Exsolution of Metallic Ru Nanoparticles from Defective, Fluorite-Type Solid Solutions Sm2RuxCe2–xO7 To Impart Stability on Dry Reforming Catalysts

In situ investigation of ruthenium doped lanthanum nickel titanium double perovskite and its exsolution behaviour

Exsolution, an innovative method for fabricating perovskite-based oxides decorated with metal nanoparticles, has garnered significant interest in the fields of catalyst fabrication and electrochemical devices. Although dopant exsolution from single perovskite structures has been extensively studied, the exsolution behaviour of double perovskite structures remains insufficiently understood. In this study, we synthesized B-site double perovskite Ru-doped lanthanum nickel titanates with a 7.5 at% A-site deficiency, and systematically investigated the exsolution process that formed nickel metal nanoparticles on the material surface, across a broad reduction temperature range of 350-1000 °C. Both Ex situ and in situ characterization revealed that small, uniform Ni nanoparticles exsolved at low temperatures, whereas the exsolution of ruthenium required higher reduction temperatures beyond 1000 °C. Within the reduction temperature range of 350-500 °C, a notable finding is the reconstruction of exsolved nanoparticles, implying that Ni particles exist in a thermodynamically metastable state. Electrochemical impedance spectroscopy (EIS) showed a decreased area specific resistance (ASR) during the progress of exsolution. The increase in current density of a full solid oxide cell (SOC) in electrolysis mode and the doubling of peak power density in fuel cell mode attributed to the exsolution of Ni nanoparticles highlight the potential application of metal exsolution in electrode materials for SOCs.

New trends in nanoparticle exsolution

Many relevant high-temperature chemical processes require the use of oxide-supported metallic nanocatalysts. The harsh conditions under which these processes operate can trigger catalyst degradation via nanoparticle sintering, carbon depositions or poisoning, among others. This primarily affects metallic nanoparticles created via deposition methods with low metal-support interaction. In this respect, nanoparticle exsolution has emerged as a promising method for fabricating oxide-supported nanocatalysts with high interaction between the metal and the oxide support. This is due to the mechanism involved in nanoparticle exsolution, which is based on the migration of metal cations in the oxide support to its surface, where they nucleate and grow as metallic nanoparticles partially embedded in the oxide. This anchorage confers high robustness against sintering or coking-related problems. For these reasons, exsolution has attracted great interest in the last few years. Multiple works have been devoted to proving the high catalytic stability of exsolved metallic nanoparticles in several applications for high-temperature energy storage and conversion. Additionally, considerable attention has been directed towards understanding the underlying mechanism of metallic nanoparticle exsolution. However, this growing field has not been limited to these types of studies and recent discoveries at the forefront of materials design have opened new research avenues. In this work, we define six new trends in nanoparticle exsolution, taking a tour through the most important advances that have been recently reported.

Facilitating the dry reforming of methane with interfacial synergistic catalysis in an Ir@CeO2-x catalyst

The dry reforming of methane provides an attractive route to convert greenhouse gases (CH4 and CO2) into valuable syngas, so as to resolve the carbon cycle and environmental issues. However, the development of high-performance catalysts remains a huge challenge. Herein, we report a 0.6% Ir/CeO2-x catalyst with a metal-support interface structure which exhibits high CH4 (~72%) and CO2 (~82%) conversion and a CH4 reaction rate of ~973 μmolCH4 gcat-1 s-1 which is stable over 100 h at 700 °C. The performance of the catalyst is close to the state-of-the-art in this area of research. A combination of in situ spectroscopic characterization and theoretical calculations highlight the importance of the interfacial structure as an intrinsic active center to facilitate the CH4 dissociation (the rate-determining step) and the CH2* oxidation to CH2O* without coke formation, which accounts for the long-term stability. The catalyst in this work has a potential application prospect in the field of high-value utilization of carbon resources.

