Patent ID: 8507401

Claim:
A method of making a metal catalyst comprising: a. providing a quantity of nanoparticles, wherein the step of providing comprises: (i) loading feed material in a powdered form, the feed material comprising a quantity of catalyst material and a quantity of carrier material in a desired ratio of catalyst material to carrier material, into a plasma gun comprising a plasma reactor and a highly turbulent quench chamber; (ii) vaporizing the quantity of catalyst material and the quantity of carrier material in the plasma reactor thereby forming a vapor cloud of catalyst and carrier material; and (iii) quenching the vapor cloud of catalyst material and carrier material utilizing the highly turbulent quench chamber, thereby forming solidified nanoparticles comprising catalyst material and carrier material; b. providing a quantity of supports; and c. combining the supports with the nanoparticles, wherein the step of combining the supports with the nanoparticles comprises suspending the nanoparticles in a solution, thereby forming a suspension.