Recent Developments in the Synthesis of Supported Catalysts

Combinatorial neutron imaging methods for hydrogenation catalysts

Combinatorial approach based on neutron imaging is capable of measuring more than 50 samples in situ under identical reaction conditions in one experiment.

Prospects and challenges for autonomous catalyst discovery viewed from an experimental perspective

Autonomous catalysis research requires elaborate integration of operando experiments into automated workflows. Suitable experimental data for analysis by artificial intelligence can be measured more readily according to standard operating procedures.

Ligand assisted hydrogenation of levulinic acid on Pt(111) from first principles calculations

In this study, we investigate the hydrogenation reaction of levulinic acid to 4-hydroxypentanovic acid on a ligand-modified Pt(111) using DFT. Modifying nanoparticle surfaces with ligands can have beneficial effects on...

SBA-15 obtained from rice husk ashes wet-impregnated with metals (Al, Co, Ni) as efficient catalysts for 1,4-dihydropyridine three-component reaction

A fully characterized mesoporous silica prepared from industrial waste was impregnated with metals and applied as a green heterogeneous catalyst.

A Review of Preparation Methods for Heterogeneous Catalysts

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Catalysts contribute significantly to the industrial revolution in terms of reaction rates and reduction in production costs. Extensive research has been documented on various industrial catalysis in the last few decades. The performance of catalysts is influenced by many parameters, including synthesis methods. The current work overviews the most common methods applied for the synthesis of supported catalysts. This review presents the detailed background, principles, and mechanism of each preparation method. The advantages and limitations of each method have also been elaborated in detail. In addition, the applications of each method in terms of catalyst synthesis have been documented in the present review paper.

Investigating deposition sequence during synthesis of Pd/Al2O3 catalysts modified with organic monolayers

Modification of supported metal catalysts with self-assembled monolayers (SAMs) has been shown to improve selectivity and turnover frequencies (TOFs) for many catalytic reactions. However, these benefits are often accompanied by...

Selective hydrogenation of succinic acid to gamma-butyrolactone with PVP-capped CuPd catalysts

A reusable catalyst with a low metal loading amount of PVP-capped Pd rich CuPd nanoparticles was explored for highly selective production of γ-butyrolactone via hydrogenation of succinic acid at mild hydrogen pressure.

Defect-stabilized nickel on beta zeolite as a promising catalyst for dry reforming of methane

Four different Ni-containing beta zeolite (Ni-BEA) catalysts were synthesized and applied for dry reforming of methane (DRM). Ni-BEA(I) exhibiting a nickel silicate was synthesized via the single-step interzeolite transformation of...

The Restructuring-Induced CoO x Catalyst for Electrochemical Water Splitting

Restructuring is an important yet less understood phenomenon in the catalysis community. Recent studies have shown that a group of transition metal sulfide catalysts can completely or partially restructure during electrochemical reactions which then exhibit high activity even better than the best commercial standards. However, such restructuring processes and the final structures of the new catalysts are elusive, mainly due to the difficulty from the reaction-induced changes that cannot be captured by ex situ characterizations. To establish the true structure-property relationship in these in situ generated catalysts, we use multimodel operando characterizations including Raman spectroscopy, X-ray absorption spectroscopy, and X-ray reflectivity to investigate the restructuring of a representative catalyst, Co₉S₈, that shows better activity compared to the commercial standard RuO₂ during the oxygen evolution reaction (OER), a key half reaction in water-splitting for hydrogen generation. We find that Co₉S₈ ultimately converts to oxide cluster (CoO _x ) containing six oxygen coordinated Co octahedra as the basic unit which is the true catalytic center to promote high OER activity. The density functional theory calculations verify the in situ generated CoO _x consisting of edge-sharing CoO₆ octahedral clusters as the actual active sites. Our results also provide insights to design other transition-metal-based materials as efficient electrocatalysts that experience a similar restructuring in OER.

