest precursor particles suitable for
fixed-bed catalyst production via traditional means are micron
scale particles. For example, micron scale aluminum powder and
micron scale nickel powder can be combined in a melt-based alloying
step, thereby producing nickel-aluminum alloy in a variety of alloy
phases. The nickel-aluminum alloy is then processed and activated,
such as by a leaching apparatus, resulting in a bulk porous
structure that is mostly nickel (although some aluminum may
remain). Unfortunately, the smallest pores within the structure
produced are micron scale. Additionally, traditional means can be
very involved, requiring several procedural steps and a variety of
different components, thereby consuming significant time and
money.
[0010] What is needed in the art is a system and method for
producing a catalyst having smaller particle size, and therefore
larger surface area available for catalysis. What is also needed in
the art is a system and method that enable the reuse of catalytic
materials.
SUMMARY OF THE INVENTION
[0011] The embodiments of the present invention include methods of
producing a catalyst with nano-scale structure, using the catalyst
in fixed bed catalysis of fluid flows, and reusing the catalytic
materials, and systems capable of performing these methods.
[0012] In one aspect of the present invention, a method of
producing a fixed-bed catalyst with nano-scale structure using a
nano-powder production reactor and a filter structure is disclosed.
The method comprises introducing a starting powder comprising
catalyst material into the nano-powder production reactor, and the
nano-powder production reactor nano-sizing the starting powder,
thereby producing an output. The output comprises a nano-powder
entrained in a reactor fluid stream. The nano-powder comprises a
plurality of nano-particles, with each nano-particle comprising the
catalyst material. The output from the nano-powder production
reactor may then be introduced to the filter structure, wherein the
filter structure is fluidly coupled to the nano-powder production
reactor. The filter structure separates the nano-particles from the
reactor fluid stream, wherein the filter structure collects the
nano-particles, thereby forming a structured collection of
catalytic nano-particles on the filter structure. The filter
structure can then be removed from the nano-powder production
reactor, with the structured collection of catalytic nano-particles
being maintained on the filter structure for use as a fixed-bed
catalyst.
[0013] The step of nano-sizing the starting powder can include
generating a plasma flow within the nano-powder production reactor,
and applying the plasma flow to the starting powder.
[0014] The method can further comprise employing the structured
collection of catalytic nano-particles on the filter structure as a
fixed-bed catalyst for a catalysis fluid stream, thereby forming a
structured collection of contaminated catalytic nano-particles on
the filter structure and a product output. The catalysis fluid
stream preferably comprises a desired material and an undesired
material. The step of employing the structured collection as a
fixed-bed catalyst comprises: flowing the catalysis fluid stream
through the structured collection of contaminated catalytic
nano-particles on the filter structure; and the structured
collection of nano-particles on the filter structure catalyzing the
removal of the undesired material from the catalysis fluid stream,
wherein the structured collection is contaminated with the
undesired material and product output comprises the desired
material.
[0015] The method can further comprise harvesting the contaminated
catalytic nano-particles from the filter structure, and processing
the contaminated catalytic nano-particles to form recycled starting
powder from the contaminated catalytic nano-particles, wherein the
recycled starting powder comprises the catalyst material. The
recycled starting powder can then be introduced into the
nano-powder production reactor, and the nano-powder production
reactor can nano-size the recycled starting powder, thereby
producing an output. This output comprises a nano-powder entrained
in a fluid stream, and the nano-powder comprising a plurality of
nano-particles, with each nano-particle comprising the catalyst
material.
[0016] In another aspect of the present invention, a system for
making a fixed-bed catalyst with nano-scale structure is disclosed.
The system comprises a nano-powder production reactor configured to
receive a catalyst material and nano-size the catalyst material,
thereby producing an output. The output comprises a nano-powder
entrained in a reactor fluid stream, and the nano-powder comprises
a plurality of nano-particles, with each nano-particle comprising
the catalyst material. The system further comprises a filter
structure fluidly coupled to the nano-powder production reactor and
configured to receive the nano-powder and separate the
nano-particles from the reactor fluid stream. The filter structure
collects the nano-particles, thereby forming a structured
collection of catalytic nano-particles on the filter structure. The
filter structure may be further configured to be de-coupled from
the nano-powder production reactor, wherein the structured
collection of catalytic nano-particles is maintained on the filter
structure for use as a fixed-bed catalyst.
