Abstract: Organically complexed nanocatalyst compositions are applied to or mixed with a carbon-containing fuel (e.g., tobacco, coal, briquetted charcoal, biomass, or a liquid hydrocarbon like fuel oils or gasoline) in order to enhance combustion properties of the fuel. Nanocatalyst compositions can be applied to or mixed with a solid fuel substrate in order to reduce the amount of CO, hydrocarbons and soot produced by the fuel during combustion. In addition, coal can be treated with inventive nanocatalyst compositions to reduce the amount of NOx produced during combustion (e.g., by removing coal nitrogen in a low oxygen pre-combustion zone of a low NOx burner). The nanocatalyst compositions include nanocatalyst particles made using a dispersing agent. They can be formed as a stable suspension to facilitate storage, transportation and application of the catalyst nanoparticles to a fuel substrate.

Abstract: Organically complexed nanocatalyst compositions are applied to or mixed with a carbon-containing fuel (e.g., tobacco, coal, briquetted charcoal, biomass, or a liquid hydrocarbon like fuel oils or gasoline) in order to enhance combustion properties of the fuel. Nanocatalyst compositions can be applied to or mixed with a solid fuel substrate in order to reduce the amount of CO, hydrocarbons, and soot produced by the fuel during combustion. In addition, coal can be treated with inventive nanocatalyst compositions to reduce the amount of NOx produced during combustion (e.g., by removing coal nitrogen in a low oxygen pre-combustion zone of a low NOx burner). The nanocatalyst compositions include nanocatalyst particles made using a dispersing agent. At least a portion of the nanoparticles is crystalline with a spacing between crystal planes greater than about 0.28 nm. The nanocatalyst particles can be activated by heating to a temperature greater than about 75° C., more preferably greater than about 150° C.

Abstract: An improved skeletal iron catalyst is provided for use in Fischer-Tropsch synthesis reactions for converting CO and H2 to hydrocarbon products. The skeletal iron catalyst is manufactured using iron and a removable non-ferrous component such as aluminum. The iron and removable non-ferrous component are mixed together to form a precursor catalyst and then a portion of the removable non-ferrous component is removed to leave a skeletal iron catalyst. One or more first promoter metals and optionally one or more second promoter metals are incorporated into the skeletal iron catalyst either by blending the promoter into the precursor catalyst during the formation thereof or by depositing the promoter on the skeletal iron. The first promoter metals comprises a metal selected from the group consisting of titanium, zirconium, vanadium, cobalt, molybdenum, tungsten, and platinum-group metals.

Abstract: Magnesium hydroxide nanoparticles are made from a magnesium compound that is reacted with an organic dispersing agent (e.g., a hydroxy acid) to form an intermediate magnesium compound. Magnesium hydroxide nanoparticles are formed from hydrolysis of the intermediate compound. The bonding between the organic dispersing agent and the magnesium during hydrolysis influences the size of the magnesium hydroxide nanoparticles formed therefrom. The magnesium hydroxide nanoparticles can be treated with an aliphatic compound (e.g., a monofunctional alcohol) to prevent aggregation of the nanoparticles during drying and/or to make the nanoparticles hydrophobic such that they can be evenly dispersed in a polymeric material. The magnesium hydroxide nanoparticles exhibit superior fire retarding properties in polymeric materials compared to known magnesium hydroxide particles.

Abstract: Hydrocarbon-soluble molybdenum catalyst precursors include a plurality of molybdenum cations that are each bonded with a plurality of organic anions to form an oil soluble molybdenum salt. A portion of the molybdenum atoms are in the 3+ oxidation state such that the plurality of molybdenum atoms has an average oxidation state of less than 4+, e.g., less than about 3.8+, especially less than about 3.5+. The catalyst precursors can form a hydroprocessing molybdenum sulfide catalyst in heavy oil feedstocks. The oil soluble molybdenum salts are manufactured in the presence of a reducing agent, such as hydrogen gas, to obtain the molybdenum in the desired oxidation state. Preferably the reaction is performed with hydrogen or an organic reducing agent and at a temperature such that the molybdenum atoms are reduced to eliminate substantially all molybdenum oxide species.