Scalable Synthesis of Pt/SrTiO3 Hydrogenolysis Catalysts in Pursuit of Manufacturing-Relevant Waste Plastic Solutions

An improved hydrothermal synthesis of shape-controlled, size-controlled 60 nm SrTiO₃ nanocuboid (STO NC) supports, which facilitates the scalable creation of platinum nanoparticle catalysts supported on STO (Pt/STO) for the chemical conversion of waste polyolefins, is reported herein. This synthetic method (1) establishes that STO nucleation prior to the hydrothermal treatment favors nanocuboid formation, (2) produces STO NC supports with average sizes ranging from 25 to 80 nm with narrow size distributions, and (3) demonstrates how SrCO₃ formation and variation in solution pH prevent the formation of STO NCs. The STO synthesis was scaled-up and conducted in a 4 L batch reactor, resulting in STO NCs of comparable size and morphology (m = 22.5 g, d_avg = 58.6 ± 16.2 nm) to those synthesized under standard hydrothermal conditions in a lab-scale 125 mL autoclave reactor. Size-controlled STO NCs, ranging in roughly 10 nm increments from 25 to 80 nm, were used to support Pt deposited through strong electrostatic adsorption (SEA), a practical and scalable solution-based method. Using SEA techniques and an STO support with an average size of 39.3 ± 6.3 nm, a Pt/STO catalyst with 3.6 wt % Pt was produced and used for high-density polyethylene hydrogenolysis under previously reported conditions (170 psi H₂, 300 °C, 96 h; final product: M_w = 2400, Đ = 1.03). As a well-established model system for studying the behavior of heterogeneous catalysts and their supports, the Pt/STO system detailed in this work presents a unique opportunity to simultaneously convert waste plastic into commercially viable products while gaining insight into how scalable inorganic synthesis can support transformative manufacturing.

Soluble Complexes of Cobalt Oxide Fragments Bring the Unique CO2 Photoreduction Activity of a Bulk Material into the Flexible Domain of Molecular Science

The deposition of metal oxides is essential to the fabrication of numerous multicomponent solid-state devices and catalysts. However, the reproducible formation of homogeneous metal oxide films or of nanoparticle dispersions at solid interfaces remains an ongoing challenge. Here we report that molecular hexaniobate cluster anion complexes of structurally and electronically distinct fragments of cubic-spinel and monoclinic Co₃O₄ can serve as tractable yet well-defined functional analogues of bulk cobalt oxide. Notably, the energies of the highest-occupied and lowest-unoccupied molecular orbitals (HOMO and LUMO) of the molecular complexes, 1, closely match the valence- and conduction-band (VB and CB) energies of the parent bulk oxides. Use of 1 as a molecular analogue of the parent oxides is demonstrated by its remarkably simple deployment as a cocatalyst for direct Z-scheme reduction of CO₂ by solar light and water. Namely, evaporation of an aqueous solution of 1 on TiO₂-coated fluorinated tin oxide windows (TiO₂/FTO), immersion in wet acetonitrile, and irradiation by simulated solar light under an atmosphere of CO₂ give H₂, CO, and CH₄ in ratios nearly identical to those obtained using 20 nm spinel-Co₃O₄ nanocrystals, but 15 times more rapidly on a Co basis and more rapidly overall than other reported systems. Detailed investigation of the photocatalytic properties of 1 on TiO₂/FTO includes confirmation of a direct Z-scheme charge-carrier migration pathway by in situ irradiated X-ray photoelectron spectroscopy. More generally, the findings point to a potentially important new role for coordination chemistry that bridges the conceptual divide between molecular and solid-state science.

New Solvent-Free Melting-Assisted Preparation of Energetic Compound of Nickel with Imidazole for Combustion Synthesis of Ni-Based Materials

In this work two approaches to the synthesis of energetic complex compound Ni(Im)₆(NO₃)₂ from imidazole and nicklel (II) nitrate were applied: a traditional synthesis from solution and a solvent-free melting-assisted method. According to infrared spectroscopy, X-ray diffraction, elemental and thermal analysis data, it was shown that the solvent-free melt synthesis is a faster, simpler and environmentally friendly method of Ni(Im)₆(NO₃)₂ preparation. The results show that this compound is a promising precursor for the production of nanocrystalline Ni-NiO materials by air-assisted combustion method. The combustion of this complex together with inorganic supports makes it possible to synthesize supported nickel catalysts for different catalytic processes.

Combination of Cu/ZnO Methanol Synthesis Catalysts and ZSM-5 Zeolites to Produce Oxygenates from CO2 and H2

Cu/ZnO methanol catalysts were deposited over several ZSM-5 acid zeolites to directly synthesise oxygenates (methanol and dimethyl ether) from a CO2/H2 feed. Catalysts were prepared by two different preparation methodologies: chemical vapour impregnation (CZZ-CVI) and oxalate gel precipitation (CZZ-OG). Chemical vapour impregnation led to Cu/ZnO being deposited on the zeolite surface, whilst oxalate gel precipitation led to the formation of Cu/ZnO agglomerates. For both sets of catalysts a higher concentration of mild and strong acid sites were produced, compared to the parent ZSM-5 zeolites, and CZZ-CVI had a higher concentration of acid sites compared to CZZ-OG. Nevertheless, CZZ-OG shows considerably higher oxygenate productivity, 1322 mmol Kgcat−1 h−1, compared to 192 mmol Kgcat−1 h−1 over CZZ-CVI (ZSM-5(50), 250 ℃, 20 bar, CO2/H2 = 1/3, 30 ml min−1), which could be assigned to a combination of smaller particle size and enhanced methanol mass transfer within the zeolites.

