# US 2017/0283259 A1 · Nano-Structured Catalysts > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2017/0283259 A1 - Document ID: US20170283259A1 - Status: Published application - Kind: A1 - Application number: 15/476,546 - Filed: 2017-03-31 - Published: 2017-10-05 - Earliest claimed: 2016-03-31 - Inventors: Fei Yu; Qiangu Yan - Web page: https://patentgrep.com/patent/US20170283259A1 ## CPC - C01B 3/40: characterised by the catalyst - B01J 21/18: Carbon - B01J 23/28: Molybdenum - B01J 23/30: Tungsten - B01J 23/755: Nickel - B01J 35/45: Nanoparticles - B01J 35/615: {100-500 m2/g} - B01J 37/0201: {Impregnation} - B01J 37/0213: {Preparation of the impregnating solution} - B01J 37/0236: {Drying, e.g. preparing a suspension, adding a soluble salt and drying} - B01J 37/06: Washing {(B01J37/0009, B01J37/0018 take precedence)} - B01J 37/088: {Decomposition of a metal salt} - C01B 2203/0238: the reforming step being a carbon dioxide reforming step - C01B 2203/1058: Nickel catalysts - C01B 2203/1082: Composition of support materials - Y02P 20/52: using catalysts, e.g. selective catalysts - C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C} - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract The present invention provides novel systems, methods, and processes for producing and synthesizing, through cost-effective thermal processes, highly active and stable carbide-based nano-structured catalysts and compositions that can be used in dry reforming of methane, natural gas, and biogas, for example, to synthesis gas (syngas). The invention provides for using carbon-containing raw materials for synthesizing and producing carbon-encapsulated metal-core nanoparticles such as nickel-based, tungsten-based, and molybdenum-based nano-structured catalysts that can be used in dry reforming gas to syngas. ## Claims ### Claim 1 A method for synthesizing a nanostructured catalyst, comprising: forming an aqueous solution including a metal salt; subsequently adding a carbon source to the aqueous solution; drying the aqueous solution to obtain a sample; thermally treating the sample in a carrier gas to obtain a nanostructured catalyst including a metal nanoparticle; and washing the nanostructured catalyst including the metal nanoparticle to remove the metal nanoparticle and obtain the nanostructured catalyst. ### Claim 2 (depends on 1) The method of claim 1, wherein the metal salt is selected from a nickel nitrate, a nickel sulfide, a nickel sulfate, a nickel carbonate, a nickel hydroxide, a nickel carboxylate, or a nickel halide, or a combination thereof. ### Claim 3 (depends on 2) The method of claim 2, wherein the metal salt is selected from nickel nitrate and nickel chloride. ### Claim 4 (depends on 1) The method of claim 1, wherein the metal salt is ammonium tungstate or ammonium molybdate. ### Claim 5 (depends on 1) The method of claim 1, wherein the aqueous solution comprises an equal weight ratio of the metal salt and the carbon source. ### Claim 6 (depends on 1) The method of claim 1, wherein the step of drying the aqueous solution comprises drying the aqueous solution at a temperature of about 80° C. to about 110° C. ### Claim 7 (depends on 1) The method of claim 1, wherein the carbon source is an organic carbon source and is lignin, wood char, starch, sugars, biomass-derived carbon materials, or a combination thereof. ### Claim 8 (depends on 1) The method of claim 1, wherein the step of thermally treating the sample comprises heating the sample in a tubular electric resistance furnace. ### Claim 9 (depends on 1) The method of claim 1, wherein the carrier gas is oxygen-free. ### Claim 10 (depends on 8) The method of claim 8, wherein the carrier gas is selected from Ar2, H2, N2, or a combination thereof. ### Claim 11 (depends on 1) The method of claim 1, wherein the step of thermally treating the sample is performed at a temperature of about 900° C. to about 1100° C. ### Claim 12 (depends on 1) The method of claim 1, wherein the step of thermally treating the sample comprises heating the sample for a time period of about 1 hour to about 3 hours. ### Claim 13 (depends on 2) The method of claim 2, wherein the step of thermally treating the sample comprises heating the sample at a temperature of about 900° C. for about 1 hour. ### Claim 14 (depends on 4) The method of claim 4, wherein the step of thermally treating the sample comprises heating the sample at a temperature of about 1000° C. for about 3 hours. ### Claim 15 (depends on 2) The method of claim 2, wherein the nanostructured catalyst has an average diameter of about 30 nm. ### Claim 16 (depends on 4) The method of claim 4, wherein the nanostructured catalyst has a Brunauer-Emmett-Teller (BET) surface area of about 125 to about 145 m2 g−1. ### Claim 17 (depends on 2) A nickel nanostructured catalyst according to the method of claim 2. ### Claim 18 (depends on 4) A tungsten nanostructured catalyst or a molybdenum nanostructured catalyst according to the method of claim 4. ### Claim 19 A method of dry reforming a methane-containing gas, the method comprising: synthesizing a nanostructured catalyst by first forming an aqueous solution including a metal salt; subsequently adding a carbon source to the aqueous solution; drying the aqueous solution to obtain a sample; thermally treating the sample in a carrier gas to obtain a nanostructured catalyst including a metal nanoparticle; and washing the nanostructured catalyst including the metal nanoparticle to remove the metal nanoparticle and obtain the nanostructured catalyst; and exposing the methane-containing gas to the nanostructured catalyst. ### Claim 20 (depends on 19) The method of claim 19, wherein the exposing the methane-containing gas is performed at a temperature of about 600° C. to about 800° C. ### Claim 21 (depends on 19) The method of claim 19, wherein the exposing the methane-containing gas is performed at a GHSV of between about 4000 h−1 to about 8000 h−1. ### Claim 22 (depends on 19) The method of claim 19, wherein the methane-containing gas is methane, natural gas, or biogas.