Methods of producing oxygen reduction catalyst
AssigneeMetallic Power, Inc.
InventorMark C. Lefebvre
Life of this patent
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Abstract
Methods of making an oxygen reduction catalyst are described in which carbon black, one or more metal-containing and/or nitrogen-containing precursor(s) are provided to a reaction zone, and the carbon black is rendered catalytically active. To form this catalytic activity, the carbon black and one or more metal-containing and/or nitrogen-containing precursor(s) are introduced to a reaction zone heated to a temperature of between about 600 and about 1000 degrees Celsius, and maintained together in the reaction zone for a cumulative time between 5 seconds and 240 minutes.
Claims68
An oxygen reduction catalyst comprising (a) about 95 wt % to about 99.9 wt % carbon black, and (b) about 0.1 wt % to about 5.0 wt % metal, and (c) about 0.05 wt % to about 5.0 wt % nitrogen.
A method of making a catalyst, the method comprising:
- providing carbon black, one or more metal-containing and/or nitrogen-containing precursor(s), and an optional reducing agent to a reaction zone;
- and
- heating the reaction zone to a temperature of between about 600 and about 1000 degrees Celsius and maintaining the carbon black, the one or more metal-containing and/or nitrogen-containing precursor(s), and the optional reducing agent in the reaction zone while so heated for a cumulative time in the range from between about 5 seconds and about 240 minutes.
A method of making a catalyst, comprising:
- entraining an atomized carbon black/metal salt fluid suspension in a gas mixture comprising a nitrogen-containing gas, a reducing gas, and a carrier gas;
- directing the gas mixture and entrained suspension along a flow path past a heat source;
- heating the gas mixture and entrained suspension so that the temperature at the surface of the atomized carbon black/metal salt fluid suspension is in the range from about 600 to about 1000 degrees Celsius;
- and
- heating the gas mixture and entrained suspension for a cumulative time in the range from about 5 seconds to about 240 minutes.
Dependencies are inferred from the claim text.