Interplay between pore size and nanoparticle spatial distribution: Consequences for the stability of CuZn/SiO2 methanol synthesis catalysts

Deconvoluting the Individual Effects of Nanoparticle Proximity and Size in Thermocatalysis

Nanoparticle (NP) size and proximity are two physical descriptors applicable to practically all NP-supported catalysts. However, with conventional catalyst design, independent variation of these descriptors to investigate their individual effects on thermocatalysis remains challenging. Using a raspberry-colloid-templating approach, we synthesized a well-defined catalyst series comprising Pd12Au88 alloy NPs of three distinct sizes and at two different interparticle distances. We show that NP size and interparticle distance independently control activity and selectivity, respectively, in the hydrogenation of benzaldehyde to benzyl alcohol and toluene. Surface-sensitive spectroscopic analysis indicates that the surfaces of smaller NPs expose a greater fraction of reactive Pd dimers, compared to inactive Pd single atoms, thereby increasing intrinsic catalytic activity. Computational simulations reveal how a larger interparticle distance improves catalytic selectivity by diminishing the local benzyl alcohol concentration profile between NPs, thus suppressing its readsorption and consequently, undesired formation of toluene. Accordingly, benzyl alcohol yield is maximized using catalysts with smaller NPs separated by larger interparticle distances, overcoming activity-selectivity trade-offs. This work exemplifies the high suitability of the modular raspberry-colloid-templating method as a model catalyst platform to isolate individual descriptors and establish clear structure-property relationships, thereby bridging the materials gap between surface science and technical catalysts.

Doubling the life of Cu/ZnO methanol synthesis catalysts via use of Si as a structural promoter to inhibit sintering

Cu/ZnO/Al2O3 catalysts used to synthesize methanol undergo extensive deactivation during use, mainly due to sintering. Here, we report on formulations wherein deactivation has been substantially reduced by the targeted use of a small quantity of a Si-based promoter, resulting in accrued activity benefits that can exceed a factor of 1.8 versus unpromoted catalysts. This enhanced stability also provides longer lifetimes, up to double that of prior generation catalysts. Detailed characterization of a library of aged catalysts has allowed the most important deactivation mechanisms to be established and the chemical state of the silicon promoter to be identified. We show that silicon is incorporated within the ZnO lattice, providing a pronounced improvement in the hydrothermal stability of this component. These findings have important implications for sustainable methanol production from H2 and CO2.

Thermocatalytic Hydrogenation of CO2 to Methanol Using Cu-ZnO Bimetallic Catalysts Supported on Metal–Organic Frameworks

The thermocatalytic hydrogenation of carbon dioxide (CO2) to methanol is considered as a potential route for green hydrogen storage as well as a mean for utilizing captured CO2, owing to the many established applications of methanol. Copper–zinc bimetallic catalysts supported on a zirconium-based UiO-66 metal–organic framework (MOF) were prepared via slurry phase impregnation and benchmarked against the promoted, co-precipitated, conventional ternary CuO/ZnO/Al2O3 (CZA) catalyst for the thermocatalytic hydrogenation of CO2 to methanol. A decrease in crystallinity and specific surface area of the UiO-66 support was observed using X-ray diffraction and N2-sorption isotherms, whereas hydrogen-temperature-programmed reduction and X-ray photoelectron spectroscopy revealed the presence of copper active sites after impregnation and thermal activation. Other characterisation techniques such as scanning electron microscopy, transmission electron microscopy, and thermogravimetric analysis were employed to assess the physicochemical properties of the resulting catalysts. The UiO-66 (Zr) MOF-supported catalyst exhibited a good CO2 conversion of 27 and 16% selectivity towards methanol, whereas the magnesium-promoted CZA catalyst had a CO2 conversion of 31% and methanol selectivity of 24%. The prepared catalysts performed similarly to a CZA commercial catalyst which exhibited a CO2 conversion and methanol selectivity of 30 and 15%. The study demonstrates the prospective use of Cu-Zn bimetallic catalysts supported on MOFs for direct CO2 hydrogenation to produce green methanol.

