New Strategies for the Preparation of Sinter-Resistant Metal-Nanoparticle-Based Catalysts

Towards bridging thermo/electrocatalytic CO oxidation: from nanoparticles to single atoms

Proton exchange membrane fuel cells (PEMFCs), as a feasible alternative to replace the traditional fossil fuel-based energy converter, contribute significantly to the global sustainability agenda. At the PEMFC anode, given the high exchange current density, Pt/C is deemed the catalyst-of-choice to ensure that the hydrogen oxidation reaction (HOR) occurs at a sufficiently fast pace. The high performance of Pt/C, however, can only be achieved under the premise that high purity hydrogen is used. For instance, in the presence of trace level carbon monoxide, a typical contaminant during H2 production, Pt is severely deactivated by CO surface blockage. Addressing the poisoning issue necessitates for either developing anti-poisoning electrocatalysts or using pre-purified H2 obtained via a thermo-catalysis route. In other words, the CO poisoning issue can be addressed by either thermal-catalysis from the H2 supply side or electrocatalysis at the user side, respectively. In spite of the distinction between thermo-catalysis and electro-catalysis, there are high similarities between the two routes. Essentially, a reduction in the kinetic barrier for the combination of CO to oxygen containing intermediates is required in both techniques. Therefore, bridging electrocatalysis and thermocatalysis might offer new insight into the development of cutting edge catalysts to solve the poisoning issue, which, however, stands as an underexplored frontier in catalysis science. This review provides a critical appraisal of the recent advancements in preferential CO oxidation (CO-PROX) thermocatalysts and anti-poisoning HOR electrocatalysts, aiming to bridge the gap in cognition between the two routes. First, we discuss the differences in thermal/electrocatalysis, CO oxidation mechanisms, and anti-CO poisoning strategies. Second, we comprehensively summarize the progress of supported and unsupported CO-tolerant catalysts based on the timeline of development (nanoparticles to clusters to single atoms), focusing on metal-support interactions and interface reactivity. Third, we elucidate the stability issue and theoretical understanding of CO-tolerant electrocatalysts, which are critical factors for the rational design of high-performance catalysts. Finally, we underscore the imminent challenges in bridging thermal/electrocatalytic CO oxidation, with theory, materials, and the mechanism as the three main weapons to gain a more in-depth understanding. We anticipate that this review will contribute to the cognition of both thermocatalysis and electrocatalysis.

Design of hollow structured nanoreactors for liquid-phase hydrogenations

Inspired by the attractive structures and functions of natural matter (such as cells, organelles and enzymes), chemists are constantly exploring innovative material platforms to mimic natural catalytic systems, particularly liquid-phase hydrogenations, which are of great significance for chemical upgrading and synthesis. Hollow structured nanoreactors (HSNRs), featuring unique nanoarchitectures and advantageous properties, offer new opportunities for achieving excellent catalytic activity, selectivity, stability and sustainability. Notwithstanding the great progress made in HSNRs, there still remain the challenges of precise synthetic chemistry, and mesoscale catalytic kinetic investigation, and smart catalysis. To this extent, we provide an overview of recent developments in the synthetic chemistry of HSNRs, the unique characteristics of these materials and catalytic mechanisms in HSNRs. Finally, a brief outlook, challenges and further opportunities for their synthetic methodologies and catalytic application are discussed. This review might promote the creation of further HSNRs, realize the sustainable production of fine chemicals and pharmaceuticals, and contribute to the development of materials science.

Tuning Adsorbate-Mediated Strong Metal-Support Interaction by Oxygen Vacancy: A Case Study in Ru/TiO2

The adsorbate-mediated strong metal-support interaction (A-SMSI) offers a reversible means of altering the selectivity of supported metal catalysts, thereby providing a powerful tool for facile modulation of catalytic performance. However, the fundamental understanding of A-SMSI remains inadequate and methods for tuning A-SMSI are still in their nascent stages, impeding its stabilization under reaction conditions. Here, we report that the initial concentration of oxygen vacancy in oxide supports plays a key role in tuning the A-SMSI between Ru nanoparticles and defected titania (TiO2-x). Based on this new understanding, we demonstrate the in situ formation of A-SMSI under reaction conditions, obviating the typically required CO2-rich pretreatment. The as-formed A-SMSI layer exhibits remarkable stability at various temperatures, enabling excellent activity, selectivity and long-term stability in catalyzing the reverse water gas-shift reaction. This study deepens the understanding of the A-SMSI and the ability to stabilize A-SMSI under reaction conditions represents a key step for practical catalytic applications.

Construction of mechanically robust and recyclable catalytic hydrogel based on hydroxypropyl cellulose-supported by montmorillonite/ionic liquid with different anions for pollutants(4-NP, MB, CR, Rhb) degradation

Dye wastewater poses a serious threat to the environment and human health, necessitating sustainable degradation methods. In this study, Na-based Montmorillonite (MMT) was exfoliated using different ionic liquids ([C16MIM][Cl], [C16MIM][BF4], [C16MIM][PF6]), and silver nanoparticles (Ag NPs) were green-synthesized using hydroxypropyl cellulose (HPC). The HPC significantly enhanced the dispersion of MMT in the hydrogel. By introducing lauryl methacrylate (LMA), a hydrophobic associative network was constructed in PAM/LMA/HPC/MMT@ILs&Ag NPs hydrogel. This hydrogel demonstrated outstanding mechanical properties, with a stress of 833.21 kPa, strain of 3300 %, and toughness of 14.36 MJ/m3. It also exhibited excellent catalytic activity, with a rate constant of 0.83 min-1 for 4-nitrophenol degradation at 28 °C. The effects of temperature and catalyst concentration on the catalytic reaction were systematically investigated. This study presents a simple green synthesis approach for Ag NPs using HPC, achieving superior mechanical performance and stable MMT dispersion in aqueous solutions.

