Carbon-Embedded Nickel Nanoparticles for High-Loading Catalyst Dispersion
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Solution Overview
Problem
Existing technologies fail to produce materials with high dispersion and uniform coordination of transition metal nanoparticles in combination with high metal content, leading to low catalytic activity.
Innovation Solution
A process involving the spray drying or freeze drying of an aqueous solution of metal precursors and organic carbon sources, followed by thermal treatment at moderate temperatures, results in non-graphitizing carbon grains with dispersed nickel nanoparticles, achieving a 30 wt% to 70 wt% metal content and specific nanoparticle distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If impregnation or chemical vapor deposition of metal precursors onto porous supports is used, then transition metal nanoparticles can be obtained, but high metal content leads to clustering and loss of dispersion
Solution Approach 1:
The patent applies preliminary action by using molecularly defined complexes with well-defined ligands that pre-organize the metal species before deposition. This pre-organization prevents clustering during subsequent high-temperature treatment and maintains uniform dispersion even at high metal contents (30-70 wt%), resolving the contradiction between quantity and precision.
Solution Approach 2:
The patent changes the parameter of treatment temperature to high temperatures (typically 200-500°C) after depositing molecularly defined complexes. This parameter change activates the complexes to form nanoparticles while the molecular definition and ligand structure ensure uniform coordination and prevent clustering, enabling high metal content with maintained dispersion.
2Quantity of substance
If high metal content is achieved in supported catalysts, then catalytic activity should improve, but nanoparticle clustering occurs and dispersion is lost
Solution Approach 1:
The patent uses high-temperature treatment (200-500°C) to activate molecularly defined complexes, transforming them into well-dispersed nanoparticles. This parameter change enables achieving high metal content (30-70 wt%) while maintaining uniform coordination and preventing clustering, thus improving catalytic activity reliability.
Solution Approach 2:
The patent creates composite materials by combining molecularly defined metal complexes with specific ligands on porous supports. This composite structure maintains uniform metal distribution and prevents clustering even at high metal contents, ensuring reliable catalytic activity through consistent nanoparticle dispersion and coordination.
3Ease of manufacture
If conventional impregnation methods are used, then material can be manufactured easily, but high dispersion and uniform coordination cannot be achieved simultaneously with high metal content
Solution Approach 1:
The patent uses molecularly defined complexes with well-defined ligands as intermediaries between the metal precursor and the porous support. These intermediaries provide uniform coordination environments for metal species during impregnation, enabling high dispersion and uniform coordination while maintaining the simplicity of conventional impregnation procedures, even at high metal contents.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process yields catalytically active materials with nickel nanoparticles dispersed in non-graphitizing carbon, exhibiting high catalytic activity in various chemical reactions.
Implementation Method 1
spray drying or freeze drying of an aqueous solution of metal precursors and organic carbon sources
Implementation Method 2
spray drying or freeze drying of an aqueous solution of metal precursors and organic carbon sources
Implementation Method 3
thermo-treating intermediate product P at a temperature in the range from 200° C. to 380° C.
Implementation Method 4
thermo-treating intermediate product P at a temperature in the range from 200° C. to 380° C. and thus producing grains of non-graphitizing carbon with nickel nanoparticles dispersed therein
Data Source
AI summary
The present invention relates to catalytically active material, comprising grains of non-graphitizing carbon with nickel nanoparticles dispersed therein, wherein dp, the average diameter of nickel nanoparticles in the non-graphitizing carbon grains, is in the range of 1 nm to 20 nm, D, the average distance between nickel nanoparticles in the non-graphitizing carbon grains, is in the range of 2 nm to 150 nm, and ω, the combined total mass fraction of metal in the non-graphitizing carbon grains, is in the range of 30 wt % to 70 wt % of the total mass of the non-graphitizing carbon grains, and wherein dp, D and ω conform to the following relation: 4.5 dp/ω>D≥0.25 dp/ω. The present invention, further, relates to a process for the manufacture of material according to the invention, as well as its use as a catalyst.