Preparation of Cobalt Nanocrystals Supported on Metal Oxides To Study Particle Growth in Fischer-Tropsch Catalysts

Extreme Gradient Boosting to Predict Atomic Layer Deposition for Platinum Nano-Film Coating

Extreme gradient boosting (XGBoost) is an artificial intelligence algorithm capable of high accuracy and low inference time. The current study applies this XGBoost to the production of platinum nano-film coating through atomic layer deposition (ALD). In order to generate a database for model development, platinum is coated on α-Al2O3 using a rotary-type ALD equipment. The process is controlled by four parameters: process temperature, stop valve time, precursor pulse time, and reactant pulse time. A total of 625 samples according to different process conditions are obtained. The ALD coating index is used as the Al/Pt component ratio through ICP-AES analysis during postprocessing. The four process parameters serve as the input data and produces the Al/Pt component ratio as the output data. The postprocessed data set is randomly divided into 500 training samples and 125 test samples. XGBoost demonstrates 99.9% accuracy and a coefficient of determination of 0.99. The inference time is lower than that of random forest regression, in addition to a higher prediction safety than that of the light gradient boosting machine.

Regulation of Strong Metal-Support Interaction by Alkaline Earth Metal Salts

Classical strong metal-support interaction (SMSI) is of significant importance to heterogeneous catalysis, where electronic promotion and encapsulation of noble metal by reducible support are two main intrinsic properties of SMSI. However, the excessive encapsulation will inevitably hamper the contact between active sites and reactant, leading to reduced activity in catalysis. Herein, alkaline earth metal salts are employed to depress the encapsulation of Ru nanoparticles in Ru/TiO₂ catalyst in the present study. Thermodynamic calculation, transmission electron microscopy (TEM) and chemisorption results show that the alkaline earth metal salts could successfully prevent the migration of TiO_2-x overlayer to Ru nanoparticles in Ru/TiO₂ catalyst via in situ formation of titanates, resulting in high exposure of active metal. Meanwhile, X-ray photoelectron spectroscopy (XPS) and hydrogen temperature-programmed reduction (H₂ -TPR) results reveal that an even stronger electron donation from the reduced support to Ru nanoparticles is achieved. As a result, the alkaline earth metal salts-doped Ru/TiO₂ catalysts exhibit superior activity in catalytic hydrogenation of aromatics, which is in contrast to the pristine Ru/TiO₂ catalyst that shows negligible activity under the same conditions due to the excess encapsulation of Ru nanoparticles in Ru/TiO₂ catalyst.

Design of Silica Nanoparticles-Supported Metal Catalyst by Wet Impregnation with Catalytic Performance for Tuning Carbon Nanotubes Growth

The catalytic activity of cobalt and iron nanoparticles for the growth of carbon nanotubes (CNTs) was studied by a specific reproducible and up-scalable fabrication method. Co and Fe catalysts were deposited over SiO2 nanoparticles by a wet-impregnation method and two different annealing steps were applied for the catalyst formation/activation. The samples were calcined at an optimal temperature of 450 °C resulting in the formation of metal oxide nano-islands without the detection of silicates. Further reduction treatment (700 °C) under H2 successfully converted oxide nanoparticles to Co and Fe metallic species. Furthermore, the catalytic efficiency of both supported-metal nanoparticles at 2 and 5% in weight of silica was evaluated through the growth of CNTs. The CNT structure, morphology and size dispersion were tailored according to the metal catalyst concentration.

Spiers Memorial Lecture: Understanding reaction mechanisms in heterogeneously catalysed reactions

Heterogeneous catalysis lies at the heart of the chemical and fuel manufacturing industries and hence is a cornerstone of many economies. Many of the commercially operated heterogeneous catalysts have remained basically unchanged for decades, undergoing small but important optimisation of their formulations. Yet we all acknowledge that there is a continuous drive towards improved catalysts or designing new ones. At the heart of these studies has been the need to gain an improved understanding of the reaction mechanism for these important reactions since this can unlock new ways to improve catalyst design and, of course, the ultimate aim is to design catalysts based on the detailed understanding of the reaction mechanism. These advanced studies have been aided in the last decade by two key factors, namely: (a) access to advanced characterisation techniques based on synchrotron methods and aberration-corrected microscopy that can probe the nature of the active site, and (b) the application of high-level computational methods to understand how the reactants and products interact at the active site. In this paper this theme will be explored using two examples to bring out the complexity in gaining an understanding of a reaction mechanism. Using the zeolite H-ZSM-5 as an example of a single site catalyst, the mechanism of the conversion of methanol to the first hydrocarbon carbon-carbon bond will be discussed. In this section the use of model reactants and reaction probes will be used to try to differentiate between different mechanistic proposals. The second example explores the use of gold catalysts for CO oxidation and acetylene hydrochlorination. In both these examples the importance of advanced characterisation and theory will be highlighted.

