Multi-functional composite catalyst materials and methods of synthesizing the catalyst materials

A method of producing a composite catalyst, the method comprising:

• generating an aerosolized catalyst precursor mixture by aerosolizing a catalyst precursor mixture comprising a preformed catalyst material, a catalyst support precursor, at least one catalytically active compound precursor, and a diluent, where:
• the preformed catalyst material is a particulate solid and comprises a MFI structured zeolite, a BEA structured zeolite, magnesium oxide, or combinations of these;
• the catalyst support precursor comprises at least one of fumed silica, fumed alumina, fumed titania, or combinations of these;
• and
• the at least one catalytically active compound precursor comprises a metal or metal oxide containing one or more metals selected from the group consisting of magnesium, molybdenum, rhenium, tungsten, manganese, titanium, cerium, and any combination of these;
• and
• drying the aerosolized catalyst precursor mixture to produce a plurality of composite catalyst particles, where drying causes the catalyst support precursor to form an open porous structure of catalyst support material encasing the preformed catalyst material, where at least one catalytically active compound is distributed throughout the catalyst support material, where the at least one catalytically active compound is supported by the catalyst support, the preformed catalyst material, or both, where the preformed catalyst is at least partially secured in the catalyst support, where a catalytic activity of the at least one catalytically active compound is different than a catalytic activity of the preformed catalyst material, and where a pore volume per unit mass (cm3/g) of the composite catalyst is greater than a pore volume per unit mass of the preformed catalyst material and greater than a pore volume per unit mass of a metathesis catalyst comprising the catalyst support material with the at least one catalytically active compound and without the preformed catalyst material.