Valorization of carbon dioxide and waste (Derived from the site of Eutrophication) into syngas using a catalytic thermo-chemical platform

Global warming increases a chance of eutrophication, and such fact offers that unhygienic organic waste materials (OWMs) in water must be treated. Hence, this study laid emphasis on the thermal-chemical (pyrolysis) process to establish a rapid valorization platform for OWMs. Indeed, OWMs were collected from the eutrophication site, and OWMs were mainly comprised of lignocellulosic biomass, microalgae (cyanobacteria) and the diverse types of bacteria (commonly observed from livestock waste). In an attempt to offer more sustainable valorization route for OWMs, CO₂ was used as a raw material in pyrolysis process. From the CO₂-assisted pyrolysis, the conversion of CO₂ and OWMs into gaseous fuel (CO) was observed. A cheap Ni-based catalyst was used in pyrolysis of OWMs as a strategic practice to promote conversion of CO₂ into CO. Indeed, syngas production (38 %) was enhanced from catalytic pyrolysis over Ni/SiO₂ under CO₂ condition as compared to inert condition (N₂).

Functionalized Carbon Materials in Syngas Conversion

Functionalized carbon materials are widely used in heterogeneous catalysis due to their unique properties such as adjustable surface properties, excellent thermal conductivity, high surface areas, tunable porosity, and moderate interactions with guest metals. The transformation of syngas into hydrocarbons (known as the Fischer-Tropsch synthesis) or oxygenates is an exothermic reaction and is typically catalyzed by transition metals dispersed on functionalized supports. Various carbon materials have been employed in syngas conversions not only for improving the performance or decreasing the dosage of expensive active metals but also for building model catalysts for fundamental research. This article provides a critical review on recent advances in the utilization of carbon materials, in particular the recently developed functionalized nanocarbon materials, for syngas conversions to either hydrocarbons or oxygenates. The unique features of carbon materials in dispersing metal nanoparticles, heteroatom doping, surface modification, and building special nanoarchitectures are highlighted. The key factors that control the reaction course and the reaction mechanism are discussed to gain insights for the rational design of efficient carbon-supported catalysts for syngas conversions. The challenges and future opportunities in developing functionalized carbon materials for syngas conversions are briefly analyzed.

Recent Advances in Alkaline Exchange Membrane Water Electrolysis and Electrode Manufacturing

Water electrolysis to obtain hydrogen in combination with intermittent renewable energy resources is an emerging sustainable alternative to fossil fuels. Among the available electrolyzer technologies, anion exchange membrane water electrolysis (AEMWE) has been paid much attention because of its advantageous behavior compared to other more traditional approaches such as solid oxide electrolyzer cells, and alkaline or proton exchange membrane water electrolyzers. Recently, very promising results have been obtained in the AEMWE technology. This review paper is focused on recent advances in membrane electrode assembly components, paying particular attention to the preparation methods for catalyst coated on gas diffusion layers, which has not been previously reported in the literature for this type of electrolyzers. The most successful methodologies utilized for the preparation of catalysts, including co-precipitation, electrodeposition, sol-gel, hydrothermal, chemical vapor deposition, atomic layer deposition, ion beam sputtering, and magnetron sputtering deposition techniques, have been detailed. Besides a description of these procedures, in this review, we also present a critical appraisal of the efficiency of the water electrolysis carried out with cells fitted with electrodes prepared with these procedures. Based on this analysis, a critical comparison of cell performance is carried out, and future prospects and expected developments of the AEMWE are discussed.