In Situ TEM Tracking of Disconnection Motion and Atomic Cooperative Reorientation in the Oriented Attachment of Pt Nanoparticles

The oriented attachment (OA) of nanoparticles (NPs) is an important crystal growth mechanism in many materials. However, a comprehensive understanding of the atomic-scale alignment and attachment processes is still lacking. We conducted in situ atomic resolution studies using high-resolution transmission electron microscopy to reveal how two Pt NPs coalesce into a single particle via OA, which involves the formation of atomic-scale links and a grain boundary (GB) between the NPs, as well as GB migration. Density functional theory calculations showed that the system energy changes as a function of the number of disconnections during the coalescence process. Additionally, the formation and annihilation processes of disconnection are always accompanied by the cooperative reorientation motion of atoms. These results further elucidate the growth mechanism of OA at the atomic scale, providing microscopic insights into OA dynamics and a framework for the development of processing strategies for nanocrystalline materials.

Surface-Diffusion-Induced Amorphization of Pt Nanoparticles over Ru Oxide Boost Acidic Oxygen Evolution

Phase transformation offers an alternative strategy for the synthesis of nanomaterials with unconventional phases, allowing us to further explore their unique properties and promising applications. Herein, we first observed the amorphization of Pt nanoparticles on the RuO2 surface by in situ scanning transmission electron microscopy. Density functional theory calculations demonstrate the low energy barrier and thermodynamic driving force for Pt atoms transferring from the Pt cluster to the RuO2 surface to form amorphous Pt. Remarkably, the as-synthesized amorphous Pt/RuO2 exhibits 14.2 times enhanced mass activity compared to commercial RuO2 catalysts for the oxygen evolution reaction (OER). Water electrolyzer with amorphous Pt/RuO2 achieves 1.0 A cm-2 at 1.70 V and remains stable at 200 mA cm-2 for over 80 h. The amorphous Pt layer not only optimized the *O binding but also enhanced the antioxidation ability of amorphous Pt/RuO2, thereby boosting the activity and stability for the OER.

In Situ Reconstruction of Active Heterointerface for Hydrocarbon Combustion through Thermal Aging over Strontium-Modified Co3O4 Nanocatalyst with Good Sintering Resistance

The issue of catalyst deactivation due to sintering has gained significant attention alongside the rapid advancement of thermal catalysts. In this work, a simple Sr modification strategy was applied to achieve highly active Co3O4-based nanocatalyst for catalytic combustion of hydrocarbons with excellent antisintering feature. With the Co1Sr0.3 catalyst achieving a 90% propane conversion temperature (T90) of only 289 °C at a w8 hly space velocity of 60,000 mL·g-1·h-1, 24 °C lower than that of pure Co3O4. Moreover, the sintering resistance of Co3O4 catalysts was greatly improved by SrCO3 modification, and the T90 over Co1Sr0.3 just increased from 289 to 337 °C after thermal aging at 750 °C for 100 h, while that over pure Co3O4 catalysts increased from 313 to 412 °C. Through strontium modification, a certain amount of SrCO3 was introduced on the Co3O4 catalyst, which can serve as a physical barrier during the thermal aging process and further formation of Sr-Co perovskite nanocrystals, thus preventing the aggregation growth of Co3O4 nanocrystals and generating new active SrCoO2.52-Co3O4 heterointerface. In addition, propane durability tests of the Co1Sr0.3 catalysts showed strong water vapor resistance and stability, as well as excellent low-temperature activity and resistance to sintering in the oxidation reactions of other typical hydrocarbons such as toluene and propylene. This study provides a general strategy for achieving thermal catalysts by perfectly combining both highly low-temperature activity and sintering resistance, which will have great significance in practical applications for replacing precious materials with comparative features.

Small-size and well-dispersed Fe nanoparticles embedded in carbon rods for efficient oxygen reduction reaction

The preparation of ultra-small and well-dispersed metal nanoparticles (NPs) is of great importance for promoting oxygen reduction. Here, a metal (Fe and Zn) NP (7 nm) based catalyst derived from a Zn-based metal-organic framework was obtained by a vapor adsorption strategy, demonstrating a high half-wave potential (0.868 V) and power density (196 mW cm-2).

Controlling Pt nanoparticle sintering by sub-monolayer MgO ALD thin films

Metal nanoparticle (NP) sintering is a major cause of catalyst deactivation, as NP growth reduces the surface area available for reaction. A promising route to halt sintering is to deposit a protective overcoat on the catalyst surface, followed by annealing to generate overlayer porosity for gas transport to the NPs. Yet, such a combined deposition-annealing approach lacks structural control over the cracked protection layer and the number of NP surface atoms available for reaction. Herein, we exploit the tailoring capabilities of atomic layer deposition (ALD) to deposit MgO overcoats on archetypal Pt NP catalysts with thicknesses ranging from sub-monolayers to nm-range thin films. Two different ALD processes are studied for the growth of MgO overcoats on Pt NPs anchored on a SiO2 support, using Mg(EtCp)2 and H2O, and Mg(TMHD)2 and O3, respectively. Spectroscopic ellipsometry and X-ray photoelectron spectroscopy measurements reveal significant growth on both SiO2 and Pt for the former process, while the latter exhibits a drastically lower growth per cycle with an initial chemical selectivity towards Pt. These differences in MgO growth characteristics have implications for the availability of uncoated Pt surface atoms at different stages of the ALD process, as probed by low energy ion scattering, and for the sintering behavior during O2 annealing, as monitored in situ with grazing incidence small angle X-ray scattering (in situ GISAXS). The Mg(TMHD)2-O3 ALD process enables exquisite coverage control allowing a balance between physically blocking the Pt surface to prevent sintering and keeping Pt surface atoms free for reaction. This approach avoids the need for post-annealing, hence also safeguarding the structural integrity of the as-deposited overcoat.