Identification of deactivation-resistant origin of In(OH)3 for efficient and durable photodegradation of benzene, toluene and their mixtures

Aromatic hydrocarbon is a representative type of VOCs, which causes adverse effects to human health. The degradation stability of aromatic hydrocarbon is of vital importance to commercializing a photocatalyst for its practical application. The most commonly used titanium dioxide photocatalyst (P25) was deactivated rapidly in the photocatalytic VOCs degradation process. In this work, the indium hydroxide (In(OH)₃) photocatalyst was developed, which exhibited not only higher efficient activity but also ultra-stable stability for degradation of benzene, toluene and their mixtures. The origin of the activity difference between two catalysts was investigated by combined experimental and theoretical ways. Based on in situ DRIFTS and GC-MS, it was revealed that benzoic acid and carbonaceous byproducts were specifically formed and accumulated on P25, which were responsible for deactivation of photocatalyst. In contrast, as revealed by both DFT calculations and experimental results, the reaction pathway with byproducts blocking the active sites can be thermodynamically avoided on In(OH)₃. This rendered high durability to In(OH)₃ photocatalyst in degradations of aromatic pollutants. The elucidation of deactivation-resistant effect and reaction mechanism as an ideal photocatalyst for practical usage were provided.

Nanoscale Spatial Distribution of Supported Nanoparticles Controls Activity and Stability in Powder Catalysts for CO Oxidation and Photocatalytic H2 Evolution

Supported metal nanoparticles are essential components of high-performing catalysts, and their structures are intensely researched. In comparison, nanoparticle spatial distribution in powder catalysts is conventionally not quantified, and the influence of this collective property on catalyst performance remains poorly investigated. Here, we demonstrate a general colloidal self-assembly method to control uniformity of nanoparticle spatial distribution on common industrial powder supports. We quantify distributions on the nanoscale using image statistics and show that the type of nanospatial distribution determines not only the stability, but also the activity of heterogeneous catalysts. Widely investigated systems (Au-TiO2 for CO oxidation thermocatalysis and Pd-TiO2 for H2 evolution photocatalysis) were used to showcase the universal importance of nanoparticle spatial organization. Spatially and temporally resolved microkinetic modeling revealed that nonuniformly distributed Au nanoparticles suffer from local depletion of surface oxygen, and therefore lower CO oxidation activity, as compared to uniformly distributed nanoparticles. Nanoparticle spatial distribution also determines the stability of Pd-TiO2 photocatalysts, because nonuniformly distributed nanoparticles sinter while uniformly distributed nanoparticles do not. This work introduces new tools to evaluate and understand catalyst collective (ensemble) properties in powder catalysts, which thereby pave the way to more active and stable heterogeneous catalysts.

Capsule-Structured Copper-Zinc Catalyst for Highly Efficient Hydrogenation of Carbon Dioxide to Methanol

To develop a new and efficient CO₂ -to-methanol catalyst is of extreme significance but still remains a challenge. Herein, an innovative indirect two-step strategy is reported to synthesize a highly efficient capsule-structured copper-based CO₂ -to-methanol catalyst (CZA-r@CZM). It consists of a structurally reconstructed millimeter-sized Cu/ZnO/Al₂ O₃ core (CZA-r) with intensified Cu-ZnO interactions, which is made by a facile hydrothermal treatment in an alkaline aqueous solution, and a Cu/ZnO/MgO (CZM) shell prepared by an ethylene glycol-assisted physical coating method. The CZA-r core displays 2.7 times higher CO₂ hydrogenation activity with 2.0 times higher CO selectivity than the previously reported Cu/ZnO/Al₂ O₃ (CZA-p), whereas the CZM shell can efficiently catalyze hydrogenation of the as-formed CO from the CZA-r core to methanol as it passes through the shell. As a result, the developed capsule-structured CZA-r@CZM catalyst exhibits 2.4 times higher CO₂ conversion with 1.8 times higher turnover frequency and 2.3-fold higher methanol space-time yield than the CZA-p catalyst (729.8 vs. 312.6 g_MeOH  kg_cat ^-1  h^-1 ). In situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTs) experiments reveal that the CO₂ hydrogenation reaction proceeds through a reverse water-gas shift reaction followed by a CO hydrogenation pathway via an *H₃ CO intermediate. This work not only produces an efficient CO₂ -to-methanol catalyst, but also opens a new avenue for designing superior catalysts for other consecutive transformations.

