Nanocatalysts and Single-Atom Catalysts Development and Manufacturing Assisted by Inexpensive Custom Designed Low-Temperature Plasma

Catalysts play a vital role in chemical and energy industries. The global catalyst market size was valued at $35 billion in 2020 and is expected to grow at a compound annual growth rate (CAGR) of 4.4% from 2020 to 2027 [1]. Shifting energy trends towards renewable fuels including hydrogen have propelled the demand for catalysts. Bimetallic nanocatalysts and single-atom catalysts (SACs) have unique catalytic properties for the rational design of new catalysts with high activity, selectivity, stability and most importantly better atom economy. Plasma contains electrons, positive ions, negative ions, radicals, excited species, and neutral species. Low- Temperature Plasma (LTP) could enable a significantly reduced catalyst synthesis temperature compared to conventional chemical methods from 600-800°C to under 200°C, which is key to avoid metal agglomeration and clusters during metal nanocatalysts and SACs preparation. LTP is also an environmentally friendly, fast, and provides an efficient alternative to air/oxygen oxidation or hydrogen reduction at mild conditions for catalyst calcination and activation stages. Bimetallic nanocatalysts and SACs manufacturing is very challenging, especially for metals with agglomeration at higher temperature (500?) such as copper. Recently we developed an inexpensive LTP device for rare earth metals recycling by hydrogen reduction. In this project, the device will be modified and improved with both hydrogen and oxygen gas compatible and more work zones for the preparation of bimetallic nanocatalysts. We will demonstrate our LTP technology on bimetallic nanocatalyst Ru- Cu/zeolite and SACs Ru/Cu-zeolite catalyst manufacturing for our current customers. The catalysts will be evaluated side-by-side with non-LTP processed catalysts. Figure 1 shows the product development flow chart.The LTP technology will greatly improve catalysts manufacturing efficiency and performance through innovations by 1) reducing catalyst calcination and activation temperature and time, 2) minimizing metal agglomeration leading to more uniform distribution of bi/multi- metal particles, and 3) enhancing anchoring of metals on the support for more robust and longer catalyst life. The technology to be developed will strengthen our catalyst manufacturing business, broaden the customer base, and increase revenue. The PI, Dr. Maoqi Mark Feng, has over 8 years in plasma technology development and 22 years of experience in catalyst preparation, testing and manufacturing. University of Wyoming’s Prof. Maohong Fan and Prof. Hertanto Adidharma will help the development. After a successful Phase 1 program, Phase 2 will lead to sales of our LTP device and catalysts after further scaling up the process. This project will develop a promising and environmentally friendly LTP tool for the manufacturing of bimetallic nanocatalysts and SACs which can be used by our current customers. The success of the project will bring catalyst manufacturing to a higher level and provide the industry a more sustainable pathway. This project will meet DOE’s needs by using LTP Science and Engineering for nanotechnology development.