Renaissance of Strong Metal-Support Interactions

Strong metal-support interactions (SMSIs) have emerged as a significant and cutting-edge area of research in heterogeneous catalysis. They play crucial roles in modifying the chemisorption properties, interfacial structure, and electronic characteristics of supported metals, thereby exerting a profound influence on the catalytic properties. This Perspective aims to provide a comprehensive summary of the latest advancements and insights into SMSIs, with a focus on state-of-the-art in situ/operando characterization techniques. This overview also identifies innovative designs and applications of new types of SMSI systems in catalytic chemistry and highlights their pivotal role in enhancing catalytic performance, selectivity, and stability in specific cases. Particularly notable is the discovery of SMSI between active metals and metal carbides, which opens up a new era in the field of SMSI. Additionally, the strong interactions between atomically dispersed metals and supports are discussed, with an emphasis on the electronic effects of the support. The chemical nature of SMSI and its underlying catalytic mechanisms are also elaborated upon. It is evident that SMSI modification has become a powerful tool for enhancing catalytic performance in various catalytic applications.

Highly Stable Pt/CeO2 Catalyst with Embedding Structure toward Water-Gas Shift Reaction

Strong metal-support interaction (SMSI) has been extensively studied in heterogeneous catalysis because of its significance in stabilizing active metals and tuning catalytic performance, but the origin of SMSI is not fully revealed. Herein, by using Pt/CeO2 as a model catalyst, we report an embedding structure at the interface between Pt and (110) plane of CeO2, where Pt clusters (∼1.6 nm) are embedded into the lattice of ceria within 3-4 atomic layers. In contrast, this phenomenon is absent in the CeO2(100) support. This unique geometric structure, as an effective motivator, triggers more significant electron transfer from Pt clusters to CeO2(110) support accompanied by the formation of interfacial structure (Ptδ+-Ov-Ce3+), which plays a crucial role in stabilizing Pt nanoclusters. A comprehensive investigation based on experimental studies and theoretical calculations substantiates that the interfacial sites serve as the intrinsic active center toward water-gas shift reaction (WGSR), featuring a moderate strength CO activation adsorption and largely decreased energy barrier of H2O dissociation, accounting for the prominent catalytic activity of Pt/CeO2(110) (a reaction rate of 15.76 molCO gPt-1 h-1 and a turnover frequency value of 2.19 s-1 at 250 °C). In addition, the Pt/CeO2(110) catalyst shows a prominent durability within a 120 h time-on-stream test, far outperforming the Pt/CeO2(100) one, which demonstrates the advantages of this embedding structure for improving catalyst stability.

The phenomenon of "dead" metal in heterogeneous catalysis: opportunities for increasing the efficiency of carbon-supported metal catalysts

This review addresses the largely overlooked yet critical issue of "dead" metal in heterogeneous metal catalysts. "Dead" metal refers to the fraction of metal in a catalyst that remains inaccessible to reactants, significantly reducing the overall catalyst performance. As a representative example considered in detail here, this challenge is particularly relevant for carbon-supported metal catalysts, extensively employed in research and industrial settings. We explore key factors contributing to the formation of "dead" metal, including the morphology of the support, metal atom intercalation within the support layers, encapsulation of metal nanoparticles, interference by organic molecules during catalyst preparation, and dynamic behavior under microwave irradiation. Notably, the review outlines a series of strategic approaches to mitigate the occurrence of "dead" metal during catalyst preparation, thus boosting the catalyst efficiency. The knowledge gathered is important for enhancing the preparation of catalysts, especially those containing precious metals. Beyond the practical implications for catalyst design, this study introduces a novel perspective for understanding and optimizing the catalyst performance. The insights are expected to broadly impact different scientific disciplines, empowered with heterogeneous catalysis and driving innovation in energy, environmental science, and materials chemistry, among others. Exploring the "dead" metal phenomenon and potential mitigation strategies brings the field closer to the ultimate goal of high-efficiency, low-cost catalysis.

Precision Synthesis of Bimetallic Nanoparticles via Nanofluidics in Nanopipets

Bimetallic nanoparticles often show properties superior to their single-component counterparts. However, the large parameter space, including size, structure, composition, and spatial arrangement, impedes the discovery of the best nanoparticles for a given application. High-throughput methods that can control the composition and spatial arrangement of the nanoparticles are desirable for accelerated materials discovery. Herein, we report a methodology for synthesizing bimetallic alloy nanoparticle arrays with precise control over their composition and spatial arrangement. A dual-channel nanopipet is used, and nanofluidic control in the nanopipet further enables precise tuning of the electrodeposition rate of each element, which determines the final composition of the nanoparticle. The composition control is validated by finite element simulation as well as electrochemical and elemental analyses. The scope of the particles demonstrated includes Cu-Ag, Cu-Pt, Au-Pt, Cu-Pb, and Co-Ni. We further demonstrate surface patterning using Cu-Ag alloys with precise control of the location and composition of each pixel. Additionally, combining the nanoparticle alloy synthesis method with scanning electrochemical cell microscopy (SECCM) allows for fast screening of electrocatalysts. The method is generally applicable for synthesizing metal nanoparticles that can be electrodeposited, which is important toward developing automated synthesis and screening systems for accelerated material discovery in electrocatalysis.

Strengthening Pt/WOx interfacial interactions to increase the CO tolerance of Pt for hydrogen oxidation reaction

Here, the modulation of the Pt electronic structure by the formation of an amorphous WOx overlayer on Pt nanoparticles is proposed. The resulting Pt/WOx@NC electrode shows exceptional CO oxidation potential (0.24 V vs. RHE) in aqueous test, and the corresponding membrane electrode assembly (MEA) steadily generates power in fuel cells fed with H2 gas containing 1000 ppm CO.

Strong metal-support interactions for high sintering resistance of Ru-based catalysts toward the HER and ORR

B, N co-doped carbon-supported small-sized Ru nanoparticles (RuBCN) were constructed by a facile ion exchange strategy using closo-[B12H12]2- and Ru(bpy)32+ as the precursors. Benefitting from strong metal-support interactions caused by the synergistic coupling effect of co-dopants B and N, RuBCN exhibits improved sintering resistance and the Ru nanoparticles are stabilized at sub-3 nm at 900 °C. Besides, introducing B doping further increases the electron deficiency of Ru in RuBCN, which could weaken the interaction between Ru and Had species or O2 adsorption. As a result, it exhibits impressive HER (η10 = 20 mV) and ORR (E1/2 = 0.76 V) catalytic performances, as well as outstanding stability, which are much higher than those of the single dopant counterpart.

