Technique to Prepare Catalyst Particles

Reference Number(s)
     Laboratory:  107
     DOE reference no.(s): 105,070

Abstract

This invention is a one step method to prepare catalyst materials. This one step method reduces the processing time required to make catalysts, reduces the cost associated with making catalysts and significantly reduces the waste stream generated using traditional techniques. This technique can be used for large scale commercial applications.

Application(s) of the Technology

Commercial scale synthesis of gold oxidation catalysts.

Main Advantages of Invention

Gold catalysts are prepared using a variety of solution based techniques followed by heat treatments. These solution techniques generate a large amount of liquid waste, require acidic or basic conditions which compound waste problems. The typical techniques have problems with reproducibility, such as metal loading, catalytic activity and particle sizes. Catalyst clusters prepared by these solution techniques typically have poor control over size distributions of the catalysts and thermal stability.This is a one step process to prepare catalytic materials. This technique does not require the use of expensive reagents unlike conventional techniques. This method does not require heating of the catalysts to make them active. This technique generates practically no waste stream (i.e. waste water, carbon dioxide and organic waste). This technique involves the use of a magnetron sputtering set up along with a device to change the substrate orientation. Such a set up can easily be expanded to suit industrial scale production needs. This method is also aplicable to any substrate material such as Carbon, alumina, silica and titania.1. Fast 2. one-step process 3. Very little waste stream 4. recover unused precious metals 5. Cheap reagents 6. Low long term costs 7. thermal stable catalysts 8. Suitable for any catalyst support material The benefits in the marketplace revolve around the industrial scaled production of gold oxidation catalysts. This technique will lower production costs by reducing waste managments. This technique can be used for any support material without expensive swaping of equipment.

Status/Availability

Available both Exclusively and Non Exclusively

Patents & Applications

Posting Date:  Wednesday, Jan 26 2005

Contact

Catherine A Porto
Oak Ridge National Laboratory
P.O. Box 2008
Building /4500N, Room 131
Mailstop 6196
Oak Ridge, TN 37831
(865) 574-1051
portoca@ornl.gov