Interfacial Metal-Support Interaction and Catalytic Performance of Perovskite LaCrO3-Supported Ru Catalyst

Interfacial metal-support interaction (MSI) significantly affects the dispersion of active metals on the surface of the catalyst support and impacts catalyst performance. Understanding MSI is crucial for developing highly active and stable catalysts with a low metal loading, particularly for noble metal catalysts. In this work, we synthesized LaRuxCr1-xO3 catalysts with low Ru loading (x = 0.005, 0.01, and 0.02) using the sol-gel self-combustion method. We found that all of the Ru atoms immediately above or below the metal-support interface are closely bonded to the perovskite LaCrO3 surface lattice through Ru-O bonds, enhancing the MSI via interfacial reaction and charge transfer mechanisms. We identified a variety of Ru species, including small 3D Ru nanoparticles, 2D dispersed Ru surface atoms, and even 0D Ru single atoms. These highly dispersed Ru species exhibit high activity and stability under dry reforming of methane (DRM) conditions. The LaRu0.01Cr0.99O3 catalyst with very low Ru loading (0.42 wt %) was stable over a 50 h DRM test and the carbon deposition was negligible. The CH4 and CO2 conversions at 750 °C reached 83 and 86%, respectively, approaching the theoretical thermodynamic equilibrium values.

Assessing the effect of acid and alkali treatment on a halloysite-based catalyst for dry reforming of methane

Dry reforming of methane (DRM) has recently received wide attention owing to its outstanding performance in the reduction and conversion of CH4 and CO2 to syngas (H2 and CO). From an industrial perspective, nickel (Ni)-supported catalysts have been deemed among the most suitable catalysts for DRM owing to their low cost and high activity compared to noble metals. However, a downside of nickel catalysts is their high susceptibility to deactivation due to coke formation and sintering at high temperatures. Using appropriate supports and preparation methods plays a major role in improving the activity and stability of Ni-supported catalysts. Halloysite nanotubes (HNTs) are largely utilized in catalysis as a support for Ni owing to their abundance, low cost, and ease of preparation. The treatment of HNTs (chemical or physical) prior to doping with Ni is considered a suitable method for increasing the overall performance of the catalyst. In this study, the surface of HNTs was activated with acids (HNO3 and H2SO4) and alkalis (NaOH and Na2CO3 + NaNO3) prior to Ni doping to assess the effects of support treatment on the stability, activity, and longevity of the catalyst. Nickel catalysts on raw HNT, acid-treated HNT, and alkali-treated HNT supports were prepared via wet impregnation. A detailed characterization of the catalysts was conducted using X-ray diffraction (XRD), BET surface area analysis, scanning electron microscopy (SEM), transmission electron microscopy (TEM), solid-state nuclear magnetic resonance (ssNMR), H2-temperature programmed reduction, (H2-TPR), CO2-temperature programmed desorption (CO2-TPD), and Ni-dispersion via H2-pulse chemisorption. Our results reveal a clear alteration in the structure of HNTs after treatment, while elemental mapping shows a uniform distribution of Ni throughout all the different supports. Moreover, the supports treated with a molten salt method resulted in the overall highest CO2 and CH4 conversion among the studied catalysts and exhibited high stability over 24 hours testing.

Lattice-Stabilized Chromium Atoms on Ceria for N2O Synthesis

The development of selective catalysts for direct conversion of ammonia into nitrous oxide, N2O, will circumvent the conventional five-step manufacturing process and enable its wider utilization in oxidation catalysis. Deviating from commonly accepted catalyst design principles for this reaction, reliant on manganese oxide, we herein report an efficient system comprised of isolated chromium atoms (1 wt %) stabilized in the ceria lattice by coprecipitation. The latter, in contrast to a simple impregnation approach, ensures firm metal anchoring and results in stable and selective N2O production over 100 h on stream up to 79% N2O selectivity at full NH3 conversion. Raman, electron paramagnetic resonance, and in situ UV-vis spectroscopies reveal that chromium incorporation enhances the density of oxygen vacancies and the rate of their generation and healing. Accordingly, temporal analysis of products, kinetic studies, and atomistic simulations show lattice oxygen of ceria to directly participate in the reaction, establishing the cocatalytic role of the carrier. Coupled with the dynamic restructuring of chromium sites to stabilize intermediates of N2O formation, these factors enable catalytic performance on par with or exceeding benchmark systems. These findings demonstrate how nanoscale engineering can elevate a previously overlooked metal into a highly competitive catalyst for selective ammonia oxidation to N2O, paving the way toward industrial implementation.