Supported Catalyst Deactivation by Decomposition into Single Atoms Is Suppressed by Increasing Metal Loading

In the high-temperature environments needed to perform catalytic processes, supported precious metal catalysts severely lose their activity over time. Even brief exposure to high temperatures can lead to significant losses in activity, which forces manufacturers to use large amounts of noble metals to ensure effective catalyst function for a required lifetime. Generally, loss of catalytic activity is attributed to nanoparticle sintering, or processes by which larger particles grow at the expense of smaller ones. Here, by independently controlling particle size and particle loading using colloidal nanocrystals, we reveal the opposite process as a novel deactivation mechanism: nanoparticles rapidly lose activity by high-temperature nanoparticle decomposition into inactive single atoms. This deactivation route is remarkably fast, leading to severe loss of activity in as little as ten minutes. Importantly, this deactivation pathway is strongly dependent on particle density and concentration of support defect sites. A quantitative statistical model explains how for certain reactions, higher particle densities can lead to more stable catalysts.

Effect of SiO2 support properties on the performance of Cu–SiO2 catalysts for the hydrogenation of levulinic acid to gamma valerolactone using formic acid as a hydrogen source

Vapor phase catalytic transfer hydrogenation of levulinic acid with formic acid was carried out over Cu–SiO₂ catalysts having different physicochemical properties.

Structure sensitivity of Cu and CuZn catalysts relevant to industrial methanol synthesis

For decades it has been debated whether the conversion of synthesis gas to methanol over copper catalysts is sensitive or insensitive to the structure of the copper surface. Here we have systematically investigated the effect of the copper particle size in the range where changes in surface structure occur, that is, below 10 nm, for catalysts with and without zinc promotor at industrially relevant conditions for methanol synthesis. Regardless of the presence or absence of a zinc promotor in the form of zinc oxide or zinc silicate, the surface-specific activity decreases significantly for copper particles smaller than 8 nm, thus revealing structure sensitivity. In view of recent theoretical studies we propose that the methanol synthesis reaction takes place at copper surface sites with a unique configuration of atoms such as step-edge sites, which smaller particles cannot accommodate.

The dependence of the Cu-catalysed methanol synthesis on the structure of the Cu surface is a matter of debate. Here the authors show that activity falls for Cu and Cu-Zn particles below 8 nm and propose this is due to the absence of certain atomic configurations on the smaller particle surfaces.

A study on the precipitating and aging processes of CuO/ZnO/Al2O3 catalysts synthesized in micro-impinging stream reactors

Precipitating and aging processes of CuO/ZnO/Al₂O₃ catalysts were performed more uniformly in micro-impinging stream reactors than in stirred reactors.

Quantitative relationship between support porosity and the stability of pore-confined metal nanoparticles studied on CuZnO/SiO2 methanol synthesis catalysts

Metal nanoparticle growth represents a major deactivation mechanism of supported catalysts and other functional nanomaterials, particularly those based on low melting-point metals. Here we investigate the impact of the support porous structure on the stability of CuZnO/SiO2 model methanol synthesis catalysts. A series of silica materials with ordered cagelike (SBA-16 mesostructure) and disordered (SiO2-gel) porosities and varying pore sizes were employed as catalyst supports. Nitric oxide moderated nitrate decomposition enabled the synthesis of catalytically active Cu nanoparticles (3-5 nm) exclusively inside the silica pores with short interparticle spacings. Under relevant reactive conditions, confinement of the Cu particles in cagelike silica pores notably enhances catalyst stability by limiting Cu particle growth as compared to catalysts deposited in SiO2-gel host materials with also 3D and highly interconnected though unconstrained porosity. For both pore morphologies, we find a direct relationship between catalyst stability and support porosity, provided the narrowest characteristic pore dimension is employed as a porosity descriptor. For cagelike porosities this corresponds to the size of the entrances to the nanocages. Our results point to nanoparticle diffusion and coalescence as a relevant growth mechanism under reactive conditions and underscore the significance of the narrowest pore constrictions to mitigate growth and improve catalyst stability. This finding contributes to the establishment of general and quantitative structure-stability relationships which are essential for the design of catalysts and related functional nanostructures with long lifetimes under operation conditions.

Synthesis of porous microspheres composed of graphitized carbon@amorphous silicon/carbon layers as high performance anode materials for Li-ion batteries

Amorphous silicon/carbon (Si/C) layers coated on graphitized carbon black (GCB) particles in porous microspheres (PMs) exhibited an improved electrochemical performance.