Nano-skeletal catalyst

Abstract

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.

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 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; 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 and a filler material, the catalyst material having a nano-scale structure; and   removing filler material from the bulk structure of the catalyst precursor to form a nano-scale skeletal structure comprising the catalyst material.   
     
     
         2 . (canceled) 
     
     
         3 . The method of  claim 1 , wherein the step of nano-sizing the starting powder includes:
 generating a plasma flow within the nano-powder production reactor;   and applying the plasma flow to the starting powder.   
     
     
         4 . The method of  claim 1 , wherein the step of forming a catalyst precursor material includes pressing the nano-powder. 
     
     
         5 . 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. 
     
     
         6 . The method of  claim 1 , wherein the starting powder has an average grain size greater than or equal to 1 micron. 
     
     
         7 . The method of  claim 1 , wherein the catalyst material comprises a metal of the transition group VIII of the periodic table of elements. 
     
     
         8 . The method of  claim 7 , wherein the metal comprises nickel. 
     
     
         9 . The method of  claim 7 , wherein the metal comprises iron. 
     
     
         10 . The method of  claim 7 , wherein the metal comprises cobalt. 
     
     
         11 . The method of  claim 1 , wherein the filler material comprises aluminum. 
     
     
         12 . The method of  claim 1 , wherein the filler material comprises zinc. 
     
     
         13 . The method of  claim 1 , wherein the filler material comprises silicon. 
     
     
         14 . (canceled) 
     
     
         15 . The method of  claim 1 , wherein the step of removing the filler material is performed by using a leaching solution. 
     
     
         16 . 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. 
     
     
         17 . The method of  claim 1 , wherein the starting powder consists only of the catalyst material. 
     
     
         18 . The method of  claim 17 , wherein the step of nano-sizing the starting powder includes:
 generating a plasma flow within the nano-powder production reactor; and   applying the plasma flow to the starting powder.   
     
     
         19 . The method of  claim 17 , wherein the step of forming a catalyst precursor material includes pressing the nano-powder. 
     
     
         20 . The method of  claim 17 , 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. 
     
     
         21 . The method of  claim 17 , wherein the starting powder has an average grain size greater than or equal to 1 micron. 
     
     
         22 . The method of  claim 17 , wherein the catalyst material comprises a metal of the transition group VIII of the periodic table of elements. 
     
     
         23 . The method of  claim 22 , wherein the metal comprises nickel. 
     
     
         24 . The method of  claim 22 , wherein the metal comprises iron. 
     
     
         25 . The method of  claim 22 , wherein the metal comprises cobalt. 
     
     
         26 . The method of  claim 1 ,
 further comprising removing surface contamination from the catalyst material.   
     
     
         27 . The method of  claim 26 , wherein the step of removing the surface contamination is performed by using an etching solution. 
     
     
         28 . 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. 
     
     
         29 . The method of  claim 32 , further comprising:
 providing a filler powder into the nano-powder production reactor, the filler powder comprising aluminum.   
     
     
         30 . The method of  claim 29 , 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 nano-particles. 
     
     
         31 . The method of  claim 30 , further comprising removing a substantial portion of the aluminum from the bulk structure of the catalyst precursor material, thereby forming a nano-scale skeletal structure comprising the nickel, wherein the nickel is activated to form a nano-skeletal catalyst. 
     
     
         32 . The method of  claim 1 , wherein the starting powder comprises nickel. 
     
     
         33 . The method of  claim 32 , 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 nano-particles. 
     
     
         34 . The method of  claim 33 ,
 further comprising removing surface contamination from the catalyst material.   
     
     
         35 . A system for producing a catalyst material with nano-scale structure, the system comprising:
 a powder dispensing device configured to provide a starting powder, the starting powder comprising a catalyst material;   a nano-powder production reactor configured to receive the starting powder from the powder dispensing device and produce a nano-powder from the starting powder, the nano-powder comprising a plurality of nano-particles each comprising the catalyst material; and   a bonding device configured to receive the nano-powder and form 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.   
     
     
         36 . The system of  claim 35 , wherein the nano-powder production reactor is configured to produce the nano-powder by:
 generating a plasma flow within the nano-powder production reactor; and   applying the plasma flow to the starting powder.   
     
     
         37 . The system of  claim 35 , wherein the bonding device is configured to bond the nano-powder using spark plasma sintering, wherein the spark plasma sintering preserves the nano-scale structure of the catalyst material. 
     
     
         38 . The system of  claim 35 , wherein:
 the starting powder, the nano-particles from the nano-powder production reactor, and the bulk porous structure of the catalyst precursor material each further comprises a filler material; and   the system further comprises a leaching apparatus configured to remove a substantial portion of the filler material from the bulk structure of the catalyst precursor material, thereby forming a nano-scale skeletal structure comprising the catalyst material, wherein the catalyst material is activated to form a nano-skeletal catalyst.   
     
     
         39 . The system of  claim 35 , wherein:
 the nano-scale catalyst material of the bulk structure has surface contamination; and   the system further comprises an etching apparatus configured to remove the surface contamination from the nano-scale catalyst material, thereby forming a nano-scale skeletal structure comprising the catalyst material, wherein the catalyst material is activated to form a nano-skeletal catalyst.   
     
     
         40 . 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. 
     
     
         41 . 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.