Nanoparticle Exsolution on Perovskite Oxides: Insights into Mechanism, Characteristics and Novel Strategies

Supported nanoparticles have attracted considerable attention as a promising catalyst for achieving unique properties in numerous applications, including fuel cells, chemical conversion, and batteries. Nanocatalysts demonstrate high activity by expanding the number of active sites, but they also intensify deactivation issues, such as agglomeration and poisoning, simultaneously. Exsolution for bottom-up synthesis of supported nanoparticles has emerged as a breakthrough technique to overcome limitations associated with conventional nanomaterials. Nanoparticles are uniformly exsolved from perovskite oxide supports and socketed into the oxide support by a one-step reduction process. Their uniformity and stability, resulting from the socketed structure, play a crucial role in the development of novel nanocatalysts. Recently, tremendous research efforts have been dedicated to further controlling exsolution particles. To effectively address exsolution at a more precise level, understanding the underlying mechanism is essential. This review presents a comprehensive overview of the exsolution mechanism, with a focus on its driving force, processes, properties, and synergetic strategies, as well as new pathways for optimizing nanocatalysts in diverse applications.

Opportunities and Challenges of Metal-Organic Framework Micro/Nano Reactors for Cascade Reactions

Building bridges among different types of catalysts to construct cascades is a highly worthwhile pursuit, such as chemo-, bio-, and chemo-bio cascade reactions. Cascade reactions can improve the reaction efficiency and selectivity while reducing steps of separation and purification, thereby promoting the development of "green chemistry". However, compatibility issues in cascade reactions pose significant constraints on the development of this field, particularly concerning the compatibility of diverse catalyst types, reaction conditions, and reaction rates. Metal-organic framework micro/nano reactors (MOF-MNRs) are porous crystalline materials formed by the self-assembly coordination of metal sites and organic ligands, possessing a periodic network structure. Due to the uniform pore size with the capability of controlling selective transfer of substances as well as protecting active substances and the organic-inorganic parts providing reactive microenvironment, MOF-MNRs have attracted significant attention in cascade reactions in recent years. In this Perspective, we first discuss how to address compatibility issues in cascade reactions using MOF-MNRs, including structural design and synthetic strategies. Then we summarize the research progress on MOF-MNRs in various cascade reactions. Finally, we analyze the challenges facing MOF-MNRs and potential breakthrough directions and opportunities for the future.

In situ electrochemical reconstruction of Sr2Fe1.45Ir0.05Mo0.5O6-δ perovskite cathode for CO2 electrolysis in solid oxide electrolysis cells

Solid oxide electrolysis cells provide a practical solution for the direct conversion of CO2 to other chemicals (i.e. CO), however, an in-depth mechanistic understanding of the dynamic reconstruction of active sites for perovskite cathodes during CO2 electrolysis remains a great challenge. Herein, we identify that iridium-doped Sr2Fe1.45Ir0.05Mo0.5O6-δ (SFIrM) perovskite displays a dynamic electrochemical reconstruction feature during CO2 electrolysis with abundant exsolution of highly dispersed IrFe alloy nanoparticles on the SFIrM surface. The in situ reconstructed IrFe@SFIrM interfaces deliver a current density of 1.46 A cm-2 while maintaining over 99% CO Faradaic efficiency, representing a 25.8% improvement compared with the Sr2Fe1.5Mo0.5O6-δ counterpart. In situ electrochemical spectroscopy measurements and density functional theory calculations suggest that the improved CO2 electrolysis activity originates from the facilitated formation of carbonate intermediates at the IrFe@SFIrM interfaces. Our work may open the possibility of using an in situ electrochemical poling method for CO2 electrolysis in practice.