CeO2/Cu2O/Cu Tandem Interfaces for Efficient Water-Gas Shift Reaction Catalysis

Metal-oxide interfaces on Cu-based catalysts play very important roles in the low-temperature water-gas shift reaction (LT-WGSR). However, developing catalysts with abundant, active, and robust Cu-metal oxide interfaces under LT-WGSR conditions remains challenging. Herein, we report the successful development of an inverse copper-ceria catalyst (Cu@CeO₂), which exhibited very high efficiency for the LT-WGSR. At a reaction temperature of 250 °C, the LT-WGSR activity of the Cu@CeO₂ catalyst was about three times higher than that of a pristine Cu catalyst without CeO₂. Comprehensive quasi-in situ structural characterizations indicated that the Cu@CeO₂ catalyst was rich in CeO₂/Cu₂O/Cu tandem interfaces. Reaction kinetics studies and density functional theory (DFT) calculations revealed that the Cu⁺/Cu⁰ interfaces were the active sites for the LT-WGSR, while adjacent CeO₂ nanoparticles play a key role in activating H₂O and stabilizing the Cu⁺/Cu⁰ interfaces. Our study highlights the role of the CeO₂/Cu₂O/Cu tandem interface in regulating catalyst activity and stability, thus contributing to the development of improved Cu-based catalysts for the LT-WGSR.

Rapid Joule Heating Synthesis of Oxide-Socketed High-Entropy Alloy Nanoparticles as CO2 Conversion Catalysts

The unorthodox surface chemistry of high-entropy alloy nanoparticles (HEA-NPs), with numerous interelemental synergies, helps catalyze a variety of essential chemical processes, such as the conversion of CO₂ to CO, as a sustainable path to environmental remediation. However, the risk of agglomeration and phase separation in HEA-NPs during high-temperature operations are lasting issues that impede their practical viability. Herein, we present HEA-NP catalysts that are tightly sunk in an oxide overlayer for promoting the catalytic conversion of CO₂ with exceptional stability and performance. We demonstrated the controlled formation of conformal oxide overlayers on carbon nanofiber surfaces via a simple sol-gel method, which facilitated a large uptake of metal precursor ions and helped to decrease the reaction temperature required for nanoparticle formation. During the rapid thermal shock synthesis process, the oxide overlayer would also impede nanoparticle growth, resulting in uniformly distributed small HEA-NPs (2.37 ± 0.78 nm). Moreover, these HEA-NPs were firmly socketed in the reducible oxide overlayer, enabling an ultrastable catalytic performance involving >50% CO₂ conversion with >97% selectivity to CO for >300 h without extensive agglomeration. Altogether, we establish the rational design principles for the thermal shock synthesis of high-entropy alloy nanoparticles and offer a helpful mechanistic perspective on how the oxide overlayer impacts the nanoparticle synthesis behavior, providing a general platform for the designed synthesis of ultrastable and high-performance catalysts that could be utilized for various industrially and environmentally relevant chemical processes.

Transient and general synthesis of high-density and ultrasmall nanoparticles on two-dimensional porous carbon via coordinated carbothermal shock

Carbon-supported nanoparticles are indispensable to enabling new energy technologies such as metal-air batteries and catalytic water splitting. However, achieving ultrasmall and high-density nanoparticles (optimal catalysts) faces fundamental challenges of their strong tendency toward coarsening and agglomeration. Herein, we report a general and efficient synthesis of high-density and ultrasmall nanoparticles uniformly dispersed on two-dimensional porous carbon. This is achieved through direct carbothermal shock pyrolysis of metal-ligand precursors in just ~100 ms, the fastest among reported syntheses. Our results show that the in situ metal-ligand coordination (e.g., N → Co²⁺) and local ordering during millisecond-scale pyrolysis play a crucial role in kinetically dominated fabrication and stabilization of high-density nanoparticles on two-dimensional porous carbon films. The as-obtained samples exhibit excellent activity and stability as bifunctional catalysts in oxygen redox reactions. Considering the huge flexibility in coordinated precursors design, diversified single and multielement nanoparticles (M = Fe, Co, Ni, Cu, Cr, Mn, Ag, etc) were generally fabricated, even in systems well beyond traditional crystalline coordination chemistry. Our method allows for the transient and general synthesis of well-dispersed nanoparticles with great simplicity and versatility for various application schemes.

A review study on methanol steam reforming catalysts: Evaluation of the catalytic performance, characterizations, and operational parameters

Conventional fossil-based energy sources have numerous environmental demerits; sustainable and renewable sources are attracting the undivided attention of researchers owing to their valuable physical and chemical features. Several industrial-scale technologies are employing hydrogen as a green energy source as the most preferential source. Not only is hydrogen a potent energy carrier but also it is not detrimental to the environment. Among many other hydrogen production processes, steam reforming of methanol (SRM) is deemed a practical method due to its low energy consumption. Cu, Ni, noble metals, etc., are the salient catalysts in SRM. Many researchers have conducted thorough studies incorporating improvement of the catalysts’ activity, mechanism predictions, and the impacts of operational parameters and reformers. This review concentrates on the SRM catalysts, supports, promoters, and the effect of the operational parameters on the process efficiency and H2 production yield. In this regard, the methanol conversion, H2 and CO selectivity, and operating parameters are notably contingent on the surface characterization and chemistry of the catalysts. Herein, Cu-, Ni-, and noble metal-based catalysts on various metal oxide supports, such as Al2O3 and ZnO, are assessed meticulously in the SRM process from the standpoint of mechanism and catalyst characterization. Most of the peer-reviewed studies had encountered agglomeration, metal particle sintering at high temperatures, coke formation, and deactivation of catalysts as the prevalent barriers. Hence, the novel methods of conquering the above-mentioned obstacles are evaluated in this review. Employment of diverse synthetic methods, bimetallic catalysts, distinct catalyst promoters, and unconventional supports, such as metal–organic frameworks, carbon nanotubes, and zeolites, are the salient routes to overcome the metal dispersion and thermal stability issues. In addition, the influence of operational parameters (temperature of the process, steam/carbon ratio, and feed flow rate) has been weighed painstakingly, along with introducing the research gap and future perspectives in the territory of SRM catalysts.