[0017] The system may also comprise an airlock structure configured
to enable selective air-tight isolation of the structured
collection of catalytic nano-particles for the de-coupling of the
filter structure from the nano-powder production reactor; and
enable selective exposure of the structured collection of catalytic
nano-particles to a catalysis fluid stream after the de-coupling of
the filter structure from the nano-powder production reactor. This
airlock structure preferably comprises at least one valve disposed
on the filter structure.
[0018] The system can further comprise a gas dispensing device
fluidly coupled to the nano-powder production reactor and
configured to provide a motive gas to the nano-powder production
reactor, and a powder dispensing device fluidly coupled to the
nano-powder production reactor and configured to provide the
catalyst material in powder form to the nano-powder production
reactor.
[0019] The system can further include an exhaust that is fluidly
coupled downstream from the filter structure and configured to
receive the filtered reactor fluid stream.
[0020] In the systems and methods of the present invention, the
catalyst material is preferably a metal of the transition group
VIII of the periodic table of elements. Examples of preferred
metals include nickel, iron, and cobalt. In some embodiments, the
catalyst material is copper. Preferably, the starting powder,
recycled or not, is micron-scale, meaning it has an average grain
size of at least 1 micron.
[0021] By forming the catalyst structure from nano-sized particles
instead of micron-sized (or larger sized) particles, the present
invention can significantly increase the total catalytic surface
area, given that a nano-particle is significantly smaller than a
micron particle thereby allowing for a greater quantity of
nano-particles than micron particles. The nano-skeletal structure
produced via the present invention preferably has a surface area of
at least 10,000 times the surface area of a micron scale structure
of the same volume. This increase in surface area results in
massive cost savings.
[0022] Additionally, by using a filter structure to form a
structured collection of catalytic nano-particles, the present
invention can make the production and use of the catalytic
structure significantly more efficient and can enable the reuse of
catalytic materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1A is a schematic illustration of one embodiment of a
system for producing a reusable filter-based catalyst in accordance
with the principles of the present invention.
[0024] FIG. 1B is a schematic illustration of one embodiment of a
reusable filter-based catalyst in accordance with the principles of
the present invention.
[0025] FIG. 2A is a partially transparent isometric view of one
embodiment of a reusable filter structure in accordance with the
principles of the present invention.
[0026] FIG. 2B is an isometric view of one embodiment of a reusable
filter for producing reusable filter-based catalysts in accordance
with the principles of the present invention.
[0027] FIG. 3 is a schematic illustration of one embodiment of a
life-cycle of a reusable filter-based catalyst in accordance with
the principles of the present invention.
[0028] FIG. 4 is a flowchart illustrating one embodiment of a
method for producing a fixed bed catalyst, using the fixed bed
catalyst, and reusing the catalyst material in accordance with the
principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The description below concerns several embodiments of the
present invention. The discussion references the illustrated
preferred embodiment. However, the scope of the present invention
is not limited to either the illustrated embodiment, nor is it
limited to those discussed, to the contrary, the scope should be
interpreted as broadly as possible based on the language of the
Claims section of this document.
[0030] This disclosure refers to both particles and powders. These
two terms are equivalent, except for the caveat that a singular
"powder" refers to a collection of particles. The present invention
may apply to a wide variety of powders and particles. Additionally,
for the purposes of this disclosure, the terms nano-powders and
nano-particles refer to powders and particles having an average
grain size less than 250 nanometers and an aspect ratio between one
and one million.
[0031] The present invention will be readily understood by the
following detailed description in conjunction with the accompanying
drawings. To facilitate this description, like reference numerals
designate like elements.
