Trapping mobile Pt species by PdO in diesel oxidation catalysts: Smaller is better

Palladium Catalysts for Methane Oxidation: Old Materials, New Challenges

ConspectusMethane complete oxidation is an important reaction that is part of the general scheme used for removing pollutants contained in emissions from internal combustion engines and, more generally, combustion processes. It has also recently attracted interest as an option for the removal of atmospheric methane in the context of negative emission technologies. Methane, a powerful greenhouse gas, can be converted to carbon dioxide and water via its complete oxidation. Despite burning methane being facile because the combustion sustains its complete oxidation after ignition, methane strong C-H bonds require a catalyst to perform the oxidation at low temperatures and in the absence of a flame so as to avoid the formation of nitrogen oxides, such as those produced in flares. This process allows methane removal to be obtained under conditions that usually lead to higher emissions, such as under cold start conditions in the case of internal combustion engines. Among several options that include homo- and heterogeneous catalysts, supported palladium-based catalysts are the most active heterogeneous systems for this reaction. Finely divided palladium can activate C-H bonds at temperatures as low as 150 °C, although complete conversion is usually not reached until 400-500 °C in practical applications. Major goals are to achieve catalytic methane oxidation at as low as possible temperature and to utilize this expensive metal more efficiently.Compared to any other transition metal, palladium and its oxides are orders of magnitude more reactive for methane oxidation in the absence of water. During the last few decades, much research has been devoted to unveiling the origin of the high activity of supported palladium catalysts, their active phase, the effect of support, promoters, and defects, and the effect of reaction conditions with the goal of further improving their reactivity. There is an overall agreement in trends, yet there are noticeable differences in some details of the catalytic performance of palladium, including the active phase under reaction conditions and the reasons for catalyst deactivation and poisoning. In this Account we summarize our work in this space using well-defined catalysts, especially model palladium surfaces and those prepared using colloidal nanocrystals as precursors, and spectroscopic tools to unveil important details about the chemistry of supported palladium catalysts. We describe advanced techniques aimed at elucidating the role of several parameters in the performance of palladium catalysts for methane oxidation as well as in engineering catalysts through advancing fundamental understanding and synthesis methods. We report the state of research on active phases and sites, then move to the role of supports and promoters, and finally discuss stability in catalytic performance and the role of water in the palladium active phase. Overall, we want to emphasize the importance of a fundamental understanding in designing and realizing active and stable palladium-based catalysts for methane oxidation as an example for a variety of energy and environmental applications of nanomaterials in catalysis.

Recent Advances in Structured Catalytic Materials Development for Conversion of Liquid Hydrocarbons into Synthesis Gas for Fuel Cell Power Generators

The paper considers the current state of research and development of composite structured catalysts for the oxidative conversion of liquid hydrocarbons into synthesis gas for fuel cell feeding and gives more detailed information about recent advances in the Boreskov Institute of Catalysis. The main factors affecting the progress of the target reaction and side reactions leading to catalyst deactivation are discussed. The properties of the Rh/Ce_0.75Zr_0.25O₂/Al₂O₃/FeCrAl composite multifunctional catalyst for the conversion of diesel fuel into synthesis gas are described. The results of the catalyst testing and mathematical modeling of the process of diesel fuel steam-air conversion into synthesis gas are reported.

Thermally-stable single-atom catalysts and beyond: A perspective

Single-atom catalysis is a research Frontier and has attracted extensive interests in catalysis. Significant progresses have been carried out in the synthesis and characterization of metal single-atom catalysts (SACs). However, the stability and catalytic reactivity of metal SAC at elevated temperatures are not well documented because single atoms sinter at elevated temperatures. Therefore, the development of stable and reactive SAC at high temperatures remains a formidable challenge. In this perspective, we summarize recent efforts on the preparation of the thermally-stable SACs synthesized at elevated temperature via the reverse-Ostwald ripening mechanism, including the approaches of atom trapping and vapor-phase self-assembly. The reducibility of lattice oxygen, the loading upper limit and the location of the metal single atom are discussed, combining experiments with simulations. In addition, we demonstrate that the coordination structure of the metal single atom can be tailored to address the relationship of structure and performances of the metal SAC in reactions. We expect that this perspective can provide some insights to guide the study for the rational design of thermally-stable and active single atom catalysts, which are especially suitable for high-temperature reactions.