Metal Nanocatalyst Sintering Interrogated at Complementary Length Scales

Metal nanoparticle (NP) sintering is a prime cause of catalyst degradation, limiting its economic lifetime and viability. To date, sintering phenomena are interrogated either at the bulk scale to probe averaged NP properties or at the level of individual NPs to visualize atomic motion. Yet, "mesoscale" strategies which bridge these worlds can chart NP populations at intermediate length scales but remain elusive due to characterization challenges. Here, a multi-pronged approach is developed to provide complementary information on Pt NP sintering covering multiple length scales. High-resolution scanning electron microscopy (HRSEM) and Monte Carlo simulation show that the size evolution of individual NPs depends on the number of coalescence events they undergo during their lifetime. In its turn, the probability of coalescence is strongly dependent on the NP's mesoscale environment, where local population heterogeneities generate NP-rich "hotspots" and NP-free zones during sintering. Surprisingly, advanced in situ synchrotron X-ray diffraction shows that not all NPs within the small NP sub-population are equally prone to sintering, depending on their crystallographic orientation on the support surface. The demonstrated approach shows that mesoscale heterogeneities in the NP population drive sintering and mitigation strategies demand their maximal elimination via advanced catalyst synthesis strategies.

Encapsulating Metal Nanoparticles into a Layered Zeolite Precursor with Surface Silanol Nests Enhances Sintering Resistance

Supported metal nanoparticles are used as heterogeneous catalysts but often deactivated due to sintering at high temperatures. Confining metal species into a porous matrix reduces sintering, yet supports rarely provide additional stabilization. Here, we used the silanol-rich layered zeolite IPC-1P to stabilize ultra-small Rh nanoparticles. By adjusting the IPC-1P interlayer space through swelling, we prepared various architectures, including microporous and disordered mesoporous. In situ scanning transmission electron microscopy confirmed that Rh nanoparticles are resistant to sintering at high temperature (750 °C, 6 hrs). Rh clusters strongly bind to surface silanol quadruplets at IPC-1P layers by hydrogen transfer to clusters, while high silanol density hinders their migration based on density functional theory calculations. Ultimately, combining swelling with long-chain surfactant and utilizing metal-silanol interactions resulted in a novel, catalytically active material-Rh@IPC_C22.

Fabrication of r-GO/GO/α-Fe2O3/Fe2TiO5 Nanocomposite Using Natural Ilmenite and Graphite for Efficient Photocatalysis in Visible Light

Hematite (α-Fe₂O₃) and pseudobrookite (Fe₂TiO₅) suffer from poor charge transport and a high recombination effect under visible light irradiation. This study investigates the design and production of a 2D graphene-like r-GO/GO coupled α-Fe₂O₃/Fe₂TiO₅ heterojunction composite with better charge separation. It uses a simple sonochemical and hydrothermal approach followed by L-ascorbic acid chemical reduction pathway. The advantageous band offset of the α-Fe₂O₃/Fe₂TiO₅ (TF) nanocomposite between α-Fe₂O₃ and Fe₂TiO₅ forms a Type-II heterojunction at the Fe₂O₃/Fe₂TiO₅ interface, which efficiently promotes electron-hole separation. Importantly, very corrosive acid leachate resulting from the hydrochloric acid leaching of ilmenite sand, was successfully exploited to fabricate α-Fe₂O₃/Fe₂TiO₅ heterojunction. In this paper, a straightforward synthesis strategy was employed to create 2D graphene-like reduced graphene oxide (r-GO) from Ceylon graphite. The two-step process comprises oxidation of graphite to graphene oxide (GO) using the improved Hummer's method, followed by controlled reduction of GO to r-GO using L-ascorbic acid. Before the reduction of GO to the r-GO, the surface of TF heterojunction was coupled with GO and was allowed for the controlled L-ascorbic acid reduction to yield r-GO/GO/α-Fe₂O₃/Fe₂TiO₅ nanocomposite. Under visible light illumination, the photocatalytic performance of the 30% GO/TF loaded composite material greatly improved (1240 Wcm^-2). Field emission scanning electron microscopy (FE-SEM) and high-resolution transmission electron microscopy (HR-TEM) examined the morphological characteristics of fabricated composites. X-ray photoelectron spectroscopy (XPS), Raman, X-ray diffraction (XRD), X-ray fluorescence (XRF), and diffuse reflectance spectroscopy (DRS) served to analyze the structural features of the produced composites.

Boosting CO hydrogenation towards C2+ hydrocarbons over interfacial TiO2−x/Ni catalysts

Considerable attention has been drawn to tune the geometric and electronic structure of interfacial catalysts via modulating strong metal-support interactions (SMSI). Herein, we report the construction of a series of TiO2−x/Ni catalysts, where disordered TiO2−x overlayers immobilized onto the surface of Ni nanoparticles (~20 nm) are successfully engineered with SMSI effect. The optimal TiO2−x/Ni catalyst shows a CO conversion of ~19.8% in Fischer–Tropsch synthesis (FTS) process under atmospheric pressure at 220 °C. More importantly, ~64.6% of the product is C2+ paraffins, which is in sharp contrast to the result of the conventional Ni catalyst with the main product being methane. A combination study of advanced electron microscopy, multiple in-situ spectroscopic characterizations, and density functional theory calculations indicates the presence of Niδ−/TiO2−x interfacial sites, which could bind carbon atom strongly, inhibit methane formation and facilitate the C-C chain propagation, lead to the production of C2+ hydrocarbon on Ni surface.