Direct observation of the evolving metal-support interaction of individual cobalt nanoparticles at the titania and silica interface

Understanding the metal–support interaction (MSI) is crucial to comprehend how the catalyst support affects performance and whether this interaction can be exploited in order to design new catalysts with enhanced properties. Spatially resolved soft X-ray absorption spectroscopy (XAS) in combination with Atomic Force Microscopy (AFM) and Scanning Helium Ion-Milling Microscopy (SHIM) has been applied to visualise and characterise the behaviour of individual cobalt nanoparticles (CoNPs) supported on two-dimensional substrates (SiO_xSi(100) (x < 2) and rutile TiO₂(110)) after undergoing reduction–oxidation–reduction (ROR). The behaviour of the Co species is observed to be strongly dependent on the type of support. For SiO_xSi a weaker MSI between Co and the support allows a complete reduction of CoNPs although they migrate and agglomerate. In contrast, a stronger MSI of CoNPs on TiO₂ leads to only a partial reduction under H₂ at 773 K (as observed from Co L₃-edge XAS data) due to enhanced TiO₂ binding of surface-exposed cobalt. SHIM data revealed that the interaction of the CoNPs is so strong on TiO₂, that they are seen to spread at and below the surface and even to migrate up to ∼40 nm away. These results allow us to better understand deactivation phenomena and additionally demonstrate a new understanding concerning the nature of the MSI for Co/TiO₂ and suggest that there is scope for careful control of the post-synthetic thermal treatment for the tuning of this interaction and ultimately the catalytic performance.

Understanding the metal–support interaction (MSI) is crucial to comprehend how the catalyst support affects performance and whether this interaction can be exploited in order to design new catalysts with enhanced properties.

Engineering Nanoscale Interfaces of Metal/Oxide Nanowires to Control Catalytic Activity

The interfacial effect between a metal catalyst and its various supporting transition metal oxides on the catalytic activity of heterogeneous catalysis has been extensively explored; engineering interfacial sites of metal supported on metal oxide has been found to influence catalytic performance. Here, we investigate the interfacial effect of Pt nanowires (NWs) vertically and alternatingly stacked with titanium dioxide (TiO₂) or cobalt monoxide (CoO) NWs, which exhibit a strong metal-support interaction under carbon monoxide (CO) oxidation. High-resolution nanotransfer printing based on nanoscale pattern replication and e-beam evaporation were utilized to obtain the Pt NWs cross-stacked on the CoO or TiO₂ NW on the silicon dioxide (SiO₂) substrate with varying numbers of nanowires. The morphology and interfacial area were precisely determined by means of atomic force microscopy and scanning electron microscopy. The cross-stacked Pt/TiO₂ NW and Pt/CoO NW catalysts were estimated with CO oxidation under 40 Torr CO and 100 Torr O₂ from 200 to 240 °C. Higher catalytic activity was found on the Pt/CoO NW catalyst than on Pt/TiO₂ NWs and Pt NWs, which indicates the significance of nanoscale metal-oxide interfaces. As the number of nanowire layers increased, the catalytic activity became saturated. Our study demonstrates the interfacial role of nanoscale metal-oxide interfaces under CO oxidation, which has intriguing applications in the smart design of catalytic materials.

Stability of Colloidal Iron Oxide Nanoparticles on Titania and Silica Support

Using model catalysts with well-defined particle sizes and morphologies to elucidate questions regarding catalytic activity and stability has gained more interest, particularly utilizing colloidally prepared metal(oxide) particles. Here, colloidally synthesized iron oxide nanoparticles (Fe _x O _y -NPs, size ∼7 nm) on either a titania (Fe _x O _y /TiO₂) or a silica (Fe _x O _y /SiO₂) support were studied. These model catalyst systems showed excellent activity in the Fischer-Tropsch to olefin (FTO) reaction at high pressure. However, the Fe _x O _y /TiO₂ catalyst deactivated more than the Fe _x O _y /SiO₂ catalyst. After analyzing the used catalysts, it was evident that the Fe _x O _y -NP on titania had grown to 48 nm, while the Fe _x O _y -NP on silica was still 7 nm in size. STEM-EDX revealed that the growth of Fe _x O _y /TiO₂ originated mainly from the hydrogen reduction step and only to a limited extent from catalysis. Quantitative STEM-EDX measurements indicated that at a reduction temperature of 350 °C, 80% of the initial iron had dispersed over and into the titania as iron species below imaging resolution. The Fe/Ti surface atomic ratios from XPS measurements indicated that the iron particles first spread over the support after a reduction temperature of 300 °C followed by iron oxide particle growth at 350 °C. Mössbauer spectroscopy showed that 70% of iron was present as Fe²⁺, specifically as amorphous iron titanates (FeTiO₃), after reduction at 350 °C. The growth of iron nanoparticles on titania is hypothesized as an Ostwald ripening process where Fe²⁺ species diffuse over and through the titania support. Presynthesized nanoparticles on SiO₂ displayed structural stability, as only ∼10% iron silicates were formed and particles kept the same size during in situ reduction, carburization, and FTO catalysis.