[0032] The embodiments of the present invention revolve around the
use of a nano-powder production reactor to produce nano-skeletal
catalytic precursors. In general, vapor phase nano-powder
production means are preferred Most preferably, the embodiments of
the present invention use nano-powder production systems similar to
those disclosed in U.S. patent application Ser. No. 11/110,341,
filed on Apr. 19, 2005 and entitled, "HIGH THROUGHPUT DISCOVERY OF
MATERIALS THROUGH VAPOR PHASE SYNTHESIS", which is currently
published as U.S. Publication No. 2005-0233380-A. In such a
nano-powder production system, working gas is supplied from a gas
source to a plasma reactor. Within the plasma reactor, energy is
delivered to the working gas, thereby creating a plasma. A variety
of different means can be employed to deliver this energy,
including, but not limited to, DC coupling, capacitive coupling,
inductive coupling, and resonant coupling. One or more material
dispensing devices introduce at least one material, preferably in
powder form, into the plasma reactor. The combination within the
plasma reactor of the plasma and the material(s) introduced by the
material dispensing device(s) forms a highly reactive and energetic
mixture, wherein the powder can be vaporized. This mixture of
vaporized powder moves through the plasma reactor in the flow
direction of the working gas. As it moves, the mixture cools and
particles are formed therein. The still-energetic output mixture,
comprising hot gas and energetic particles, is emitted from the
plasma reactor. Following emission from the plasma reactor, the
output mixture cools further and is exposed to a sampling device,
which selectively samples portions of the output mixture, which
comprises hot gas and particles of relatively homogeneous size
distribution. Each particle can comprise a combination of the
materials introduced by the material dispensing devices. It is
contemplated that other nano-powder production means, including
non-vapor phase nano-powder production means, are within the scope
of the present invention.
[0033] FIG. 1A illustrates one embodiment of a system 100 for
producing a reusable filter-based catalyst with nano-scale
structure. The system 100 comprises a nano-powder production
reactor 130 and a filter structure 140 fluidly coupled to the
nano-powder production reactor 130. The system 100 can further
include a gas supply 110 and a catalyst material dispensing device
120, each fluidly coupled to the nano-powder production reactor
130. The gas supply 110 is configured to provide a motive gas to
the reactor 130, while the dispensing device 120 is configured to
provide a powder of a catalyst material into the nano-powder
production reactor 130, thereby enabling the nano-powder production
reactor 130 to produce an output comprising nano-powder catalyst
material entrained in a fluid stream. Preferably, the fluid stream
comprises a gas from the gas supply 110.
[0034] The fluid stream from the reactor 130 flows to the filter
structure 140. The filter structure 140 is configured to separate
the nano-powder catalyst material from the fluid stream. The filter
structure 140 collects the catalyst nano-particles, and in doing
so, forms a structured collection of catalyst nano-particles, as
will be discussed in further detail below with respect to FIG.
1B.
[0035] In a preferred embodiment, the filter structure 140
comprises an air filter 144. However, it is contemplated that a
variety of other means may be employed to separate the nano-powder
from the fluid stream. The filter 144 is part of the filter
structure 140. The filter structure 140 can also include a first
valve 142 and a second valve 146. In a preferred embodiment, the
first valve 142 and the second valve 146 are separately sealable
and are substantially airtight when sealed. The first valve 142 is
fluidly coupled to the output of the nano-powder production reactor
130 and serves as an input valve to the filter structure 140, while
the second valve 146 is fluidly coupled to an exhaust 150 of the
system and serves as an output valve of the filter structure 140.
Upon receiving the fluid stream, the exhaust 150 can remove the
received fluid stream and any remaining entrained material from the
system 100. Additionally or alternatively, the exhaust 150 can
recycle the received fluid stream and any remaining entrained
material back into the system 100, such as by feeding it back into
the nano-powder production reactor 130.
