Plasma generation of supported metal catalysts

Abstract

A novel method to prepare supported metal catalysts is described. A microwave frequency plasma torch was employed to create supported metal catalysts from physical mixtures of a metal (palladium, particles or molecular precursor) and a traditional support material (alumina). Specifically, an aerosol containing particles of metal and support was injected into the center of an atmosphere pressure plasma generated with a commercial microwave torch. Catalytic studies of the selective isomerization of 1-butene indicate that catalysts created in this novel fashion are more selective, but less active, than catalysts prepared on the same support by incipient wetness. Catalysts prepared by incipient wetness impregnation of alumina (no metal) pre-treated in the microwave torch were found to have both high activity and enhanced selectivity. Characterization studies suggest that the plasma generated catalysts consist of nano-scale metal particles on highly modified support material.