Technology Overview

A key challenge in the design of new materials is obtaining a fundamental understanding of the key interactions that influence material properties. Rational Design combines computational approaches with scientific experience and experimental methodologies in order to obtain this fundamental knowledge and accelerate the development of new materials. Nanostellar specializes in Rational Catalyst Design (RCD) with emphasis in the fields of quantum computational nanoscience, chemistry, materials science, and chemical engineering.

Automotive catalytic converters use supported metals to catalyze the transformation of toxic pollutants such as CO, NOx, and hydrocarbons into more environmentally benign molecules. Automotive catalysts typically use the precious metals platinum, palladium, and rhodium, the costs of which are high and unstable. Nanostellar's metal nanocluster catalysts provide high activity at lower cost by optimizing precious metal efficiency. We can adjust the composition of nanoclusters to tailor a catalyst's performance to specific industrial applications. Nanostellar uses its Rational Catalyst Design process to create metal and metal nanocomposite particle-based catalysts with tailored activity and selectivity.

Nanostellar's unique combination of algorithms, software, synthesis processes, and testing methodologies enables the rapid development of novel heterogeneous catalysts, thus reducing R&D cost. Nanostellar has over 50 man-years of Rational Catalyst Design experience and a substantial database of catalyst-specific knowledge, developed from both computational and experimental approaches. We have unique algorithms and software that address computational catalyst design. The company also has proprietary synthesis technologies to generate supported nanoparticles and novel testing methods that provide a detailed understanding of catalytic processes.

What Makes Nanostellar Different: Rational Catalyst Design

The traditional method of catalyst design has been by trial-and-error, which typically involves making a large number of materials and testing them. The results of testing, along with empirical knowledge are used to modify existing materials and drive them toward desired properties. The trial-and-error approach can consume a great deal of time and money, with no assurance of success. Recently, combinatorial approaches have been tried, in which a very large number of materials are synthesized and tested in a high-throughput manner. Unfortunately, such high throughput (HT) chemistry and testing often gives a large number of false results. In addition, the material preparation methods available to HT screening are limited. While there was much initial enthusiasm for high-throughput methods, it is fair to say that they have yet to live up to their promise.

In contrast, Nanostellar's Rational Catalyst Design technology uses fundamental knowledge of a catalyst's structure and reactivity to guide the creation of new products. Nanostellar obtains its fundamental understanding of catalysts by combining state-of-the-art computational methods with novel synthesis and testing procedures. The following figure shows the interplay between the various tools we use in the RCD process.

Nanostellar's unique rational design approach is changing the face of nanomaterials design, in the same way that EDI changed electronic product design and development and CAD/CAM reshaped automotive and aircraft design in the last two decades. Computer-based design slash costs and reduces time to market.

Nanostellar's competitive advantage will increase as it continues to refine the Rational Catalyst Design methodology. Nanostellar has become a leader in understanding exactly how nanomaterial properties change under different environments, and in developing the highest-performing materials for demanding applications, such as reducing diesel exhaust emissions in the automotive industry.

Nanostellar's Technology Achievement

Nanostellar released its first two products, promoted platinum and Pt:Pd in mid-2006, within two years from initial concept. These products increased performance by 25%-30% over commercial platinum only products and matched industry's most advanced laboratory products. Nanostellar released its second generation product, NS Gold™ by Q1, 2007, which surpasses first generation's performance by 20+%. Nanostellar's $15 million total cost and three years time for developing these products pales in comparison with traditional catalyst industry's materials R&D budget of over $100 million in the same three years.