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.

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.