In Situ TEM Observation of the Atomic Transport Process during the Coalescence of Au Nanoparticles

In practical applications, the coalescence of metal nanoparticles (NPs) is a major factor affecting their physical chemistry properties. Currently, due to a lack of understanding of the atomic-level mechanisms during the nucleation and growth stages of coalescence, the correlation between the different dynamic factors in the different stages of NP coalescence is unclear. In this study, we used advanced in situ characterization techniques to observe the formation of atomic material transport channels (Au chains) during the initiation of coalescence nucleation. We focused on the movement and migration states of Au atoms and discovered an atomic ordered arrangement growth mechanism that occurs after the completion of nucleation. Simultaneously, we used density functional theory to reveal the formation principle of Au chains. These findings improve our understanding of the atomic-scale coalescence process, which can provide a new perspective for further research on coalescence atomic dynamics.

Atomic-Scale Structure Dynamics of Nanocrystals Revealed By In Situ and Environmental Transmission Electron Microscopy

Nanocrystals are of great importance in material sciences and industry. Engineering nanocrystals with desired structures and properties is no doubt one of the most important challenges in the field, which requires deep insight into atomic-scale dynamics of nanocrystals during the process. The rapid developments of in situ transmission electron microscopy (TEM), especially environmental TEM, reveal insights into nanocrystals to digest. According to the considerable progress based on in situ electron microscopy, a comprehensive review on nanocrystal dynamics from three aspects: nucleation and growth, structure evolution, and dynamics in reaction conditions are given. In the nucleation and growth part, existing nucleation theories and growth pathways are organized based on liquid and gas-solid phases. In the structure evolution part, the focus is on in-depth mechanistic understanding of the evolution, including defects, phase, and disorder/order transitions. In the part of dynamics in reaction conditions, solid-solid and gas-solid interfaces of nanocrystals in atmosphere are discussed and the structure-property relationship is correlated. Even though impressive progress is made, additional efforts are required to develop the integrated and operando TEM methodologies for unveiling nanocrystal dynamics with high spatial, energy, and temporal resolutions.

Metal Sites in Zeolites: Synthesis, Characterization, and Catalysis

Zeolites with ordered microporous systems, distinct framework topologies, good spatial nanoconfinement effects, and superior (hydro)thermal stability are an ideal scaffold for planting diverse active metal species, including single sites, clusters, and nanoparticles in the framework and framework-associated sites and extra-framework positions, thus affording the metal-in-zeolite catalysts outstanding activity, unique shape selectivity, and enhanced stability and recyclability in the processes of Brønsted acid-, Lewis acid-, and extra-framework metal-catalyzed reactions. Especially, thanks to the advances in zeolite synthesis and characterization techniques in recent years, zeolite-confined extra-framework metal catalysts (denoted as metal@zeolite composites) have experienced rapid development in heterogeneous catalysis, owing to the combination of the merits of both active metal sites and zeolite intrinsic properties. In this review, we will present the recent developments of synthesis strategies for incorporating and tailoring of active metal sites in zeolites and advanced characterization techniques for identification of the location, distribution, and coordination environment of metal species in zeolites. Furthermore, the catalytic applications of metal-in-zeolite catalysts are demonstrated, with an emphasis on the metal@zeolite composites in hydrogenation, dehydrogenation, and oxidation reactions. Finally, we point out the current challenges and future perspectives on precise synthesis, atomic level identification, and practical application of the metal-in-zeolite catalyst system.

Surface deposition of 2D covalent organic frameworks for minimizing nanocatalyst sintering during hydrogenation

A strategy of in situ depositing 2D COFs on heterogeneous catalysts was reported for the first time to suppress the agglomeration and sintering of the supported metal nanoparticles during hydrogenation processes. The COF-decorated nanocatalysts exhibited excellent stability in various hydrogenation reactions including the reduction of dimethyl oxalate (DMO), furfural, and other chemicals.

Effect of Hydroxyl Groups on Metal Anchoring and Formaldehyde Oxidation Performance of Pt/Al2O3

Pt/Al₂O₃ catalysts showing excellent activity and stability have been used in various reactions, including HCHO oxidation. Herein, we prepared Pt-Na/Al₂O₃ catalysts with a Pt content of 0.05 wt % to reveal the key factors determining the anchoring of Pt as well as the catalytic activity and mechanism of HCHO oxidation. Pt-Na/nano-Al₂O₃ (denoted as Pt-Na/nAl₂O₃) catalysts with 0.05 wt % Pt content could completely oxidize HCHO to CO₂ at room temperature, which is the lowest Pt content used in HCHO catalytic oxidation to our knowledge. After Na addition, terminal hydroxyl groups (denoted as HO-μ_ter) on nano-Al₂O₃ were transformed to doubly bridging hydroxyl groups between Na and Al (denoted as HO-μ_bri(Na-Al)), which atomically dispersed Pt species. Pt anchoring further promoted the regeneration of HO-μ_bri(Na-Al) by activating O₂ and H₂O, oxidizing HCHO to CO₂ directly by the fast reaction step ([HCOO^-] + [OH]_a → CO₂ + H₂O). Our study revealed that the HO-μ_bri(Na-Al) synergistically generated by HO-μ_ter and Na species provided anchoring sites for Pt species.

Understanding and application of metal-support interactions in catalysts for CO-PROX

Preferential oxidation of carbon monoxide (CO-PROX) plays a vital role in H₂ purification in the upstream systems of proton exchange membrane fuel cells (PEMFCs) for its high efficiency, low cost and practicability. The key to the application of CO-PROX is the design and preparation of catalysts, and the supported metal catalysts have been the mainstay after decades of development. The metal-support interaction (MSI), which acts as a bridge between the design of supported catalysts and atomic-level theoretical research, has triggered increasing attention. There is a growing body of literature that recognizes the importance of the MSI in heterogeneous catalysis. In this review, the impacts of the MSI including strong metal-support interactions and electronic metal-support interactions on the essential characteristics of supported single atom, nanocluster and nanoparticle catalysts, and therefore, on catalytic behaviors were discussed, respectively, primarily focusing on electron transfer, chemical bonding and the encapsulation of active sites induced by the MSI. We also presented an overview of how the MSI can be utilized to rationally design catalysts to meet target requirements such as high activity, selectivity or stability via appropriate selection and modification of support and active species. The perspectives of the future development for comprehensive understanding of the MSI were also proposed.

