Nano-array based monolithic catalysts: Concept, rational materials design and tunable catalytic performance

Hierarchically Structured Catalysts Toward Sustainable Hydrogen Economy: Electro- and Thermo-Chemical Pathways

Hydrogen, as an important clean energy source, plays a more and more crucial role in decarbonizing the planet and meeting the global climate challenge due to its high energy density and zero-emission. The demand for sustainable hydrogen is increasing drastically worldwide as driven by the global shift towards low-carbon energy solutions. Thermochemical catalysis process dominates hydrogen production at scale given its relatively mature technology and commercialization status, as well as the established manufacturing infrastructure. While due to its environmentally friendly nature and growing abundant sources of renewable electricity, the electrochemical path for hydrogen production is rising as a major alternative to the thermochemical means. Nevertheless, hierarchically structured catalysts and devices have gradually taken the center stage toward replacing the traditional counterparts, especially with the rapid advancement of the design and manufacture of such ordered nanostructure assemblies toward high activity, efficient mass transport, and superb stability. In this review, the latest progress of the hierarchically structured catalysts for hydrogen production have been surveyed on electro- and thermo- chemical pathways comparatively. It covers the structure designs of atomic dispersion, nanoscale surfaces and interfaces for achieving highly active and durable catalysts, components, and devices. Both electrochemical and thermochemical approaches are reviewed in terms of the vast design details, engineered benefits, and understandings of various Pt-group metal (PGM) and non-PGM based transition metal catalysts for hydrogen production. As the growing trend, brief discussions are also presented toward the high-level assembly and manufacture of complexly structured components and devices at scale in the electrochemical and thermochemical energy systems.

Pd/δ-MnO2 nanoflower arrays cordierite monolithic catalyst toward toluene and o-xylene combustion

Exploring high-efficiency and stable monolithic structured catalysts is vital for catalytic combustion of volatile organic compounds. Herein, we prepared a series of Pd/δ-MnO₂ nanoflower arrays monolithic integrated catalysts (0.01–0.07 wt% theoretical Pd loading) via the hydrothermal growth of δ-MnO₂ nanoflowers onto the honeycomb cordierite, which subsequently served as the carrier for loading the Pd nanoparticles (NPs) through the electroless plating route. Moreover, we characterized the resulting monolithic integrated catalysts in detail and evaluated their catalytic activities for toluene combustion, in comparison to the controlled samples including only Pd NPs loading and the δ-MnO₂ nanoflower arrays. Amongst all the monolithic samples, the Pd/δ-MnO₂ nanoflower arrays monolithic catalyst with 0.05 wt% theoretical Pd loading delivered the best catalytic performance, reaching 90% toluene conversion at 221°C at a gas hourly space velocity (GHSV) of 10,000 h⁻¹. Moreover, this sample displayed superior catalytic activity for o-xylene combustion under a GHSV of 10,000 h⁻¹. The monolithic sample with optimal catalytic activity also displayed excellent catalytic stability after 30 h constant reaction at 210 and 221°C.

Oxygen Vacancies and Lewis Acid Sites Synergistically Promoted Catalytic Methane Combustion over Perovskite Oxides

An in-depth understanding of the surface properties-activity relationship could provide a fundamental guidance for the design of highly efficient perovskite-based catalysts for the control of anthropogenic methane emission. Herein, both oxygen vacancies and Coⁿ⁺ Lewis acid sites were purposely introduced on ordered macroporous La_0.8Sr_0.2CoO₃ monolithic catalysts by one-step reduction and selective etching in oxalic acid, and their synergistic effect on methane combustion was investigated. Combined with experimental and theoretical investigations, we revealed that the positively charged Coⁿ⁺ Lewis acid sites and single-electron-trapped oxygen vacancies (Vo·) formed an active pair, which enabled an effective localized electron cloud shift from Vo· to Coⁿ⁺. The characteristic electronic effect modulates surface electronic properties and coordination structures, thus resulting in superior oxygen activation capacity, lattice oxygen mobility, and reducibility, as well as favorable CH₄ interaction and oxidation. Our work not only gives insights into surface properties-activity relationships on perovskite for hydrocarbon combustion but also sheds substantial light on future environmental catalyst design and modulation for hydrocarbon pollutants elimination.

Intermetallic Cu5Zr Clusters Anchored on Hierarchical Nanoporous Copper as Efficient Catalysts for Hydrogen Evolution Reaction

Designing highly active and robust platinum-free electrocatalysts for hydrogen evolution reaction is vital for large-scale and efficient production of hydrogen through electrochemical water splitting. Here, we report nonprecious intermetallic Cu₅Zr clusters that are in situ anchored on hierarchical nanoporous copper (NP Cu/Cu₅Zr) for efficient hydrogen evolution in alkaline medium. By virtue of hydroxygenated zirconium atoms activating their nearby Cu-Cu bridge sites with appropriate hydrogen-binding energy, the Cu₅Zr clusters have a high electrocatalytic activity toward the hydrogen evolution reaction. Associated with unique architecture featured with steady and bicontinuous nanoporous copper skeleton that facilitates electron transfer and electrolyte accessibility, the self-supported monolithic NP Cu/Cu₅Zr electrodes boost violent hydrogen gas release, realizing ultrahigh current density of 500 mA cm⁻² at a low potential of -280 mV versus reversible hydrogen electrode, with exceptional stability in 1 M KOH solution. The electrochemical properties outperform those of state-of-the-art nonprecious metal electrocatalysts and make them promising candidates as electrodes in water splitting devices.