[0036] FIG. 2A illustrates an exemplary embodiment of a filter
structure 200 in accordance with the principles of the present
invention. The filter structure 200 preferably comprises a filter
230 housed within an output chamber 220. In a preferred embodiment,
the filter structure 200 further comprises an inlet conduit 212 and
an outlet conduit 214 each fluidly coupled to the filter 230. The
inlet conduit 212 and the outlet conduit 214 form a conduit system
that, along with the rest of the filter structure 200, is
configured to receive a matter stream flowing into the inlet 202 of
the inlet conduit 212, collect some, most or all of the particles
from the stream, and deliver the remainder of the stream to the
outlet 204 of the outlet conduit 214.
[0037] The outer structure of the filter structure 200 can include
a cylindrical body, which forms the output chamber 220. This
cylindrical body is preferably coupled to first and second axially
directed end plates 222 and 224. In a preferred embodiment, the
interfaces between the cylindrical body and the axially directed
end plates 222 and 224 are sealed. In some embodiments, the
cylindrical body and the end plates can be integrally formed.
[0038] Preferably, each axially directed end plate includes ports
configurable to mate with a conduit structure. As shown, the first
axially directed end plate 222 includes a main inlet coupled to the
inlet conduit 212. Preferably, this coupling is sealed airtight and
permits delivery of a matter stream from the inlet conduit 212 into
the filter 230. Similarly, the second axially directed end plate
224 preferably includes a main outlet coupled to outlet conduit
214. This coupling can also be sealed airtight and can permit
delivery, following particle collection, of a remainder of a matter
stream to the outlet 204.
[0039] In one embodiment, the output chamber 220 has a longitudinal
axis parallel with the axes of the inlet conduit 212 and the outlet
conduit 214. The output chamber 220 can have a cylindrical shape
and can form a radially directed surface, but narrow to meet the
inlet conduit 212 and/or the outlet conduit 214. This narrowing can
occur in the region of the first axially directed end plate 222 and
or the second axially directed end plate 224. In some embodiments,
the faces of the first and second axially directed end plates 222
and 224 are not completely axially directed, but instead form an
angle with the axis of the chamber, so as to gradually narrow the
output chamber 220. This configuration is preferred. In some
embodiments, the inner surface of the output chamber 220 forms a
curve as it narrows to meet the inlet conduit 212 and/or the outlet
conduit 214.
[0040] The filter 230 and the output chamber 220 can be coupled
with one another in a fixed position. This coupling can produce a
narrowed channel, shaped like a cylindrical shell, between a
radially directed outer surface of the filter 230 and the radially
directed inner surface of the output chamber 220.
[0041] FIG. 2B is an isometric view of the filter 230. In a
preferred embodiment, a high efficiency particulate air (HEPA)
filter is used. The filter 230 preferably includes structures for
decelerating a matter stream, distributing the particle load
evenly, and facilitating particle collection. The filter 230
preferably has an axis parallel with that of the output chamber
220, a first end 252 and a second end 254 opposite the first end
252. In a preferred embodiment, the filter 230 comprises an inlet
conduit 242 at the first end 252 and an outlet conduit at the
second end 254, each fluidly coupled to the interior of the filter
230. An inlet 232 of the inlet conduit 242 is fluidly coupled to
the inlet conduit 212. The filter 230 preferably widens from the
inlet 232 at its first end 252, with its walls forming a radially
directed surface 256.
[0042] The filter 230 can comprise a set of filters and filter
components, such as those represented by circumferential ridges 258
and 260. In some embodiments, the filters are radially directed and
the ridges 258 and 260 represent surface-area-increasing features
of the filters. In these embodiments, the second end 254 of the
filter 230 is preferably a curved, non-porous surface that directs
matter flow into the radially directed filters. In some embodiments
the filters are axially directed and the ridges 258 and 260
represent edges of individual filters. In these embodiments, the
second end 254 of the filter 230 is preferably a filter itself.
Additionally, the filters can be arranged in series.
[0043] In operation, the catalyst dispensing device 120 provides a
powder of a catalyst material into the nano-powder production
reactor 130. Similarly, the gas supply 110 provides gas to the
nano-powder production reactor 130. Upon reception of the catalyst
powder and the gas, the reactor 130 produces an output comprising
nano-powder catalyst material entrained in a fluid stream.
[0044] The output is provided to the filter structure 140, which
separates the nano-powder catalyst material from the fluid stream.
