Mechanically fused materials for pollution abatement in mobile and stationary sources

Abstract

Described are catalyst composites containing mechanically fused components, methods of making the catalyst composites, and methods of using the catalyst composites such as in pollution abatement applications. The catalyst composites contain a core and a shell at least substantially covering the core, the shell mechanically fused to the core and comprising particles mechanically fused to each other, wherein a size ratio of the core to particles of the shell is at least about 10:1.

1 - 7 . (canceled) 
     
     
         8 . A method of making a catalyst composite for pollution abatement, comprising:
 conducting mechanical fusion for about 30 seconds to about 5 hours at a temperature from about 10° C. to about 100° C. on a mixture of core materials and shell materials, the shell materials comprising an active catalyst and a sorbent material, wherein a particle size ratio of the core materials to the shell materials is at least about 10:1 to provide the catalyst composite.   
     
     
         9 . The method of  claim 8 , wherein mechanical fusion is conducted using a rotor speed from about 1,000 rpm to about 10,000 rpm. 
     
     
         10 . The method of  claim 8 , wherein mechanical fusion is conducted for about 5 minutes to about 1 hour at a temperature from about 30° C. to about 70° C. 
     
     
         11 . The method of  claim 8 , wherein mechanical fusion is conducted under at least one of an inert gas, air, oxygen, steam, and carbon dioxide. 
     
     
         12 . The method of  claim 8 , further comprising drying the catalyst composite. 
     
     
         13 . The method of  claim 8 , wherein the particle size ratio of the core materials to the shell materials is at least about 40:1. 
     
     
         14 . The method of  claim 8 , wherein the core materials have an average size from about 5 microns to about 1 mm and the shell materials have an average size from about 10 nm to about 100 microns. 
     
     
         15 . A method of forming a pollution abatement film surrounding a core, comprising:
 mixing core materials and shell materials, the shell materials comprising an active catalyst and a sorbent material, wherein a particle size ratio of the core materials to the shell materials is at least about 20:1; and   conducting mechanical fusion for about 1 minute to about 2 hours at a temperature from about 20° C. to about 80° C. on the mixture of core materials and shell materials to provide the pollution abatement film comprising shell materials substantially surrounding a core particle.   
     
     
         16 . The method of  claim 15 , wherein mechanical fusion is conducted using a rotor speed from about 2,000 rpm to about 8,000 rpm. 
     
     
         17 . The method of  claim 15 , wherein the pollution abatement film has a thickness from about 10 nm to about 100 microns. 
     
     
         18 . The method of  claim 15 , wherein the particle size ratio of the core materials to the shell materials is at least about 50:1. 
     
     
         19 . The method of  claim 15 , wherein the active catalyst facilitates conversion of pollution to a less harmful substance and the sorbent material adsorbs and/or absorbs pollution. 
     
     
         20 . The method of  claim 15 , wherein the core materials have an average size from about 10 microns to about 700 microns and the shell materials have an average size from about 25 nm to about 5 microns. 
     
     
         21 . A method of abating pollution, comprising:
 contacting a pollution containing emission with a catalyst composite comprising a core and a shell at least substantially covering the core, the shell mechanically fused to the core and comprising particles mechanically fused to each other, the shell comprising an active catalyst and a sorbent material, wherein a size ratio of the core to particles of the shell is at least about 10:1.   
     
     
         22 . The method of  claim 21 , wherein the pollution containing emission is generated by a mobile pollution source. 
     
     
         23 . The method of  claim 21 , wherein the pollution containing emission is generated by a stationary pollution source. 
     
     
         24 - 25 . (canceled)