Fabrication of hierarchical CoP nanosheet@microwire arrays via space-confined phosphidation toward high-efficiency water oxidation electrocatalysis under alkaline conditions

In spite of recent advances in the synthesis of transition metal phosphide nanostructures, the simple fabrication of hierarchical arrays with more accessible active sites still remains a great challenge. In this Communication, we report a space-confined phosphidation strategy toward developing hierarchical CoP nanosheet@microwire arrays on nickel foam (CoP NS@MW/NF) using a Co(H2PO4)2·2H3PO4 microwire array as the precursor. The thermally stable nature of the anion in the precursor is key to hierarchical nanostructure formation. When used as a 3D electrode for water oxidation electrocatalysis, such CoP NS@MW/NF needs an overpotential as low as 296 mV to drive a geometrical catalytic current density of 100 mA cm-2 in 1.0 M KOH, outperforming all reported Co phosphide catalysts in alkaline media. This catalyst also shows superior long-term electrochemical durability, maintaining its activity for at least 65 h. This study offers us a general method for facile preparation of hierarchical arrays for applications.

Electrophoretic deposition of single-source precursors as a general approach for the formation of hybrid nanorod array heterostructures

HYPOTHESIS

Subjecting colloids to electric fields often results in (electrophoretic) deposition on conductive substrates. Dispersing a single-source precursor (SSP) of choice in an appropriate solvent, should allow its deposition on different substrates. The SSP-solvent interaction might play a role in the deposition (e.g., direction, rate, coverage). After thermal decomposition, the SSPs convert to the designed material, thus allowing formation of thin films or hybrid nanostructures.

EXPERIMENTS

Electrophoretic deposition (EPD) was applied on two representative SSPs in different solvents. These SSPs were deposited onto substrates covered with vertically-aligned ZnO nanorod (NR) arrays. After thermal decomposition, hybrid nanostructures were obtained and their morphology and interfaces were characterized by electron microscopy, X-ray diffraction, UV-vis, and electrochemistry.

FINDINGS

Tuning the organic dispersant-SSP interaction allows control over the final film morphology, which can result in coating and filling of NRs with metal-sulfides or metal-oxides after thermal decomposition of the SSP. These findings introduce a new facile method for a fast and large-scale uniform deposition of different (nanostructured) thin film semiconductors on a variety of substrates. We discuss the influence of the dispersant medium on the deposition of metallo-organic SSPs. As an example, the formed ZnO-CdS interface supports charge transfer upon illumination.

CoP nanoarray: a robust non-noble-metal hydrogen-generating catalyst toward effective hydrolysis of ammonia borane

A CoP nanoarray behaves as a robust non-noble-metal recyclable catalyst for effective on-demand hydrogen generation from ammonia borane hydrolysis, with an initial turnover frequency and activation energy of 42.8 mol_H2 mol_CoP⁻¹ min⁻¹ and 34.1 kJ mol⁻¹, respectively.

Fe-Doped CoP Nanoarray: A Monolithic Multifunctional Catalyst for Highly Efficient Hydrogen Generation

An Fe-doped CoP nanoarray behaves as a robust 3D monolithic multifunctional catalyst for electrolytic and hydrolytic hydrogen evolution with high activity. Its two-electrode electrolyzer needs a cell voltage of only 1.60 V for 10 mA cm^-2 water-splitting current. It also catalyzes effectively NaBH₄ hydrolysis with a low activation energy of ≈39.6 kJ mol^-1 and a hydrogen generation rate of 6.06 L min^-1 g^-1 .

Grand challenges for catalysis in the Science and Technology Roadmap on Catalysis for Europe: moving ahead for a sustainable future

This perspective discusses the general concepts that will guide future catalysis and related grand challenges based on the Science and Technology Roadmap on Catalysis for Europe prepared by the European Cluster on Catalysis.

High-performance monoliths in heterogeneous catalysis with single-phase liquid flow

On-line control and monitoring in heterogeneous catalysis utilizing high-performance supports allows rapid screening of intrinsic reaction parameters in continuous-flow mode.

Self-supported spinel FeCo2O4 nanowire array: an efficient non-noble-metal catalyst for the hydrolysis of NaBH4 toward on-demand hydrogen generation

NaBH₄ has been considered as one of the most advantageous candidates for chemical hydrogen storage, but it is still a huge challenge to design efficient non-noble-metal catalysts for on-demand hydrogen generation from NaBH₄ hydrolysis. In this paper, we demonstrate for the first time that a spinel FeCo₂O₄ nanowire array supported on carbon cloth (FeCo₂O₄ NA/CC) behaves as an efficient earth-abundant catalyst toward NaBH₄ hydrolysis in alkaline solutions with an activation energy of 44.98 kJ mol^-1. Such FeCo₂O₄ NA/CC offers a hydrogen generation rate of 2551 ml min^-1 g^-1 under ambient conditions, with good stability and reusability. Its use as an ON/OFF switch for on-demand hydrogen generation is also demonstrated successfully.