Method and system for forming plug and play metal compound catalysts

A method of making a supported metal compound catalyst comprising:

• a. providing a quantity of nanoparticles for combining with a quantity of supports, comprising the steps:
• i. loading a quantity of catalyst material in powder form into a plasma gun and loading a quantity of a carrier comprising an oxide into the plasma gun in a desired ratio, wherein the catalyst comprises a metal;
• ii. vaporizing the quantity of catalyst material and vaporizing the quantity of carrier using the plasma gun, thereby forming a vapor cloud;
• iii. receiving the vapor cloud from the plasma gun by a quench chamber;
• iv. quenching the vapor cloud received from the plasma gun, thereby forming a quantity of precipitate nanoparticles;
• v. injecting a co-reactant into a substantially low oxygen environment such that the co-reactant will react with one of the vapor cloud, the precipitate nanoparticles, and any combination thereof;
• wherein at least some of the nanoparticles comprise a first portion comprising a catalyst material bonded to a second portion comprising a carrier;
• and
• b. impregnating the at least some of the nanoparticles into a quantity of dry porous supports comprising a porous oxide, wherein the porous oxide comprises a same oxide as the carrier loaded in the plasma gun, comprising the steps:
• i. combining the at least some of the nanoparticles with a liquid dispersant to form a dispersion;
• ii. combining the dispersion with the quantity of dry porous supports to create a mixture;
• iii. subjecting the mixture to one of agitating, heating, and applying pressure;
• iv. allowing the mixture to dry, thereby creating impregnated supports;
• v. calcining the impregnated supports by exposing them to one of heat and pressure;
• thereby making a supported metal compound catalyst having a structure in which the support is bonded with the carrier through an oxide-oxide bond and the carrier is bonded with the catalyst material.

A method of making a supported metal compound catalyst comprising:

• a. providing a quantity of nanoparticles for combining with a quantity of supports, comprising the steps:
• i. loading a quantity of catalyst material comprising a metal into a plasma gun and loading a quantity of a carrier comprising an oxide in powder form into the plasma gun in a desired ratio, wherein the carrier comprises an oxide;
• ii. vaporizing the quantity of catalyst material and vaporizing the quantity of carrier using the plasma gun, thereby forming a vapor cloud;
• iii. receiving the vapor cloud from the plasma gun by a quench chamber;
• iv. quenching the vapor cloud received from the plasma gun, thereby forming a quantity of precipitate nanoparticles;
• v. injecting a co-reactant into a substantially low oxygen environment such that the co-reactant will react with one of the vapor cloud, the precipitate nanoparticles, and any combination thereof;
• wherein at least some of the nanoparticles comprise a first portion comprising a catalyst material bonded to a second portion comprising a carrier;
• and
• b. impregnating the at least some of the nanoparticles into a quantity of macroscopic support particles comprising a same oxide as in the carrier loaded in the plasma gun, comprising the steps:
• i. combining the at least some of the nanoparticles with a liquid dispersant to form a dispersion;
• ii. combining a quantity of macroscopic support particles with a selected liquid to create a slurry, wherein the selected liquid comprises one of water, alcohol, organic liquid, and inorganic liquid, and wherein the selected liquid does not react with the macroscopic supports and does not react with the at least some of the nanoparticles;
• iii. combining the dispersion with the slurry to create a mixture;
• iv. subjecting the mixture to one of agitating, heating, and applying pressure;
• v. allowing the mixture to dry, thereby creating impregnated supports;
• vi. calcining the impregnated supports by exposing them to one of heat and pressure;
• thereby making a supported metal compound catalyst in which the support is bonded with the carrier through an oxide-oxide bond and the carrier is bonded with the catalyst material.