Economizing on Precious Metals in Three-Way Catalysts: Thermally Stable and Highly Active Single-Atom Rhodium on Ceria for NO Abatement under Dry and Industrially Relevant Conditions*

Single-zinc vacancy unlocks high-rate H2O2 electrosynthesis from mixed dioxygen beyond Le Chatelier principle

Le Chatelier's principle is a basic rule in textbook defining the correlations of reaction activities and specific system parameters (like concentrations), serving as the guideline for regulating chemical/catalytic systems. Here we report a model system breaking this constraint in O2 electroreduction in mixed dioxygen. We unravel the central role of creating single-zinc vacancies in a crystal structure that leads to enzyme-like binding of the catalyst with enhanced selectivity to O2, shifting the reaction pathway from Langmuir-Hinshelwood to an upgraded triple-phase Eley-Rideal mechanism. The model system shows minute activity alteration of H2O2 yields (25.89~24.99 mol gcat-1 h-1) and Faradaic efficiencies (92.5%~89.3%) in the O2 levels of 100%~21% at the current density of 50~300 mA cm-2, which apparently violate macroscopic Le Chatelier's reaction kinetics. A standalone prototype device is built for high-rate H2O2 production from atmospheric air, achieving the highest Faradaic efficiencies of 87.8% at 320 mA cm-2, overtaking the state-of-the-art catalysts and approaching the theoretical limit for direct air electrolysis (~345.8 mA cm-2). Further techno-economics analyses display the use of atmospheric air feedstock affording 21.7% better economics as comparison to high-purity O2, achieving the lowest H2O2 capital cost of 0.3 $ Kg-1. Given the recent surge of demonstrations on tailoring chemical/catalytic systems based on the Le Chatelier's principle, the present finding would have general implications, allowing for leveraging systems "beyond" this classical rule.

Independent Multiple-Atom-Site Functionality in Composition Adjustable Immiscible Ru-Rh-Pd-Pt Solid-Solution High-Entropy Alloys for NOx Reduction Outperforming Rh

The high-entropy-alloy (HEA) nanoparticles with four, five or more metals significantly can yield the developments of functional materials with excellent performances in various reactions. However, the underlying reaction mechanisms of heterogeneous catalysis for HEA have been rarely investigated, due to their diverse elements and complex compositions. In this study, we successfully synthesized the homogeneously dispersed Ru-Rh-Pd-Pt HEA with adjustable compositions, as the multiple-atom-site catalysts (MASC). In the NOx reduction performance tests, Ru0.4 (Rh0.33Pd0.33Pt0.33)0.6 MASC showed the highest activity, which was significantly improved compared to that of the best monometal Rh, with the light-off temperature decreasing by ca. 50 °C. The Fourier transform infrared measurements revealed that the outstanding activity of Ru-Rh-Pd-Pt MASC was attributable to the well-coupled elementary steps of the CO adsorption, NO adsorption, NO dissociation and O spillover on the Ru, Rh, Rh-Pd and Pt sites, respectively, which explained the first clear reaction mechanism in heterogeneous catalysis for HEA.

Hydrogenation of cyclohexene over single-atom Pt or Pd incorporated porous ceria nanoparticles under solvent-free conditions

In order to maximize the utilization of noble metals in catalysis, single atom of palladium (Pd) and platinum (Pt) were incorporated individually in the framework of porous ceria (CeO2) by using a one-step flash combustion method. Samples with different Pd and Pt loading (0.5, 1, 2.5, and 5 wt%) were prepared and examined by using different analysis techniques such as XRD, ICP, N2 sorption measurements, SEM, HR-TEM, and XPS. The characterization data confirms the formation of zero-state single-atom Pt and Pd (with possible formation of Pd nanoparticles with a size less than 5 nm) incorporated onto the three-dimensional porous ceria structure. The catalytic activity of the synthesized materials was studied in the cyclohexene reduction to cyclohexane at 393 K and 3 atm of pure hydrogen (H2) gas as a model reaction. The obtained results demonstrated that the conversion percentage of cyclohexene is increasing with Pd or Pt loading. The best cyclohexene conversion, 21% and 29%, was achieved over the sample that contains 5 wt% of Pt and Pd, respectively. The collected catalytic data fit the zero-order reaction model, and the rate constant of each catalyst was determined. The catalytic experiments of the most-performed catalysts were repeated five times and the obtained loss in activity was insignificant.

