Continuous process for the use of metal carbonyls for the production of nano-scale metal particles

Abstract

A process for producing nano-scale metal particles includes feeding at least one metal carbonyl into a reactor vessel; exposing the metal carbonyl to a source of energy sufficient to decompose the metal carbonyl and produce nano-scale metal particles; and depositing or collecting the nano-scale metal particles.

Description

TECHNICAL FIELD [0001] The present invention relates to a continuous process for the production of nano-scale metal particles using metal carbonyls. The resulting nano-scale metal particles are useful for catalysis and other purposes. By the practice of the present invention, nano-scale metal particles can be produced from metal carbonyls and deposited or collected with greater speed, precision and flexibility than can be accomplished with conventional processing. Thus, the invention provides a practical and cost-effective means for preparing such nano-scale metal particles. BACKGROUND OF THE INVENTION [0002] Catalysts are becoming ubiquitous in modern chemical processing. Catalysts are used in the production of materials such as fuels, lubricants, refrigerants, polymers, drugs, etc., as well as playing a role in water and air pollution mediation processes. Indeed, catalysts have been ascribed as having a role in fully one third of the material gross national product of the United S...

AI Technical Summary

Benefits of technology

[0035] In one embodiment of the inventive process, a single feeder feeds a single carbonyl into the reactor vessel for formation of nano-scale metal particles. In another embodiment, however, a plurality of feeders each feeds metal carbonyls into the reactor vessel. In this way, all feeders can feed the same carbonyl or different feeders can feed different carbonyls, such as additional metal carbonyls, so as to provide nano-scale particles containing different metals such as platinum-nickel combinations or nickel-iron combinations as desired, in proportions determined by the amount of the carbonyl fed into the reactor vessel by each feeder. For instance, by feeding different carbonyls through different feeders, one can produce a nano-scale particle having a core of a first metal, with domains of a second or third, etc. metal coated thereon. Indeed, altering the carbonyl fed into the reactor vessel by each feeder can alter the nature and / or constitution of the nano-scale particles produced. In other words, if different proportions of metals making up the nano-scale particles, or different orientations of the metals making up the nano-scale particles is desired, altering the metal carbonyl fed into the reactor vessel by each feeder can produce such different proportions or different orientations.

[0036] Indeed, in the case of the flow-through reactor vessel, each of the feeders can be arrayed about the circumference of the conduit forming the reactor vessel at approximately the same location, or the feeders can be arrayed along the length of the conduit so as to feed metal carbonyls into the reactor vessel at different locations along the flow path of the conduit to provide further control of the nano-scale particles produced.

Problems solved by technology

One major drawback to the preparation of catalyst materials through loading on a carrier particle is in the amount of time the loading reactions take, which can be measured in hours in some cases.

Thus, these processes are difficult and expensive to operate.

Even if technically feasible, however, the Bert and Bianchini methods require high temperatures (on the order of 300° C. to 800° C.)

, and require several hours. A

ccordingly, these processes are of limited value.

However, more significant uses of metal carbonyls are in the production and / or deposition of the metals present in the carbonyl, since metal carbonyls are generally viewed as easily decomposed and volatile resulting in deposition of the metal and carbon monoxide.

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