Exsolution of Ru Nanoparticles on BaCe0.9 Y0.1 O3-δ Modifying Geometry and Electronic Structure of Ru for Ammonia Synthesis Reaction Under Mild Conditions

Green ammonia is an efficient, carbon-free energy carrier and storage medium. The ammonia synthesis using green hydrogen requires an active catalyst that operates under mild conditions. The catalytic activity can be promoted by controlling the geometry and electronic structure of the active species. An exsolution process is implemented to improve catalytic activity by modulating the geometry and electronic structure of Ru. Ru nanoparticles exsolved on a BaCe_0.9 Y_0.1 O_3-δ support exhibit uniform size distribution, 5.03 ± 0.91 nm, and exhibited one of the highest activities, 387.31 mmol_NH3  g_Ru ^-1  h^-1 (0.1 MPa and 450 °C). The role of the exsolution and BaCe_0.9 Y_0.1 O_3-δ support is studied by comparing the catalyst with control samples and in-depth characterizations. The optimal nanoparticle size is maintained during the reaction, as the Ru nanoparticles prepared by exsolution are well-anchored to the support with in-plane epitaxy. The electronic structure of Ru is modified by unexpected in situ Ba promoter accumulation around the base of the Ru nanoparticles.

A-site deficient La0.52Sr0.28Ti0.94Ni0.06O3by low-pulsed electric current treatment: achieved exsolution of B-site Ni nanoparticles and significant improvement of electrocatalytic properties

Perovskite materials with exsolved nanoparticles have a wide range of applications in energy conversion systems owing to their unique basal plane active sites and excellent catalytic properties. The introduction of A-site deficiency can help the formation of highly mobile oxygen vacancies and remarkably enhance the reducibility of Ni nanoparticles, thus significantly increasing electronic conductivity and catalytic activity simultaneously. Herein, we adopt pulsed electric current (PEC) treatment, a novel approach instead of the long-time high-temperature reduction technique, and for the first time review that the exsolution of minuscule Ni nanoparticles (8-20 nm) could be facilitated on Ni-doped La_0.52Sr_0.28Ti_0.94Ni_0.06O₃(LSTN) anodes with A-site deficiency. Encouragingly, finding that low PEC can successfully lead to nanoparticle exsolution and show a significantly improved oxygen evolution reaction performance of LSTN-PEC (LSTN after PEC treatment) possessing A-site deficiency, the onset potential of LSTN-PEC (500 V) (LSTN after PEC treatment with 500 V-4 Hz-90 s) was advanced by 0.173 V, theR_ctvalue was reduced by 82.38 Ω·cm², and the overpotential was also reduced by 73 mV.

The structural evolution of Mo2C and Mo2C/SiO2 under dry reforming of methane conditions: morphology and support effects

The thermal carburization of MoO₃ nanobelts (nb) and SiO₂-supported MoO₃ nanosheets under a 1 : 4 mixture of CH₄ : H₂ yields Mo₂C-nb and Mo₂C/SiO₂. Following this process by in situ Mo K-edge X-ray absorption spectroscopy (XAS) reveals different carburization pathways for unsupported and supported MoO₃. In particular, the carburization of α-MoO₃-nb proceeds via MoO₂, and that of MoO₃/SiO₂via the formation of highly dispersed MoO_x species. Both Mo₂C-nb and Mo₂C/SiO₂ catalyze the dry reforming of methane (DRM, 800 °C, 8 bar) but their catalytic stability differs. Mo₂C-nb shows a stable performance when using a CH₄-rich feed (CH₄ : CO₂ = 4 : 2), however deactivation due to the formation of MoO₂ occurs for higher CO₂ concentrations (CH₄ : CO₂ = 4 : 3). In contrast, Mo₂C/SiO₂ is notably more stable than Mo₂C-nb under the CH₄ : CO₂ = 4 : 3 feed. The influence of the morphology of Mo₂C and its dispersion on silica on the structural evolution of the catalysts under DRM is further studied by in situ Mo K-edge XAS. It is found that Mo₂C/SiO₂ features a higher resistance to oxidation under DRM than the highly crystalline unsupported Mo₂C-nb and this correlates with an improved catalytic stability. Lastly, the oxidation of Mo in both Mo₂C-nb and Mo₂C/SiO₂ under DRM conditions in the in situ XAS experiments leads to an increased activity of the competing reverse water gas shift reaction.

