A method of producing a catalyst material with nano-scale structure, the method comprising: introducing a starting powder into a nano-powder production reactor, the starting powder comprising a catalyst material; the nano-powder production reactor nano-sizing the starting powder, thereby producing a
A method of producing a catalyst material with nano-scale structure, the method comprising: introducing a starting powder into a nano-powder production reactor, the starting powder comprising a catalyst material; the nano-powder production reactor nano-sizing the starting powder, thereby producing a nano-powder from the starting powder, the nano-powder comprising a plurality of nano-particles, each nano-particle comprising the catalyst material; and forming a catalyst precursor material from the nano-powder, wherein the catalyst precursor material is a densified bulk porous structure comprising the catalyst material, the catalyst material having a nano-scale structure.
대표청구항▼
1. A method of producing a catalyst material with nano-scale structure, the method comprising: providing a starting powder into a nano-powder production reactor, the starting powder comprising a catalyst material;nano-sizing the starting powder by using a plasma flow in the nano-powder production re
1. A method of producing a catalyst material with nano-scale structure, the method comprising: providing a starting powder into a nano-powder production reactor, the starting powder comprising a catalyst material;nano-sizing the starting powder by using a plasma flow in the nano-powder production reactor, thereby producing a nano-powder from the starting powder, the nano powder comprising a plurality of nano-particles, each nano-particle comprising the catalyst material;forming a catalyst precursor material from the nano-powder by using a bonding device, wherein the catalyst precursor material is a densified bulk porous structure comprising the catalyst material, the catalyst material having a nano-scale structure, wherein the bulk porous structure of the catalyst precursor material further comprises a filler material; andfurther comprising removing a substantial portion of the filler material from the bulk structure of the catalyst precursor to form a nano-scale skeletal structure comprising the catalyst material, such that the catalyst material is activated to form a nano-skeletal catalyst. 2. The method of claim 1, wherein the step of nano-sizing the starting powder includes: generating the plasma flow within the nano-powder production reactor; andapplying the plasma flow to the starting powder. 3. The method of claim 1, wherein the step of forming a catalyst precursor material includes pressing the nano-powder. 4. The method of claim 1, wherein the step of forming a catalyst precursor material includes bonding the nano-powder using spark plasma sintering, thereby preserving the nano-scale structure of the catalyst material. 5. The method of claim 1, wherein the starting powder has an average grain size greater than or equal to 1 micron. 6. The method of claim 1, wherein the filler material comprises aluminum, zinc, or silicon. 7. The method of claim 1, wherein the step of removing the filler material is performed by using a leaching solution. 8. The method of claim 1, wherein the step of forming the catalyst precursor material includes adding a promoter material to the bulk porous structure, the promoter material comprising at least one of zinc, molybdenum and chromium. 9. The method of claim 1, further comprising the step of removing surface contamination from the catalyst material. 10. The method of claim 1, wherein the bonding device is fluidly coupled to the nano-powder production reactor. 11. The method of claim 1, wherein the bonding device is separated from the nano-powder production reactor. 12. The method of claim 1, wherein the bonding device is configured to receive the nano-powder to form the catalyst precursor material. 13. The method of claim 1, wherein the bonding device employs spark-plasma sintering. 14. The method of claim 1, wherein the nano-powder production reactor is coupled to a sampling device such that the nano-powder is exposed to the sampling device as the nano-powder is emitted from the nano-powder production reactor. 15. The method of claim 1, wherein the nano-powder production reactor comprises one or more dispensing devices, each dispensing device coupled with a port that opens into the nano-powder production reactor. 16. The method of claim 1, wherein the catalyst material comprises a metal of the transition group VIII of the periodic table of elements. 17. The method of claim 16, wherein the metal comprises nickel, iron, or cobalt. 18. The method of claim 1, wherein the starting powder consists only of the catalyst material. 19. The method of claim 18, wherein the step of nano-sizing the starting powder includes: generating the plasma flow within the nano powder production reactor; andapplying the plasma flow to the starting powder. 20. The method of claim 18, wherein the step of forming a catalyst precursor material includes pressing the nano-powder. 21. The method of claim 18, wherein the step of forming a catalyst precursor material includes bonding the nano-powder using spark plasma sintering, thereby preserving the nano-scale structure of the catalyst material. 22. The method of claim 18, wherein the starting powder has an average grain size greater than or equal to 1 micron. 23. The method of claim 18, wherein the step of forming the catalyst precursor material includes adding a promoter material to the bulk porous structure, the promoter material comprising at least one of zinc, molybdenum and chromium. 24. The method of claim 18, wherein the catalyst material comprises a metal of the transition group VIII of the periodic table of elements. 25. The method of claim 24, wherein the metal comprises nickel, iron, or cobalt.
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