Abstract: Hydrocarbon-soluble molybdenum catalyst precursors include a plurality of molybdenum cations that are each bonded with a plurality of organic anions to form an oil soluble molybdenum salt. A portion of the molybdenum atoms are in the 3+ oxidation state such that the plurality of molybdenum atoms has an average oxidation state of less than 4+, e.g., less than about 3.8+, especially less than about 3.5+. The catalyst precursors can form a hydroprocessing molybdenum sulfide catalyst in heavy oil feedstocks. The oil soluble molybdenum salts are manufactured in the presence of a reducing agent, such as hydrogen gas, to obtain the molybdenum in the desired oxidation state. Preferably the reaction is performed with hydrogen or an organic reducing agent and at a temperature such that the molybdenum atoms are reduced to eliminate substantially all molybdenum oxide species.

Abstract: The reforming catalysts include a halogen promoter and a plurality of nanocatalyst particles supported on a support material. The nanocatalyst particles have a controlled crystal face exposure of predominately (110). The controlled coordination structure is manufactured by reacting a plurality of catalyst atoms with a control agent such as polyacrylic acid and causing or allowing the catalyst atoms to form nanocatalyst particles. The catalysts are used in a reforming reaction to improve the octane number of gasoline feedstock. The reforming catalysts show improved C5+ hydrocarbon production and improved octane barrel number increases as compared to commercially available reforming catalysts.

Abstract: Oil soluble catalysts are used in a process to hydrodesulfurize petroleum feedstock having a high concentration of sulfur-containing compounds and convert the feedstock to a higher value product. The catalyst complex includes at least one attractor species and at least one catalytic metal that are bonded to a plurality of organic ligands that make the catalyst complex oil-soluble. The attractor species selectively attracts the catalyst to sulfur sites in sulfur-containing compounds in the feedstock where the catalytic metal can catalyze the removal of sulfur. Because the attractor species selectively attracts the catalysts to sulfur sites, non-productive, hydrogen consuming side reactions are reduced and greater rates of hydrodesulfurization are achieved while consuming less hydrogen per unit sulfur removed.

Abstract: Supported catalysts are manufactured from a pretreated porous support material and a nanocatalyst solution of catalyst nanoparticles. The porous support material is pre-treated with a gaseous solvent (e.g., steam or alcohol) to protect the support material from cracking during impregnation of the nanocatalyst solution. The supported catalysts have more uniform size, lower attrition of metals during manufacturing and use, and improved distributions of metal loading compared to catalysts manufactured using known techniques. Hydrogen peroxide manufactured from such catalysts is less likely to be contaminated with catalyst metal.

Abstract: Improved bi-metallic nanocatalysts are manufactured using a control agent to produce nanoparticles having a controlled crystal face exposure. The bi-metallic nanocatalyst particles are manufactured in a two-step process. In a first step, nanocatalyst particles are manufactured using the control agent and the primary metal atoms. The primary metal atoms and the control agent are reacted to form complexed metal atoms. The complexed metal atoms are then allowed or caused to form nanoparticles. The nanoparticles formed in the first step using the control agent have a desired crystal face exposure. In a second step, the secondary metal atoms are deposited on the surface of the primary metal nanoparticles. The secondary catalyst atoms maintain the same crystal face exposure as the primary metal nanoparticles.

Abstract: Reforming nanocatalysts are formed using a dispersing agent to increase the activity, selectivity and longevity of the catalyst when used in a reforming process. The nanocatalyst particles are formed using a dispersing agent having at least one functional group selected from the group of a hydroxyl, a carboxyl, a carbonyl, an amide, an amine, a thiol, a sulfonic acid, sulfonyl halide, an acyl halide, an organometallic complex, and combinations of these. The dispersing agent is particularly useful for forming multicomponent catalysts comprising an alloy, combination, mixture, decoration, or interspersion of platinum and one or more of tin, rhenium or iridium. The formation of the nanoparticles may include a heat treating process performed in an inert or oxidative environment to maintain the catalyst atoms in a non-zero oxidation state to thereby maintain a stronger bond between the dispersing agent and the catalyst atoms.

Abstract: Hydrocarbons containing polynuclear aromatics, such as cycle oil and pyrolysis fuel oil (PFO), are upgraded using an catalyst complex that selectively cracks the polynuclear aromatic compounds to form higher value mono-aromatic compounds, such as benzene toluene, xylenes and ethyl benzene (i.e., BTX). The catalyst complexes include a catalytic metal center and a plurality of organic ligands. During the hydrocracking procedure, the organic ligand preserves one of the aromatic rings of the polynuclear aromatic compounds while the catalytic metal breaks the other aromatic rings thereby yielding a monoaromatic compound.