Disk-Shaped Cobalt Nanocrystals as Fischer–Tropsch Synthesis Catalysts Under Industrially Relevant Conditions

Colloidal synthesis of metal nanocrystals (NC) offers control over size, crystal structure and shape of nanoparticles, making it a promising method to synthesize model catalysts to investigate structure-performance relationships. Here, we investigated the synthesis of disk-shaped Co-NC, their deposition on a support and performance in the Fischer–Tropsch (FT) synthesis under industrially relevant conditions. From the NC synthesis, either spheres only or a mixture of disk-shaped and spherical Co-NC was obtained. The disks had an average diameter of 15 nm, a thickness of 4 nm and consisted of hcp Co exposing (0001) on the base planes. The spheres were 11 nm on average and consisted of ε-Co. After mild oxidation, the CoO-NC were deposited on SiO2 with numerically 66% of the NC being disk-shaped. After reduction, the catalyst with spherical plus disk-shaped Co-NC had 50% lower intrinsic activity for FT synthesis (20 bar, 220 °C, H2/CO = 2 v/v) than the catalyst with spherical NC only, while C5+-selectivity was similar. Surprisingly, the Co-NC morphology was unchanged after catalysis. Using XPS it was established that nitrogen-containing ligands were largely removed and in situ XRD revealed that both catalysts consisted of 65% hcp Co and 21 or 32% fcc Co during FT. Furthermore, 3–5 nm polycrystalline domains were observed. Through exclusion of several phenomena, we tentatively conclude that the high fraction of (0001) facets in disk-shaped Co-NC decrease FT activity and, although very challenging to pursue, that metal nanoparticle shape effects can be studied at industrially relevant conditions.

Influence of Promotion on the Growth of Anchored Colloidal Iron Oxide Nanoparticles during Synthesis Gas Conversion

Using colloidal iron oxide nanoparticles with organic ligands, anchored in a separate step from the supports, has been shown to be beneficial to obtain homogeneously distributed metal particles with a narrow size distribution. Literature indicates that promoting these particles with sodium and sulfur creates an active Fischer–Tropsch catalyst to produce olefins, while further adding an H-ZSM-5 zeolite is an effective way to obtain aromatics. This research focused on the promotion of iron oxide colloids with sodium and sulfur using an inorganic ligand exchange followed by the attachment to H-ZSM-5 zeolite crystals. The catalyst referred to as FeP/Z, which consists of iron particles with inorganic ligands attached to a H-ZSM-5 catalyst, was compared to an unpromoted Fe/Z catalyst and an Fe/Z-P catalyst, containing the colloidal nanoparticles with organic ligands, promoted after attachment. A low CO conversion was observed on both FeP/Z and Fe/Z-P, originating from an overpromotion effect for both catalysts. However, when both promoted catalysts were washed (FeP/Z-W and Fe/Z–P-W) to remove the excess of promoters, the activity was much higher. Fe/Z-P-W simultaneously achieved low selectivity toward methane as part of the promoters were still present after washing, whereas for FeP/Z-W the majority of promoters was removed upon washing, which increased the methane selectivity. Moreover, due to the addition of Na+S promoters, the iron nanoparticles in the FeP/Z(-W) catalysts had grown considerably during catalysis, while those in Fe/Z-P(-W) and Fe/Z(-W) remained relatively stable. Lastly, as a large broadening of particle sizes for the used FeP/Z-W was found, where particle sizes had both increased and decreased, Ostwald ripening is suggested for particle growth accelerated by the presence of the promoters.

Cobalt oxide-carbon nanocatalysts with highly enhanced catalytic performance for the green synthesis of nitrogen heterocycles through the Friedländer condensation

A novel series of eco-sustainable catalysts developed by supporting CoO nanoparticles on different carbon supports, highly efficient in the synthesis of quinolines and naphthyridines, through the Friedländer condensation, are reported for the first time. Textural properties, dispersion and location of the Co-phase are influenced by the nature of the carbon support, Co-precursor salt and metal loading, having a significant impact on the catalytic performance. Thus, the presence of the mesopores and macropores in carbon aerogels together with the homogeneous distribution of the active phase favours the formation of product 3a as a function of the metal loading. However, an increase in the metal content when using CNTs indicates the formation of CoO aggregates and an optimal concentration of 3 wt% CoO was observed, providing the highest conversion values. The carbon-based catalysts herein reported can be considered to be a sustainable alternative having advantages such as easy preparation, superior stability and notably enhanced catalytic performance, operating at lower temperature and under solvent-free conditions.

Role of well-defined cobalt crystal facets in Fischer-Tropsch synthesis: a combination of experimental and theoretical studies

Pure-phase cobalt nanocrystals with well-defined specific exposed facets were synthesized via controllable reduction of their CoO counterparts while retaining the same scale of particle size. Three different catalysts, i.e. hexagonal close-packed (hcp) Co pyramid with (10-11) and rodlike with (10-10) facets, as well as face-centred cubic (fcc) Co octahedron with (111) exposed were obtained and studied for Fischer-Tropsch synthesis (FTS) reaction. No noticeable changes of either the shape or the exposed facets were found under practical FTS reaction conditions. The hcp (10-11) facet exhibits the highest FTS activity and C5+ product selectivity with the lowest apparent activation energy and CH4 selectivity. Theoretical calculations of the energy barrier for CO dissociation and methanation of the reaction intermediate CHx rationalize the experimental results.