Strong Metal-Support Interactions of Ni-CeO2 Effectively Improve the Performance of a Molten Hydroxide Direct Carbon Fuel Cell

A strong metal-support interaction (SMSI) type catalyst has been synthesized and applied to a molten hydroxide direct carbon fuel cell (MHDCFC) to enhance the reaction activity of the anode carbon fuel through the interaction between the metal Ni and the support CeO₂. Two catalysts have been prepared by a direct precipitation method (denoted NiO@CeO₂) and a hydrothermal method (denoted NiO-CeO₂), which are reduced by H₂ to obtain Ni@CeO₂ and Ni-CeO₂, respectively. X-ray photoelectron spectroscopy (XPS), Raman, and temperature-programmed hydrogen reduction (H₂-TPR) analysis results show that there are obvious oxygen vacancies and a Ni-O-Ce interface structure in NiO-CeO₂ and Ni-CeO₂, which is induced by the interaction between Ni and CeO₂. The calculation results of current density and power density show that the performance of the MHDCFC is significantly improved in the presence of Ni-CeO₂. The function fitting curves of the logarithm of the reaction rate constant (ln k) and the reciprocal of the temperature (1/T) show that the slope of the curve is decreased significantly after the addition of Ni-CeO₂. In combination with density functional theory (DFT), the anode carbon reaction path is simulated in the MHDCFC, and the calculation results show that the reaction energy for the anodic carbon to generate carbon dioxide is decreased by 1.03 eV in the presence of Ni-CeO₂.

The preparation of ultrastable Al3+ doped CeO2 supported Au catalysts: Strong metal-support interaction for superior catalytic activity towards CO oxidation

The classical strong metal-support interaction (SMSI) plays a key role in improving thermal stability for supported Au catalysts. However, it always decreases the catalytic activity because of the encapsulation of Au species by support. Herein, we demonstrate that Al³⁺ is a functional additive which could effectively improve both catalytic activity and sintering resistant property for H₂ pretreated Al³⁺ doped CeO₂ supported Au (AuCeAl) catalyst at high temperature. The physical characterization and in-situ DRIFTS results provide insight that more oxygen vacancies generated by Al³⁺ doping could be as preferential adsorption sites for CO molecules when the encapsulation of Au species occurred, which is certificated by an accelerated formation of bicarbonate species. In the meantime, smaller Au nanoparticles with higher dispersion (2.8 nm, 85.63%) is achieved in AuCeAl catalysts, compared with that in CeO₂ supported Au (AuCe) catalysts (5.1 nm, 36.17%). Additionally, the as-prepared AuCeAl catalysts also have superior catalytic performance even after calcination at 800 °C in air.

Atomic Insight into the Local Structure and Microenvironment of Isolated Co-Motifs in MFI Zeolite Frameworks for Propane Dehydrogenation

Embedding metal species into zeolite frameworks can create framework-bond metal sites in a confined microenvironment. The metals sitting in the specific T sites of zeolites and their crystalline surroundings are both committed to the interaction with the reactant, participation in the activation, and transient state achievement during the whole catalytic process. Herein, we construct isolated Co-motifs into purely siliceous MFI zeolite frameworks (Co-MFI) and reveal the location and microenvironment of the isolated Co active center in the MFI zeolite framework particularly beneficial for propane dehydrogenation (PDH). The isolated Co-motif with the distorted tetrahedral structure ({(≡SiO)₂Co(HO-Si≡)₂}, two Co-O-Si bonds, and two pseudobridging hydroxyls (Co···OH-Si) is located at T₁₍₇₎ and T₃₍₉₎ sites of the MFI zeolite. DFT calculations and deuterium-labeling reactions verify that the isolated Co-motif together with the MFI microenvironment collectively promotes the PDH reaction by providing an exclusive microenvironment to preactivate C₃H₈, polarizing the oxygen in Co-O-Si bonds to accept H* ({(≡SiO)CoH^δ- (H^δ+O-Si≡)₃}), and a scaffold structure to stabilize the C₃H₇* intermediate. The Co-motif active center in Co-MFI goes through the dynamic evolutions and restoration in electronic states and coordination states in a continuous and repetitive way, which meets the requirements from the series of elementary steps in the PDH catalytic cycle and fulfills the successful catalysis like enzyme catalysis.

Solid-State Reaction Synthesis of Nanoscale Materials: Strategies and Applications

Nanomaterials (NMs) with unique structures and compositions can give rise to exotic physicochemical properties and applications. Despite the advancement in solution-based methods, scalable access to a wide range of crystal phases and intricate compositions is still challenging. Solid-state reaction (SSR) syntheses have high potential owing to their flexibility toward multielemental phases under feasibly high temperatures and solvent-free conditions as well as their scalability and simplicity. Controlling the nanoscale features through SSRs demands a strategic nanospace-confinement approach due to the risk of heat-induced reshaping and sintering. Here, we describe advanced SSR strategies for NM synthesis, focusing on mechanistic insights, novel nanoscale phenomena, and underlying principles using a series of examples under different categories. After introducing the history of classical SSRs, key theories, and definitions central to the topic, we categorize various modern SSR strategies based on the surrounding solid-state media used for nanostructure growth, conversion, and migration under nanospace or dimensional confinement. This comprehensive review will advance the quest for new materials design, synthesis, and applications.

Support Morphology Effect on Selective Hydrogenation of 3-Nitrostyrene to 3-Vinylaniline over Pt/α-Fe2 O3 Catalysts

Selective hydrogenation of substituted nitroaromatic compounds is an extremely important and challenging reaction. Supported metal catalysts attract much attention in this reaction because the properties of metal nanoparticles (NPs) can be modified by the nature of the support. Herein, the support morphology on the catalytic performance of selective hydrogenation of 3-nitrostyrene to 3-vinylaniline was investigated. Pt NPs supported on octadecahedral α-Fe₂ O₃ supports with a truncated hexagonal bipyramid shape (Pt/α-Fe₂ O₃ -O) and rod-shaped α-Fe₂ O₃ supports (Pt/α-Fe₂ O₃ -R) were prepared by glycol reduction method. Detailed characterizations reveal that the electronic structure and dispersion of Pt NPs can be modified by the supports. The Pt/α-Fe₂ O₃ -O catalyst exhibited superior catalytic performance for hydrogenation of 3-nitrostyrene because of its low coordinated Pt sites and the small Pt NPs size, which is benefit from the high-index exposed surfaces of truncated hexagonal bipyramid-shaped α-Fe₂ O₃ support. The structural evolution during the catalytic reaction was investigated in detail by identical location transmission electron microscopy (IL-TEM) method, which found that the high cycling activity of Pt/α-Fe₂ O₃ -O catalyst during the cycle experiment results from the stability of Pt NPs.