The remainder of the fluid stream flows to the exhaust 150, where
it can be recycled for reuse, either with the gas supply 110 or via
other means, and/or removed from the system 100. The catalyst
nano-powder filtered by the filter structure 140 forms a structured
collection of catalyst nano-particles, preferably within the filter
structure 140.
[0045] When a sufficient amount of nano-powder is present in the
structured collection, the filter structure 140 can be fluidly
isolated from the nano-powder production reactor 130 and the
exhaust 150. In a preferred embodiment, the first valve 142 and the
second valve 146 are sealed to form airtight barriers, thereby
preventing leakage from or contamination of the filter structure
140. Preferably, the second valve 146 is sealed prior to the
sealing of the first valve 142, resulting in a slight
pressurization of the filter structure 140.
[0046] Once sealed, the filter structure 140 can be removed from
the system 100 of FIG. 1A. FIG. 1B illustrates the filter structure
140' containing the activated filter 144', which comprises the
filter and the structured collection of catalyst nano-particles.
The first valve 142 and the second valve 146 are sealed and the
filter structure 140' is ready for integration into a system where
it provides catalysis. By removing the filter structure from the
system, the structured collection of catalytic nano-particles is
removed and immediately available for use as a fixed-bed catalyst
for fluid flows.
[0047] Preferably, airtight isolation and de-coupling of the filter
structure from the nano-powder production reactor are facilitated
by the use of valves, as discussed above. However, it is
contemplated that a variety of airlock structures may be employed
to permit selective airtight isolation and exposure of the
structured collection of catalytic nano-particles.
[0048] In some embodiments, the system of the present invention
further includes a dispensing device configured to provide a powder
of a promoter material into the nano-powder production reactor 130,
similar to dispensing device 120, thereby permitting the
nano-powder production reactor 130 to produce an output comprising
nano-powder promoter material entrained in a fluid stream. Such use
of the promoter material may be employed with or without the use of
catalyst material. In such embodiments, the filter structure 140 is
preferably used to separate the nano-powder promoter material from
the fluid stream and to form a structured collection of promoter
nano-particles, with or without catalyst material. The promoter
material can include, but is not limited to, zinc, molybdenum, and
chromium. In some embodiments, a single dispensing device is used
for both promoter and catalyst materials.
[0049] In a preferred embodiment, the catalyst material is a metal
of the transition group VIII of the periodic table of elements.
Most preferably, the metal is selected from the group consisting of
nickel, iron, and cobalt. In some embodiments, the catalyst
material is copper.
[0050] Some embodiments of the present invention relate to a
substantially closed life cycle for catalyst materials. FIG. 3
illustrates one embodiment of such a life cycle 300.
[0051] In a first phase of the life cycle 300, some means of
nano-particle production provides catalyst nano-particles into a
filter system, as illustrated at stage 310. The illustration shows
unspecified catalyst nano-particles Ct entrained within an argon
stream Ar. The catalyst Ct and argon Ar stream flows into the
filter structure, which retains the catalyst nano-particles Ct,
while the argon Ar flows through the filter structure. As a result,
an activated filter is produced.
[0052] Next, at stage 320, the filter structure is isolated.
Preferably, a downstream valve is closed, then an upstream valve,
and some pressurization of argon Ar is retained within the
activated filter structure, along with catalyst nano-particles
Ct.
[0053] Then, in a second phase of the life cycle, the activated
filter structure and catalyst Ct are used as a fixed-bed catalyst
for catalyzing a fluid flow, as illustrated at stage 330. In the
illustration, a desired gas contaminated with undesired oxygen
O.sub.2 is provided to the upstream valve. The upstream valve is
opened. Gas then flows into the activated filter structure, where
catalyst nano-particles Ct catalyze removal of oxygen O.sub.2,
essentially filtering the oxygen O.sub.2 from the mixed gas stream.
Downstream, once the downstream valve is opened, the filter
structure outputs pure desired gas.