Increasing the Size-Selectivity in Laser-Based g/h Liquid Flow Synthesis of Pt and PtPd Nanoparticles for CO and NO Oxidation in Industrial Automotive Exhaust Gas Treatment Benchmarking

PtPd catalysts are state-of-the-art for automotive diesel exhaust gas treatment. Although wet-chemical preparation of PtPd nanoparticles below 3 nm and kg-scale synthesis of supported PtPd/Al₂O₃ are already established, the partial segregation of the bimetallic nanoparticles remains an issue that adversely affects catalytic performance. As a promising alternative, laser-based catalyst preparation allows the continuous synthesis of surfactant-free, solid-solution alloy nanoparticles at the g/h-scale. However, the required productivity of the catalytically relevant size fraction <10 nm has yet to be met. In this work, by optimization of ablation and fragmentation conditions, the continuous flow synthesis of nanoparticles with a productivity of the catalytically relevant size fraction <10 nm of >1 g/h is presented via an in-process size tuning strategy. After the laser-based preparation of hectoliters of colloid and more than 2 kg of PtPd/Al₂O₃ wash coat, the laser-generated catalysts were benchmarked against an industry-relevant reference catalyst. The conversion of CO by laser-generated catalysts was found to be equivalent to the reference, while improved activity during NO oxidation was achieved. Finally, the present study validates that laser-generated catalysts meet the size and productivity requirements for industrial standard operating procedures. Hence, laser-based catalyst synthesis appears to be a promising alternative to chemical-based preparation of alloy nanoparticles for developing industrial catalysts, such as those needed in the treatment of exhaust gases.

Spatially Separated Bifunctional Cocatalysts Decorated on Hollow-Structured TiO2 for Enhanced Photocatalytic Hydrogen Generation

Efficient charge separation can promote photocatalysis of semiconductors. Herein, a hollow-structured TiO₂ sphere decorated with spatially separated bifunctional cocatalysts was designed, which exhibited enhanced photocatalytic hydrogen generation. Ultrasmall-sized MO_x (M = Pd, Co, Ni, or Cu) nanoparticles (NPs) were first introduced into a zeolite via confinement synthesis, and then, hollow TiO₂ was fabricated by using the zeolite as a sacrificial template forming MO_x@TiO₂. Finally, Pt NPs were decorated on the outer shell, giving rise to MO_x@TiO₂@Pt, in which the MO_x NPs and Pt NPs acted as hole capturers and electron sinks, respectively. Thanks to the enhanced light harvesting of the hollow structure and improved charge separation induced by the smaller-sized cocatalysts as well as spatially separated bifunctional cocatalysts, the as-prepared PdO_x@TiO₂@Pt catalyst exhibited a superior photocatalytic hydrogen-generation property (0.45 mmol h^-1). This work demonstrates the advantage of the spatially separated bifunctional cocatalysts in enhancing the photocatalytic properties of semiconductors.

Ion-imprinted chitosan fiber for recovery of Pd(II): Obtaining high selectivity through selective adsorption and two-step desorption

Selective separation of platinum group metals from acidic solutions is of great importance due to their cumulative supply risk and environmental concern. In this study, a Pd(II) ion-imprinted chitosan fiber (ICF) was prepared as the novel adsorbent, and a well-designed two-step desorption process was implemented for selectively recovering Pd(II) from acidic solution containing Pd(II) and interfering metals of Co(II), Ni(II), Cu(II) and Pt (IV). The ICF showed higher selectivity for Pd(II) adsorption, comparing the non-imprinted chitosan fiber (NICF) towards other metals adsorption. The first selective desorption was achieved by NaOH solution, since only Pt (IV) adsorbed on the ICF in a small amount could be eluted, without any acting on Pd(II) ions. The second desorption process was carried out using acidified thiourea solution for the exclusive Pd(II) ions desorption. Therefore, much higher selective recovery of Pd(II) was achieved through ICF with a good selective adsorption performance and a well-designed desorption process. Furthermore, the mechanisms of selective adsorption and desorption were investigated by X-ray photoelectron spectra (XPS) and X-ray diffraction (XRD) analyses. Finally, ICF-packed column system was conducted using synthetic multiple metals solution and a practical hydrometallurgy wastewater as influent, respectively, with a good adsorption capacity of 87.2 mg g^-1 and 94.2 mg g^-1, resulting quite high concentrated effluent consisted of 97.4% of Pd(II) and 99.5% of Pd(II), respectively. It was opened up a promising designed material and technique for selectively recovering Pd(II) in the further practical large-scale application.

Palladium oxidation leads to methane combustion activity: Effects of particle size and alloying with platinum

Pd- and Pt-based catalysts are highly studied materials due to their widespread use in emissions control catalysis. However, claims continue to vary regarding the active phase and oxidation state of the metals. Different conclusions have likely been reached due to the heterogeneous nature of such materials containing various metal nanoparticle sizes and compositions, which may each possess unique redox features. In this work, using uniform nanocrystal catalysts, we study the effect of particle size and alloying on redox properties of Pd-based catalysts and show their contribution to methane combustion activity using operando quick extended x-ray absorption fine structure measurements. Results demonstrate that for all studied Pd sizes (3 nm-16 nm), Pd oxidation directly precedes CH₄ combustion to CO₂, suggesting Pd oxidation as a prerequisite step to methane combustion, and an oxidation pretreatment shows equal or better catalysis than a reduction pretreatment. Results are then extended to uniform alloyed Pt_xPd_1-x nanoparticles, where oxidative pretreatments are shown to enhance low-temperature combustion. In these uniform alloys, we observe a composition-dependent effect with Pt-rich alloys showing the maximum difference between oxidative and reductive pretreatments. In Pt-rich alloys, we initially observe that the presence of Pt maintains Pd in a lower-activity reduced state. However, with time on stream, PdO eventually segregates under oxidizing combustion conditions, leading to a slowly increasing activity. Overall, across particle sizes and alloy compositions, we relate increased catalytic activity to Pd oxidation, thus shedding light on previous contrasting results related to the methane combustion activity of these catalysts.