Abstract: Oil soluble catalysts are used to convert polynuclear aromatic compounds in a hydrocarbon feedstock to higher value mono-aromatic compounds. The catalyst complex includes a catalytic metal center that is bonded to a plurality of organic ligands that make the catalyst complex oil-soluble. The ligands include an aromatic ring and a ligand spacer group. The ligand spacer group provides spacing of 2-6 atoms between the metal center and the aromatic ring. The spacing between the aromatic group and the catalytic metal center advantageously allows the catalyst to selectively crack polynuclear aromatic rings while preserving one of the aromatic rings, thereby increasing the content of mono-aromatic compounds in the hydrocarbon feedstock.

Abstract: Catalysts suitable for use in reforming hydrocarbons have a halogen promoter and a plurality of dispersed nanocatalyst particles supported on a solid support. The dispersed nanocatalyst particles are manufactured using a dispersing agent to control the size and/or crystal face exposure of the particles. The controlled size and dispersion of the nanocatalyst particles allows the reforming catalyst to be loaded with significantly less halogen promoter while still maintaining or increasing the catalyst's reforming performance. The catalysts of the present invention have shown improved C5+ production with the significantly reduced levels of halogen promoter.

Abstract: Methods for manufacturing supported catalysts and the use of these catalysts in, e.g., the direct synthesis of hydrogen peroxide. The nanocatalyst particles are manufactured from catalyst atoms complexed with organic agent molecules (e.g., polyacrylic acid). The complexed catalyst atoms are heated to cause formation of the nanocatalyst particles. The temperature used to cause formation of the particles is typically greater than 30° C., preferably greater than 50° C, and more preferably greater than 70° C.

Abstract: Catalysts suitable for use in reforming hydrocarbons have a halogen promoter and a plurality of dispersed nanocatalyst particles supported on a solid support. The dispersed nanocatalyst particles are manufactured using a dispersing agent to control the size and/or crystal face exposure of the particles. The controlled size and dispersion of the nanocatalyst particles allows the reforming catalyst to be loaded with significantly less halogen promoter while still maintaining or increasing the catalyst's reforming performance. The catalysts of the present invention have shown improved C5+ production with the significantly reduced levels of halogen promoter.

Abstract: The burn properties of hydrocarbon fuels are improved by incorporating bimetallic fuel additives. The fuel additives include oil-soluble iron as a primary metal component and an oil-soluble platinum-group metal as a secondary metal component. The concentration of the platinum-group metal in the fuel additive is significantly less (e.g., an order of magnitude less) than the concentration of iron. The minute amount of platinum-group metal in combination with 1 to 100 ppm iron synergistically improves smoke point and/or utilizes less iron to achieve the same improvement in smoke point as compared to iron-based fuel additives without a platinum-group metal. The additives can also include one or more oil-soluble metal compound including an alkali metal, alkaline earth metal, lanthanide metal, actinide metal, or base transition metal such as manganese.

Abstract: A catalyst manufacturing process includes heat treating an intermediate catalyst composition that includes catalyst nanoparticles having catalyst atoms in a non-zero oxidation state bonded to a dispersing/anchoring agent. The catalyst nanoparticles are formed using a dispersing agent having at least one functional group selected from the group of a hydroxyl, a carboxyl, a carbonyl, an amide, an amine, a thiol, a sulfonic acid, sulfonyl halide, an acyl halide, an organometallic complex, and combinations of these. The dispersing agent can be used to form single- or multicomponent supported nanocatalysts. The dispersing agent also acts as an anchoring agent to firmly bond the nanocatalyst to a support. Performing the heat treating process in an inert or oxidative environment to maintain the catalyst atoms in a non-zero oxidation helps maintains a stronger bonding interaction between the dispersing agent and the catalyst atoms.

Abstract: Methods for manufacturing supported catalysts and the use of these catalysts in, e.g., the direct synthesis of hydrogen peroxide. The nanocatalyst particles are manufactured from catalyst atoms complexed with organic agent molecules (e.g., polyacrylic acid). The complexed catalyst atoms are heated to cause formation of the nanocatalyst particles. The temperature used to cause formation of the particles is typically greater than 30° C., preferably greater than 50° C, and more preferably greater than 70° C.

Abstract: Supported catalysts are manufactured from a pretreated porous support material and a nanocatalyst solution of catalyst nanoparticles. The porous support material is pre-treated with a gaseous solvent (e.g., steam or alcohol) to protect the support material from cracking during impregnation of the nanocatalyst solution. The supported catalysts have more uniform size, lower attrition of metals during manufacturing and use, and improved distributions of metal loading compared to catalysts manufactured using known techniques. Hydrogen peroxide manufactured from such catalysts is less likely to be contaminated with catalyst metal.