Single-Atom Methane Coupling Catalyst via CVD Deposition
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Solution Overview
Problem
Existing catalyst technologies for oxidative coupling of methane require significant amounts of metal resources and do not effectively maximize catalytic activity due to limitations in reducing catalyst particle size and dispersion.
Innovation Solution
A method for preparing single-atom or single-molecule catalysts using chemical vapor deposition (CVD) to deposit ultra-small catalyst particles, allowing for maximized reactivity and minimized metal use through alloying heat treatment with specific metal combinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalyst preparation methods (impregnation, precipitation, ion exchange) are used, then catalyst particles can be dispersed on support, but metal usage is excessive and catalytic activity is not maximized
Solution Approach 1:
The patent applies segmentation by dividing the catalyst into individual single atoms or small clusters rather than continuous particles. This is achieved through CVD deposition where metal precursors are deposited atom-by-atom or in small clusters onto the support surface, creating discrete catalytic units that maximize surface area and activity per unit mass of metal
Solution Approach 2:
The patent changes the fundamental parameter of catalyst structure from conventional particles to single atoms or small clusters. This parameter change is accomplished through controlled CVD deposition conditions that limit metal accumulation to atomic or near-atomic levels, thereby maximizing catalytic efficiency while minimizing metal consumption
2Area of stationary object
If catalyst particle size is reduced to maximize active area, then dispersion improves, but maintaining stability and activity becomes difficult
Solution Approach 1:
The patent uses the support material as an intermediary that stabilizes the single atoms or small clusters. The support provides anchoring sites that prevent aggregation of the metal species while maintaining their catalytic activity. The CVD deposition process ensures uniform distribution of metal species on the support surface, creating a stable interface between metal and support
Solution Approach 2:
The patent creates a composite catalyst system consisting of single atoms or small clusters of metal M combined with metal M' on a support material. This composite structure leverages the synergistic effects between different metals and the support to achieve both high dispersion (maximized active area) and enhanced stability under reaction conditions
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 method synthesizes ultra-small catalyst particles with high reactivity, minimizing metal usage while maximizing catalytic activity and durability under high-temperature or high-pressure conditions.
Implementation Method 1
a step of depositing a single M metal atom on a M′ catalyst deposited on a support by chemical vapor deposition
Implementation Method 2
a step of preparing a M-M′ catalyst by alloying the support with the single M metal atom deposited and the deposited M′ catalyst through alloying heat treatment
Data Source
AI summary
According to various aspects and exemplary embodiments of the present disclosure, ultra-small catalyst particles having extremely high reactivity may be synthesized in single-atom or single-molecule state. When the ultra-small-sized single-atom or single-molecule catalyst is used, the use of metal raw materials can be minimized and, at the same time, catalytic activity may be maximized through maximized reactivity of the single-atom or single-molecule catalyst.