Supercritical flow synthesis of PtPdFe alloyed nanoparticles with enhanced low-temperature activity and thermal stability for propene oxidation under lean exhaust gas conditions

Supercritical flow technology was used for the one step production of PtPd and PtPdFe nanoparticles supported on high surface area γ-Al₂O₃.

Key role of surface oxidation and reduction processes in the coarsening of Pt nanoparticles

Particle coarsening is the main cause for thermal deactivation and lifetime reduction of supported Pt nanocatalysts. Here, Atomic Layer Deposition (ALD) was used to prepare a model system of Pt nanoparticles with high control over the metal loading and the nanoparticle size and coverage. A series of samples with distinct as-deposited size and interparticle spacing was annealed under different oxygen environments while Grazing Incidence Small Angle X-ray Scattering (GISAXS) was employed as in situ tool for monitoring the change in average nanoparticle size. The obtained results revealed three morphological stages during the thermal treatment, which can be explained by (I) the formation of a PtO₂ shell on stable Pt nanoparticles at low temperature (below 300 °C), (II) the reduction of the PtO₂ shell at moderate temperature (300 to 600 °C), creating mobile species that trigger particle coarsening until a steady morphological state is reached, and (III) the evaporation of PtO₂ at high temperature (above 650 °C), causing particle instability and coarsening reactivation. The onset temperatures for stages (II) and (III) were found to depend on the initial particle size and spacing as well as on the O₂ partial pressure during annealing, and could be summarized in a morphological stability diagram for Pt nanoparticles. The coarsening model indicates an important role for the reduction of the PtO₂ shell in inducing particle coarsening. The key role of the reduction process was corroborated through isothermal experiments under decreasing O₂ partial pressure and through forced reduction experiments near room temperature via H₂ exposure.

Nanofence Stabilized Platinum Nanoparticles Catalyst via Facet-Selective Atomic Layer Deposition

A facet-selective atomic layer deposition method is developed to fabricate oxide nanofence structure to stabilize Pt nanoparticles. CeO_x is selectively deposited on Pt nanoparticles' (111) facets and naturally exposes Pt (100) facets. The facet selectivity is realized through different binding energies of Ce precursor fragments chemisorbed on Pt (111) and Pt (100), which is supported by in situ mass gain experiment and corroborated by density functional theory simulations. Such nanofence structure not only has exposed Pt active facets for carbon monoxide oxidation but also forms ceria-metal interfaces that are beneficial for activity enhancement. The composite catalysts show excellent sintering resistance up to 700 °C calcination. CeO_x anchors Pt nanoparticles with a strong metal oxide interaction, and nanofence structure around Pt nanoparticles provides physical blocking that suppresses particles migration. The study reveals that forming oxide nanofence structure to encapsulate precious metal nanoparticles is an effective way to simultaneously enhance catalytic activity and thermal stability.

Thermally Stable and Regenerable Platinum-Tin Clusters for Propane Dehydrogenation Prepared by Atom Trapping on Ceria

Ceria (CeO₂) supports are unique in their ability to trap ionic platinum (Pt), providing exceptional stability for isolated single atoms of Pt. The reactivity and stability of single‐atom Pt species was explored for the industrially important light alkane dehydrogenation reaction. The single‐atom Pt/CeO₂ catalysts are stable during propane dehydrogenation, but are not selective for propylene. DFT calculations show strong adsorption of the olefin produced, leading to further unwanted reactions. In contrast, when tin (Sn) is added to CeO₂, the single‐atom Pt catalyst undergoes an activation phase where it transforms into Pt–Sn clusters under reaction conditions. Formation of small Pt–Sn clusters allows the catalyst to achieve high selectivity towards propylene because of facile desorption of the product. The CeO₂‐supported Pt–Sn clusters are very stable, even during extended reaction at 680 °C. Coke formation is almost completely suppressed by adding water vapor to the feed. Furthermore, upon oxidation the Pt–Sn clusters readily revert to the atomically dispersed species on CeO₂, making Pt–Sn/CeO₂ a fully regenerable catalyst.

Challenges and breakthroughs in post-combustion catalysis: how to match future stringent regulations

This short overview briefly summarizes the prominent evolutions and scientific breakthroughs in the development of end-of-pipe technologies with respect to the standard regulations of atmospheric pollutant emissions from automotive exhaust.