Activation of inert metal components to catalysts

Abstract

Processes for transforming an inert metal component into an active metal catalyst are provided. Apparatus and methods using active metal catalyst prepared according the process described herein are also provided.

1 - 16 . (canceled) 
     
     
         17 . A reactor, comprising a catalytic metal component prepared by a method comprising constructing an inert metal component;
 wherein the inert metal component is constructed by additive manufacturing; and   exposing the inert metal component to a cyclic oxidative and reducing environment for a sufficient number of cycles to activate the inert metal component.   
     
     
         18 . The reactor of  claim 17 , wherein the catalytic metal component has the geometry of one of a monolith, sphere, bead, pellet, extrudate, trilobe, quadralobe, cube, ring, 1-hole, 2-hole, 3-hole, 4-hole, saddle, cross-web, and wire mess. 
     
     
         19 . The reactor of  claim 17 , wherein the metal component comprises a metal alloy. 
     
     
         20 . The reactor of  claim 19 , wherein the metal alloy comprises a Group 10 element. 
     
     
         21 . The reactor of  claim 20 , wherein the Group 10 element comprises one of nickel, platinum, and palladium. 
     
     
         22 . The reactor of  claim 19 , wherein the metal alloy is one of an Inconel, Hastelloy, and Monel variant. 
     
     
         23 . The reactor of  claim 17 , wherein the catalytic metal component has the geometry of a monolith; wherein the monolith comprises a plurality of cells with channels extending therefrom. 
     
     
         24 . The reactor of  claim 23 , wherein the plurality of cells with channels form squares, circles, ovals, hexagons, trilobes, quadrolobes, or a combination thereof. 
     
     
         25 . The reactor of  claim 23 , wherein the plurality of cells with channels comprises channels with non-linear pathways through the monolith. 
     
     
         26 . The reactor of  claim 23 , wherein the monolith further comprises void spaces interrupting the channels forming chambers within the monolith. 
     
     
         27 - 29 . (canceled)