[0054] The mechanism by which the catalyst nano-particles Ct remove
the oxygen from the gas stream results in oxygen contamination of
the catalyst nano-particles Ct. This product, oxidized catalyst
nano-particles Ct+O, is reused within the life cycle. Specifically,
the oxidized Ct+O nano-particles are combined and/or processed at
stage 340 to produce an input to the nano-particle production stage
350. In the illustration, the oxidized Ct+O nano-particles are
processed to produce micron scale oxidized catalyst powder Ct+O,
which serves as an input to the nano-particle production means at
stage 350.
[0055] Finally, the nano-particle production means provides an
output of catalyst nano-particles to the first phase of the life
cycle back at stage 310.
[0056] The life cycle of FIG. 3 embodies a method, or methods, of
using and reusing catalyst materials in a substantially closed
cycle. Although specific gases, catalysts, and catalysis reactions
are mentioned with respect to FIG. 3, the present invention is
intended to cover variations on these components and configurations
of the illustrated life cycle and its related methods.
[0057] FIG. 4 is a flow chart illustrating one embodiment of a
method 400 for producing a fixed bed catalyst, using the fixed bed
catalyst, and reusing the catalyst material in accordance with the
principles of the present invention.
[0058] At step 410, a starting powder is introduced into the
nano-powder production reactor. This starting powder preferably
contains catalyst material.
[0059] At step 415, the reactor nano-sizes the starting powder,
thereby producing a plurality of nano-particles, with each particle
containing catalyst material. These nano-particles are preferably
entrained in a fluid stream to form an output of the reactor. In a
preferred embodiment, the reactor nano-sizes the starting powder by
applying a plasma flow to the staring powder, as previously
discussed.
[0060] At step 420, the output from the reactor is introduced into
the filter structure. For example, the output can flow from the
reactor into the filter structure. The filter structure filters
this fluid stream, separating the catalyst nano-particles from the
rest of the fluid stream, and thereby forming a structured
collection of catalyst nano-particles on the filter structure.
[0061] At step 425, the filter structure can then be removed, or
fluidly de-coupled, from the nano-powder production reactor in
preparation for its use as a fixed-bed catalyst in a fluid flow.
The method 400 may then come to an end.
[0062] However, the filter structure can optionally be used as a
fixed-bed catalyst for a fluid stream at step 430. In operation as
a fixed-bed catalyst, the structured collection of catalyst
nano-particles may catalyze the removal of an undesired material
from the fluid stream, thereby forming a desired product output,
while contaminating the catalyst nano-particles with the undesired
material. The method 400 may then come to an end.
[0063] However, the collection of contaminated catalyst
nano-particles on the filter structure can optionally be harvested
at step 440 in preparation for reuse, such as discussed above with
respect to the life cycle 300 of FIG. 3.
[0064] At step 445, the contaminated catalyst nano-particles are
processed to form powder that is suitable for introduction into the
nano-powder production reactor. Such processing may include, but is
not limited to, combining the nano-particles to form micron-sized
powder, with the micron powder containing the catalyst
material.
[0065] The method may then repeat back at step 410, where the
processed catalyst powder can be re-introduced into the nano-powder
production reactor.
[0066] The embodiments of the present invention provide a variety
of systems, methods, and life cycles to permit use and reuse of a
catalytic material in nano-particle or nano-powder phase.
Preferably, an activated filter including a structured collection
of catalyst nano-particles has an effective BET surface area of at
least 10,000 times the surface area of a micron scale structure of
the same volume. This increase in surface area results in massive
cost savings.
[0067] Additionally, by using a filter structure to form a
structured collection of catalytic nano-particles, the present
invention can make the production and use of the catalytic
structure significantly more efficient and can enable the reuse of
catalytic materials.
[0068] The present invention has been described in terms of
specific embodiments incorporating details to facilitate the
understanding of the principles of construction and operation of
the invention. As such, references herein to specific embodiments
and details thereof are not intended to limit the scope of the
claims appended hereto. It will be apparent to those skilled in the
art that modifications can be made to the embodiments chosen for
illustration without departing from the spirit and scope of the
invention.
* * * * *