Continuous process for the use of metal carbonyls for the production of nano-scale metal particles formed of non-noble metals

Abstract

A continuous process for producing nano-scale metal particles includes feeding at least one metal carbonyl into a reactor vessel; exposing the metal carbonyl to a source of energy sufficient to decompose the metal carbonyl and produce nano-scale metal particles; and depositing or collecting the nano-scale metal particles.

1 . A process for producing non-noble metal nano-scale particles, comprising: 
 a) feeding at least one non-noble metal carbonyl into a reactor vessel comprising a conduit;    b) exposing the non-noble metal carbonyl to a source of energy sufficient to decompose the metal carbonyl and produce nano-scale metal particles; and    c) collecting or depositing the nano-scale metal particles.    
   
   
       2 . The process of  claim 1 , wherein the temperature within the reactor vessel is no greater than about 250° C.  
   
   
       3 . The process of  claim 2 , wherein a vacuum is maintained within the reactor vessel of no less than about 1 mm.  
   
   
       4 . The process of  claim 2 , wherein a pressure of no greater than about 2 atmospheres is maintained with the reactor vessel.  
   
   
       5 . The process of  claim 1 , wherein the reactor vessel is formed of a material which is relatively transparent to the energy supplied by the source of energy, as compared to either a support or a collector on which the nano-scale metal particles are deposited or collected or the metal carbonyl.  
   
   
       6 . The process of  claim 1 , where the source of energy comprises a source of heat.  
   
   
       7 . The process of  claim 6 , wherein the nano-scale metal particles are deposited on a support.  
   
   
       8 . The process of  claim 7 , wherein the support has incorporated therein a resistance heater.  
   
   
       9 . The process of  claim 6 , wherein the source of energy comprises a heat lamp.  
   
   
       10 . The process of  claim 9 , which further comprises cooling the reactor vessel.  
   
   
       11 . The process of  claim 7 , wherein the support is the end use substrate for the nano-scale metal particles produced.  
   
   
       12 . The process of  claim 11 , wherein the support comprises a component of an automotive catalytic converter.  
   
   
       13 . The process of  claim 7 , wherein the support is positioned within the reactor vessel.  
   
   
       14 . The process of  claim 1 , wherein oxygen is fed into the reactor vessel to partially oxidize the nano-scale metal particles produced by decomposition of the decomposable moiety.  
   
   
       15 . The process of  claim 1 , wherein a reducing material is fed into the reactor vessel to reduce the potential for oxidation of the decomposable moiety.