In situ Mo K-edge X-ray absorption spectroscopy reveals different carburization pathways for unsupported and supported MoO₃ yielding Mo₂C and Mo₂C/SiO₂. Mo₂C/SiO₂ features higher resistance to oxidation under dry reforming of methane than Mo₂C.

Elucidating the Strain-Vacancy-Activity Relationship on Structurally Deformed Co@CoO Nanosheets for Aqueous Phase Reforming of Formaldehyde

Lattice strain modulation and vacancy engineering are both effective approaches to control the catalytic properties of heterogeneous catalysts. Here, Co@CoO heterointerface catalysts are prepared via the controlled reduction of CoO nanosheets. The experimental quantifications of lattice strain and oxygen vacancy concentration on CoO, as well as the charge transfer across the Co-CoO interface are all linearly correlated to the catalytic activity toward the aqueous phase reforming of formaldehyde to produce hydrogen. Mechanistic investigations by spectroscopic measurements and density functional theory calculations elucidate the bifunctional nature of the oxygen-vacancy-rich Co-CoO interfaces, where the Co and the CoO sites are responsible for CH bond cleavage and OH activation, respectively. Optimal catalytic activity is achieved by the sample reduced at 350 °C, Co@CoO-350 which exhibits the maximum concentration of Co-CoO interfaces, the maximum concentration of oxygen vacancies, a lattice strain of 5.2% in CoO, and the highest aqueous phase formaldehyde reforming turnover frequency of 50.4 h^-1 at room temperature. This work provides not only new insights into the strain-vacancy-activity relationship at bifunctional catalytic interfaces, but also a facile synthetic approach to prepare heterostructures with highly tunable catalytic activities.

Active Exsolved Metal-Oxide Interfaces in Porous Single-Crystalline Ceria Monoliths for Efficient and Durable CH4 /CO2 Reforming

Dry reforming of CH₄ /CO₂ provides an attractive route to convert greenhouse gas into syngas; however, the resistance to sintering and coking of catalyst remains a fundamental challenge at high operation temperatures. Here we create active and durable metal-oxide interfaces in porous single-crystalline (PSC) CeO₂ monoliths with in situ exsolved single-crystalline (SC) Ni particles and show efficient dry reforming of CH₄ /CO₂ at temperatures as low as 450 °C. We show the excellent and durable performance with ≈20 % of CH₄ conversion and ≈30 % of CO₂ conversion even in a continuous operation of 240 hours. The well-defined active metal-oxide interfaces, created by exsolving SC Ni nanoparticles from PSC Ni_x Ce_1-x O₂ to anchor them on PSC CeO₂ scaffolds, prevent nanoparticle sintering and enhance the coking resistance due to the stronger metal-support interactions. Our work would enable an industrially and economically viable path for carbon reclamation, and the technique of creating active and durable metal-oxide interfaces in PSC monoliths could lead to stable catalyst designs for many challenging reactions.

