Method for preparing supported catalysts from metal loaded carbon nanotubes

Abstract

A new method for preparing a supported catalyst is herein provided. Carbon nanotubes are functionalized by contacting them with an oxidizing agent to form functionalized carbon nanotubes. A metal catalyst is then loaded or deposited onto the functionalized carbon nanotubes. The mixture is then extruded to form the supported catalyst comprising a carbon nanotube structure containing metal catalyst more evenly dispersed within the internal structure of the carbon nanotube structure.

1 . A method for preparing a supported catalyst comprising the steps of: 
 loading metal catalysts or metal catalyst precursors, onto carbon nanotubes and    forming a carbon nanotube structure from said metal loaded carbon nanotubes.    
     
     
         2 . A method for preparing a supported catalyst comprising the steps of: 
 functionalizing carbon nanotubes with a functionalizing agent to form functionalized carbon nanotubes,    loading metal catalysts, or metal catalyst precursors onto said functionalized carbon nanotubes to form metal loaded carbon nanotubes.    
     
     
         3 . A method for preparing a supported catalyst comprising the step of: 
 functionalizing carbon nanotubes with a functionalizing agent to form functionalized carbon nanotubes,    loading metal catalyst, or metal catalyst precursors onto said functionalized carbon nanotubes to form metal loaded carbon nanotubes, said metal catalysts selected from the group consisting of ruthenium, osmium, rhodium, iridium, palladium, platinum, silver, gold or a mixture thereof, and    forming a carbon nanotubes structure from said metal loaded carbon nanotubes.    
     
     
         4 . A method for preparing a supported catalyst comprising the steps of: 
 functionalizing carbon nanotubes with an oxidizing agent to form functionalized carbon nanotubes,    loading metal catalysts onto said functionalized carbon nanotubes to form metal loaded carbon nanotubes, said metal catalysts selected from the group consisting of ruthenium, osmium, rhodium, iridium, palladium, platinum, silver, gold or a mixture thereof, and    forming a carbon nanotube structure from said metal loaded carbon nanotubes.    
     
     
         5 . The method of  claim 4 , wherein said oxidizing agent is selected from the group consisting of potassium chlorate, sulfuric acid, nitric acid (HNO 3 ), persulfate, hydrogen peroxide (H 2 O 2 ), CO 2 , O 2 , steam, N 2 O, NO, NO 2 , O 3 , or ClO 2 .  
     
     
         6 . The method of  claim 4 , where said carbon nanotube structure is a rigid porous structure formed by extruding said metal loaded carbon nanotubes.  
     
     
         7 . The method of  claim 6 , further comprising calcining said metal loaded rigid porous structure.  
     
     
         8 . The method of  claim 4 , wherein said carbon nanotube structure is a rigid porous structure formed by extruding said metal loaded carbon nanotubes with gluing agents or binders selected from the group consisting of cellulose-based polymers, hydroxyl ethyl cellulose, carboxyl methyl cellulose, cellulose, carbohydrates, polyethylene, polystyrene, nylon, polyurethane, polyester, polyamides, poly(dimethylsiloxane), acrylic polymers and phenolic resins.  
     
     
         9 . The method of  claim 4 , wherein said metal catalysts are loaded onto said functionalized carbon nanotubes by mixing a solution containing salts of said metal catalysts with said functionalized carbon nanotubes and evaporating said solution.  
     
     
         10 . The method of  claim 4 , wherein said metal catalysts are loaded onto said functionalized carbon nanotubes by impregnation, incipient wetness, ion exchange, precipitation, physical or chemical adsorption or co-precipitation.  
     
     
         11 . A method for preparing a supported catalyst comprising the steps of: 
 functionalizing carbon nanotubes with an oxidizing agent to form functionalized carbon nanotubes,    loading metal catalysts onto said functionalized carbon nanotubes to form metal loaded carbon nanotubes, said metal catalysts selected from the group consisting of oxides, halides, carbides, nitrides, phosphides and sulfides of Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, La, Ce, W or combinations thereof, and    forming a carbon nanotube structure from said metal loaded carbon nanotubes.    
     
     
         12 . A method according to claims  1  or  11  where tubes are multi-wall carbon nanotubes.  
     
     
         13 . A method according to claims  1  or  11  where tubes are single wall carbon nanotubes.  
     
     
         14 . A method according to claims  1  or  11  where the carbon nanotubes are a mixture of multi-wall and single wall nanotubes.