Single-Phase Formation of Rh2 O3 Nanoparticles on h-BN Support for Highly Controlled Methane Partial Oxidation to Syngas

Single-phase formation of active metal oxides on supports has been vigorously pursued in many catalytic applications to suppress undesired reactions and to determine direct structure-property relationships. However, this is difficult to achieve in nanoscale range because the effect of non-uniform metal-support interfaces becomes dominant in the overall catalyst growth, leading to the nucleation of various metastable oxides. Herein, we develop a supported single-phase corundum-Rh₂ O₃ (I) nanocatalyst by utilizing controlled interaction between metal oxide and h-BN support. Atomic-resolution electron microscopy and first-principle calculation reveal that single-phase formation occurs via uniform and preferential attachment of Rh₂ O₃ (I) (110) seed planes on well-defined h-BN surface after decomposition of rhodium precursor. By utilizing the Rh/h-BN catalyst in methane partial oxidation, syngas is successfully produced solely following the direct route with keeping a H₂ /CO ratio of 2, which makes it ideal for most downstream chemical processes.

Photo-promoted in situ reduction and stabilization of Pd nanoparticles by H2 at photo-insensitive Sm2O3 nanorods

Controlled synthesis of noble metal nanoparticles with well-defined size and good dispersion on supports has been a long-standing challenge in heterogeneous catalysis. Here we report a facile photo-assisted H₂in situ reduction process to synthesize monodispersed Pd nanoparticles with 2-4 nm size on photo-insensitive Sm₂O₃ rare-earth metal oxide with nanorod morphology. Thanks to the contribution of UV irradiation, the photoelectrons generation in the Sm₂O₃ support accelerates the H₂ reduction of Pd²⁺ ions into Pd⁰ and stabilize the growth of very small Pd nanoparticles homogeneously dispersed on the support. The homogeneous distribution of the Pd NPs on the surface of Sm₂O₃ is most likely attributed to the profuse nucleation sites created by the UV irradiation and the abundance of hydroxyl groups on the support. The hydrogenation of styrene to ethylbenzene was studied as a model reaction. As a result, the UV radiated sample shows an excellent TOF value of 7419 h^-1, which is quadruple of the sample without UV irradiation, under the condition of 0.1 MPa H₂ at a content of 1.0 wt% Pd. Besides, UV radiated sample shows a negligible performance degradation during the repeated cycling process. This photo-promoted H₂ reduction process provides a convenient and straightforward route for assembling materials with novel structures and functions for nanotechnology applications.

Glycerol Valorization over ZrO2-Supported Copper Nanoparticles Catalysts Prepared by Chemical Reduction Method

Copper nanoparticles (NPs) and ZrO2-supported copper NPs (Cu NPs/ZrO2) were synthesized via a chemical reduction method applying different pH (4, 7 and 9) and evaluated in a glycerol dehydration reaction. Copper NPs were characterized with transmission electron microscopy (TEM) and UV–vis spectroscopy. Transmission electron microcopy (TEM) results revealed a homogeneous distribution of copper NPs. A hypsochromic shift was identified with UV–vis spectroscopy as the pH of the synthesis increased from pH = 4 to pH = 9. Zirconia-supported copper NPs catalysts were characterized using N2 physisorption, X-ray diffraction (XRD), TEM, X-ray photoelectron spectroscopy (XPS), temperature-programmed reduction (TPR), temperature-programmed desorption of ammonia (NH3-TPD) and N2O chemisorption. The presence of ZrO2 in the chemical reduction method confirmed the dispersion of the copper nanoparticles. X-ray diffraction indicated only the presence of tetragonal zirconia patterns in the catalysts. XPS identified the Cu/Zr surface atomic ratio of the catalysts. TPR patterns showed two main peaks for the Cu NPS/ZrO2 pH = 9 catalyst; the first peak between 125 and 180 °C (region I) was ascribed to more dispersed copper species, and the second one between 180 and 250 °C (region II) was assigned to bulk CuO. The catalysts prepared at pH = 4 and pH = 7 only revealed reduction at lower temperatures (region I). Copper dispersion was determined by N2O chemisorption. With NH3-TPD it was found that Cu NPs/ZrO2 pH = 9 exhibited the highest total quantity of acidic sites and the highest apparent kinetic constant, with a value of 0.004 min−1. The different pH applied to the synthesis media of the copper nanoparticles determined the resultant copper dispersion on the ZrO2 support, providing active domains for glycerol conversion.

Design of Silica Nanoparticles-Supported Metal Catalyst by Wet Impregnation with Catalytic Performance for Tuning Carbon Nanotubes Growth

The catalytic activity of cobalt and iron nanoparticles for the growth of carbon nanotubes (CNTs) was studied by a specific reproducible and up-scalable fabrication method. Co and Fe catalysts were deposited over SiO2 nanoparticles by a wet-impregnation method and two different annealing steps were applied for the catalyst formation/activation. The samples were calcined at an optimal temperature of 450 °C resulting in the formation of metal oxide nano-islands without the detection of silicates. Further reduction treatment (700 °C) under H2 successfully converted oxide nanoparticles to Co and Fe metallic species. Furthermore, the catalytic efficiency of both supported-metal nanoparticles at 2 and 5% in weight of silica was evaluated through the growth of CNTs. The CNT structure, morphology and size dispersion were tailored according to the metal catalyst concentration.

