Catalyst support structure, catalyst including the structure, reactor including a catalyst, and methods of forming same

Patent metadata

Field	Value
Publication number	US-9643159-B2
Application number	US-201314436433-A
Country	US
Kind code	B2
Filing date	Sep 26, 2013
Priority date	Oct 16, 2012
Publication date	May 9, 2017
Grant date	May 9, 2017

Abstract

Structures, catalysts, and reactors suitable for use for a variety of applications, including gas-to-liquid and coal-to-liquid processes and methods of forming the structures, catalysts, and reactors are disclosed. The catalyst material can be deposited onto an inner wall of a microtubular reactor and/or onto porous tungsten support structures using atomic layer deposition techniques.

First claim

The invention claimed is:

1. A method of forming a microtubular reactor, the method comprising the steps of:
providing one or more reactor tubes;
depositing tungsten onto an interior surface of the one or more reactor tubes using atomic layer deposition; and
depositing one or more metals selected from the group consisting of Co, Ni, NiPt, Rh, Ru, Pd, Os, V, Fe, and Mn to form islands or an incomplete layer of the one or more metals onto the tungsten.

2. The method of forming a microtubular reactor of claim 1 , further comprising the steps of:
providing sacrificial polymer material on an interior surface of the one or more reactor tubes, wherein the step of depositing tungsten comprises depositing tungsten onto the sacrificial polymer material; and
optionally removing the sacrificial polymer material to form porous tungsten on the interior surface.

3. The method of forming a microtubular reactor of claim 2 , wherein the step of removing comprises calcination with ammonia.

4. The method of forming a microtubular reactor of claim 1 , the method further comprising the steps of:
packing sacrificial polymer material onto an interior of the one or more reactor tubes, wherein the step of depositing tungsten comprises depositing tungsten onto the sacrificial polymer material; and
optionally removing the sacrificial polymer material to form porous tungsten on the interior surface.

5. The method of forming a microtubular reactor of claim 4 , wherein the step of removing comprises calcination with ammonia.

6. The method of forming a microtubular reactor of claim 1 , wherein the step of depositing tungsten comprises forming islands or a semi-continuous layer of tungsten.

7. The method of forming a microtubular reactor of claim 6 , wherein the step of depositing tungsten comprises forming islands of tungsten having an average diameter of about 1 nm to about 20 nm.

8. The method of forming a microtubular reactor of claim 6 , wherein the step of depositing tungsten comprises forming islands of tungsten having an average diameter of about 10 nm to about 20 nm.

9. The method of forming a microtubular reactor of claim 6 , wherein the step of depositing tungsten comprises forming islands of tungsten having an average diameter of about 2 nm to about 10 nm.

10. The method of forming a microtubular reactor of claim 1 , wherein the deposited metal forms islands having an average diameter of about 1 nm to about 20 nm.

11. The method of forming a microtubular reactor of claim 1 , wherein the deposited metal forms islands having an average diameter of about 10 nm to about 20 nm.

12. The method of forming a microtubular reactor of claim 1 , wherein the deposited metal forms islands having an average diameter of about 2 nm to about 10 nm.

13. The method of forming a microtubular reactor of claim 1 , wherein the step of depositing one or more metals comprises depositing cobalt.

14. The method of forming a microtubular reactor of claim 1 , wherein the step of depositing one or more metals comprises using cobaltcene.

15. The method of forming a microtubular reactor of claim 1 , further comprising the step of exposing the tungsten to a nitrogen environment.

16. The method of forming a microtubular reactor of claim 1 , further comprising the step of forming tungsten nitride.

Assignees

• The Regents Of The Univ Of Colorado; A Body Corp
• Univ Colorado Regents

Inventors

• Van Norman Staci A
• Aston Victoria J
• Weimer Alan W

Classifications

• B01J23/8993

  with chromium, molybdenum or tungsten · CPC title

• B01J23/75

  Cobalt · CPC title

• C23C16/45555

  applied in non-semiconductor technology · CPC title

• B01J37/349

  making use of flames, plasmas or lasers · CPC title

• C10G2/333

  of the platinum-group · CPC title