The Effect of a Hydrogen Reduction Procedure on the Microbial Synthesis of a Nano-Pd Electrocatalyst for an Oxygen-Reduction Reaction

Noble-metal electrocatalysts supported by biological-organism-derived carbons have attracted attention from the public due to the growing demands for green synthesis and environmental protection. Carbonization at high temperatures and hydrogen reduction are critical steps in this technical route. Herein, Shewanella oneidensis MR-1 were used as precursors, and the effects of the hydrogen-reduction procedure on catalysts were explored. The results showed that the performances of FHTG (carbonization followed by hydrogen reduction) displayed the best performance. Its ECSA (electrochemical surface area), MA (mass activity), and SA (specific activity) reached 35.01 m2 g−1, 58.39 A·g−1, and 1.66 A cm−2, respectively, which were 1.17, 1.75, and 1.50 times that of PHTG (prepared through hydrogen reduction followed by carbonization) and 1.56, 2.26, and 1.44 times that of DHTG (double hydrogen reduction). The high performance could be attributed to its fine particle size and rich N content, and the specific regulation mechanism was also proposed in this paper. This study opens a practical guide for effectively avoiding particle agglomeration during the fabrication process for catalysts.

Bimetallic Co-Mo sulfide/carbon composites derived from polyoxometalate encapsulated polydopamine-decorated ZIF nanocubes for efficient hydrogen and oxygen evolution

The increased call for carbon neutrality by 2050 makes it compelling to develop emission-free alternative energy sources. Green hydrogen produced from water electrolyzers using renewable electricity is of great importance, and the development of efficient transition-metal-based materials for hydrogen production by electrolysis is highly desirable. In this report, a new approach to produce defect-rich and ultra-fine bimetallic Co-Mo sulfides/carbon composites from polyoxometalates@ZIF-67@polydopamine nanocubes via carbonization/sulfurization, which are highly active for hydrogen and oxygen evolution reactions (HER and OER), have been successfully developed. The coating of polydopamine (PDA) on the surface of the acid-sensitive ZIF-67 cubes can prevent the over-dissociation of ZIF-67 caused by the encapsulated phosphomolybdic acid (PMA) etching through PDA chelating with the PMA molecules. Meanwhile, the partially dissociated Co²⁺ from ZIF-67 can be captured by the coated PDA via chelation, resulting in more evenly dispersed active sites throughout the heterogeneous composite after pyrolysis. The optimized bimetallic composite CoMoS-600 exhibits a prominent improvement in HER (with an overpotential of -0.235 V vs. RHE at a current density of 10 mA cm^-2) and OER performance (with an overpotential of 0.350 V vs. RHE at a current density of 10 mA cm^-2), due to the synergistic effect of ultra-fine defect-rich Co-Mo-S nanoparticle active sites and N,S-codoped porous carbons in the composites. Moreover, this synthesis approach can be readily expanded to other acidic polyoxometalates to produce HER and OER active bimetallic Co-W sulfide/carbon composites by replacing PMA with phosphotungstic acid. This new synthesis strategy to modify acid-sensitive ZIFs with selected compounds offers an alternative approach to develop novel transition metal sulfide/carbon composites for various applications.

In Situ Transformation of ZIF-8 into Porous Overlayer on Ru/ZnO for Enhanced Hydrogenation Catalysis

Supported metal catalysts play a significant role in heterogeneous catalysis in liquid phase reaction systems, but they usually suffer from a stability problem. Encapsulation of active metal species without the compromise of catalytic performance has been considered as an effective strategy. Here, we report an ultrastable Ru-based catalyst with particle size of around 1.1 nm for selective hydrogenation reaction. The highly dispersed Ru species are covered by the in situ formed porous N-C-ZnO overlayer, which is induced through the transforming of ZIF-8 shell that derives from a ZnO substrate. The resulting Ru/ZnO@N-C-ZnO catalyst can exhibit good stability in the hydrogenation of p-chloronitrobenzene after 20 cyclic runs with 100% selectivity toward p-chloroaniline. Comparatively, the naked Ru/ZnO catalyst with larger Ru particles shows serious metal leaching issue with inferior stability and poor selectivity. It is revealed that the excellent performance of Ru/ZnO@N-C-ZnO is attributed to the porous overlayer, which strengthens the bonding of Ru nanoparticles on ZnO.

Stable Cu Catalysts Supported by Two-dimensional SiO2 with Strong Metal-Support Interaction

Cu-based catalysts exhibit excellent performance in hydrogenation reactions. However, the poor stability of Cu catalysts under high temperatures has restricted their practical applications. The preparation of stable Cu catalysts supported by SiO₂ with strong metal-support interaction (SMSI) has thus aroused great interest due to the high abundance, low toxicity, feasible processability, and low cost of SiO₂ . The challenge in the construction of such SMSI remains to be the inertness of SiO₂ . Herein, a simple and scalable method is developed to prepare 2D silica (2DSiO₂ ) supported Cu catalysts with SMSI by carefully manipulating the topological exfoliation of CaSi₂ with CuCl₂ and thereafter calcination. The prepared Cu-2DSiO₂ catalysts with the unique encapsulated Cu nanoparticles exhibit excellent activity and long-term stability in high-temperature CO₂ hydrogenation reactions. This feasible and low-cost solution for stabilizing Cu catalysts might shed light on their realistic applications.