Rational Design of Bioinspired Nanocomposites with Tunable Catalytic Activity

Biological assembly processes offer inspiration for ordering building blocks across multiple length scales into advanced functional materials. Such bioinspired strategies are attractive for assembling supported catalysts, where shaping and structuring across length scales are essential for their performance but still remain tremendously difficult to achieve. Here, we present a simple bioinspired route toward supported catalysts with tunable activity and selectivity. We coprecipitate shape-controlled nanocomposites with large specific surface areas of barium carbonate nanocrystals that are uniformly embedded in a silica support. Subsequently, we exchange the barium carbonate to cobalt while preserving the nanoscopic layout and microscopic shape, and demonstrate their catalytic performances in the Fischer-Tropsch synthesis as a case study. Control over the crystal size between 10 and 17 nm offers tunable activity and selectivity for shorter (C₅-C₁₁) and longer (C₂₀₊) hydrocarbons, respectively. Hence, these results open simple, versatile, and scalable routes to tunable and highly reactive bioinspired catalysts.

Porous Silicon Carbide (SiC): A Chance for Improving Catalysts or Just Another Active-Phase Carrier?

There is an obvious gap between efforts dedicated to the control of chemicophysical and morphological properties of catalyst active phases and the attention paid to the search of new materials to be employed as functional carriers in the upgrading of heterogeneous catalysts. Economic constraints and common habits in preparing heterogeneous catalysts have narrowed the selection of active-phase carriers to a handful of materials: oxide-based ceramics (e.g. Al₂O₃, SiO₂, TiO₂, and aluminosilicates-zeolites) and carbon. However, these carriers occasionally face chemicophysical constraints that limit their application in catalysis. For instance, oxides are easily corroded by acids or bases, and carbon is not resistant to oxidation. Therefore, these carriers cannot be recycled. Moreover, the poor thermal conductivity of metal oxide carriers often translates into permanent alterations of the catalyst active sites (i.e. metal active-phase sintering) that compromise the catalyst performance and its lifetime on run. Therefore, the development of new carriers for the design and synthesis of advanced functional catalytic materials and processes is an urgent priority for the heterogeneous catalysis of the future. Silicon carbide (SiC) is a non-oxide semiconductor with unique chemicophysical properties that make it highly attractive in several branches of catalysis. Accordingly, the past decade has witnessed a large increase of reports dedicated to the design of SiC-based catalysts, also in light of a steadily growing portfolio of porous SiC materials covering a wide range of well-controlled pore structure and surface properties. This review article provides a comprehensive overview on the synthesis and use of macro/mesoporous SiC materials in catalysis, stressing their unique features for the design of efficient, cost-effective, and easy to scale-up heterogeneous catalysts, outlining their success where other and more classical oxide-based supports failed. All applications of SiC in catalysis will be reviewed from the perspective of a given chemical reaction, highlighting all improvements rising from the use of SiC in terms of activity, selectivity, and process sustainability. We feel that the experienced viewpoint of SiC-based catalyst producers and end users (these authors) and their critical presentation of a comprehensive overview on the applications of SiC in catalysis will help the readership to create its own opinion on the central role of SiC for the future of heterogeneous catalysis.

Tuning the Catalytic Performance of Cobalt Nanoparticles by Tungsten Doping for Efficient and Selective Hydrogenation of Quinolines under Mild Conditions

Non-noble bimetallic CoW nanoparticles (NPs) partially embedded in a carbon matrix (CoW@C) have been prepared by a facile hydrothermal carbon-coating methodology followed by pyrolysis under an inert atmosphere. The bimetallic NPs, constituted by a multishell core-shell structure with a metallic Co core, a W-enriched shell involving Co7W6 alloyed structures, and small WO3 patches partially covering the surface of these NPs, have been established as excellent catalysts for the selective hydrogenation of quinolines to their corresponding 1,2,3,4-tetrahydroquinolines under mild conditions of pressure and temperature. It has been found that this bimetallic catalyst displays superior catalytic performance toward the formation of the target products than the monometallic Co@C, which can be attributed to the presence of the CoW alloyed structures.