A Bifunctional Pt/CeO2-Cu1/CeO2 Catalyst System for Isooctane Oxidation under Fully Simulated Engine-Exhaust Condition: Eliminating the Inhibition by CO

Pt-based catalysts, because of their outstanding activity for hydrocarbon oxidation, are widely used in the engine-exhaust aftertreatment system to remove hydrocarbon emissions. However, the CO and NOx present in real engine exhausts compete with hydrocarbons for active Pt sites, and thus inhibit hydrocarbon oxidation. In this work, we evaluated the inhibition effects of CO and NO on isooctane oxidation over a Pt/CeO2 catalyst under the simulated condition of the US DRIVE test protocol (S-GDI, stoichiometric gasoline direct injection). We also leveraged a low-cost single-atom Cu1/CeO2 catalyst, which is highly active for low-temperature CO oxidation, to eliminate the inhibition effect of CO. Specifically, by physically mixing Cu1/CeO2 and Pt/CeO2, all the CO is completely converted below 200 °C under simulated exhaust condition, which helps lower the isooctane oxidation temperature. However, the unconverted NO still strongly suppresses HC oxidation. Possible strategies to address the NO inhibitor were proposed.

Isolating Contiguous Ir Atoms and Forming Ir-W Intermetallics with Negatively Charged Ir for Efficient NO Reduction by CO

The lack of efficient catalysts with a wide working temperature window and vital O₂ and SO₂ resistance for selective catalytic reduction of NO by CO (CO-SCR) largely hinders its implementation. Here, a novel Ir-based catalyst with only 1 wt% Ir loading is reported for efficient CO-SCR. In this catalyst, contiguous Ir atoms are isolated into single atoms, and Ir-W intermetallic nanoparticles are formed, which are supported on ordered mesoporous SiO₂ (KIT-6). Notably, this catalyst enables complete NO conversion to N₂ at 250 °C in the presence of 1% O₂ and has a wide temperature window (250-400 °C), outperforming the comparison samples with Ir isolated-single-atomic-sites and Ir nanoparticles, respectively. Also, it possesses a high SO₂ tolerance. Both experimental results and theoretical calculations reveal that single Ir atoms are negatively charged, dramatically enhancing the NO dissociation, while the Ir-W intermetallic nanoparticles accelerate the reduction of the N₂ O and NO₂ intermediates by CO.

Fabrication of Stable Cu-Ce Catalyst with Active Interfacial Sites for NOx Elimination by Flame Spray Pyrolysis

The complete conversion of NOx to harmless N2 without N2O formation is crucial for the control of air pollution, especially at low temperatures. Cu-based catalysts are promising materials due to their low cost and high activity in NO dissociation, even comparable to noble metals; however, they suffer from low stability. Here, we established a Cu-Ce catalyst in one step with strong metal–support interaction by the flame spray pyrolysis (FSP) method. Almost 100% NO conversion was achieved at 100 °C, and they completely transferred into N2 at a low temperature (200 °C) for the FSP-CuCe catalyst, exhibiting excellent performance in NO reduction by CO reaction. Moreover, the catalytic performance can stay stable, while 23% NO conversion was lost in the same condition for the one made by the co-precipitation (CP) method. This can be attributed to the synergistic effect of abundant active interfacial sites and more flexible surface oxygen created during the FSP process. The flame technology developed here provides an efficient way to fabricate strong metal–support interactions, exhibiting notable potential in the design of stable Cu-based catalysts.

Single atom catalysis poised to transition from an academic curiosity to an industrially relevant technology

During the past decade, initial skepticism rapidly changed into widespread recognition of the role of single atoms in heterogeneous catalysts. The next decade could usher in the era of industrial applications as manufacturing of durable single atom catalysts is perfected.