Patent ID: 8575059

Claim:
A method of making a metal compound catalyst comprising: a. providing a quantity of nanoparticles, comprising the steps: i. loading a quantity of catalyst material in powder form and a quantity of carrier comprising an oxide into a plasma gun in a desired ratio; ii. vaporizing the quantity of catalyst material and the quantity of carrier by the plasma gun, thereby forming a vapor cloud; iii. quenching the vapor cloud received from the plasma gun, thereby forming precipitate nanoparticles; and iv. injecting a co-reactant into a substantially low oxygen environment such that the co-reactant will react with one of the vapor cloud, the precipitate nanoparticles, and any combination thereof, wherein at least some of the nanoparticles comprise a first portion comprising a catalyst material bonded to a second portion comprising a carrier, wherein the carrier comprises an oxide; b. providing a quantity of supports comprising a same oxide as in the carrier loaded in the plasma gun; c. combining the supports with the nanoparticles; and d. forming a structure having the catalyst material bonded with the carrier, wherein the carrier is bonded with the support through an oxide-oxide bond.