Direct Observation of Rhodium Ex-Solution from a Ceria Nanodomain and Its Use for Hydrogen Production via Propane Steam Reforming

The ex-solution phenomenon has received attention as a promising technique to prepare highly durable heterogeneous catalysts. Perovskite materials have been mainly used as host oxides for ex-solution, but their small surface areas have limited their practical use. Here, Rh was ex-solved by reducing Rh-doped ceria solid solution, and nanosized Rh catalysts with a high surface area of 70.7 m²/g were prepared. The Rh nanoparticles ex-solved from the ceria nanodomains were directly monitored by in situ transmission electron microscopy. The Rh nanoparticles whose sizes are 2-3 nm were not coarsened during the propane steam reforming process carried out at 700 °C for 65 h, leading to high resistance against sintering and coke formation. On the contrary, the Rh catalyst simply deposited on CeO₂ was significantly sintered after the reaction, and the size of Rh nanoparticles increased to 25 nm, resulting in severe coke formation. Our work shows that ex-solution from a ceria-based nanodomain can be a good way to prepare metal nanoparticle catalysts with a large surface area and excellent durability for gas-phase reactions at high temperatures.

Exploring the Stability of Fe–Ni Alloy Nanoparticles Exsolved from Double-Layered Perovskites for Dry Reforming of Methane

Exsolution is emerging as a promising route for the creation of nanoparticles that remain anchored to the oxide support, imparting remarkable stability in high temperature chemical processes such as dry reforming of methane. This process takes place at temperatures around 850 °C, which causes sintering-related issues in catalysts prepared using conventional impregnation methods, which could be overcome by using exsolution functionalized oxides. In this work, FeNi3 alloy nanoparticles exsolved from Sr2FexNi1-xMoO6-δ double-layered perovskites were evaluated as a dry reforming catalyst, paying special attention to structure–activity relationships. Our results indicate that increasing the Ni content favors the nanoparticle dispersion, eventually leading to increased CO2 and CH4 conversions. The exsolved nanoparticles presented remarkable nanoparticle size (ca. 30 nm) stability after the 10 h treatment, although the formation of some phase segregations over the course of the reaction caused a minor decrease in the nanoparticle population. Overall, the results presented here serve as materials processing guidelines that could find further potential use in the design of more efficient (electro)catalysts in other fuel production or energy conversion technologies.

Emergence and Future of Exsolved Materials

Supported nanoparticle systems have received increased attention over the last decades because of their potential for high activity levels when applied to chemical conversions, although, because of their nanoscale nature, they tend to exhibit problems with long-term durability. Over the last decade, the discovery of the so-called exsolution concept has addressed many of these challenges and opened many other opportunities to material design by providing a relatively simple, single-step, synthetic pathway to produce supported nanoparticles that combine high stability against agglomeration and poisoning with high activity across multiple areas of application. Here, the trends that define the development of the exsolution concept are reviewed in terms of design, functionality, tunability, and applicability. To support this, the number of studies dedicated to both fundamental and application-related studies, as well as the types of metallic nanoparticles and host or support lattices employed, are examined. Exciting future directions of research are also highlighted.

Constructing Ni-based confinement catalysts with advanced performances toward the CO2 reforming of CH4: state-of-the-art review and perspectives

The concept of Ni-based confinement catalysts has been proposed and developed to address the challenge of the thermal sintering of metallic Ni active sites during CRM by the space and/or lattice confinement effects.

Molybdenum carbide and oxycarbide from carbon-supported MoO3 nanosheets: phase evolution and DRM catalytic activity assessed by TEM and in situ XANES/XRD methods

Molybdenum carbide (β-Mo₂C) supported on carbon spheres was prepared via a carbothermal hydrogen reduction (CHR) method from delaminated nanosheets of molybdenum(vi) oxide (d-MoO₃/C). The carburization process was followed by combined in situ XANES/XRD analysis revealing the formation of molybdenum oxycarbide Mo₂C_xO_y as an intermediate phase during the transformation of d-MoO₃/C to β-Mo₂C/C. It was found that Mo₂C_xO_y could not be completely carburized to β-Mo₂C under a He atmosphere at 750 °C, instead a reduction in H₂ is required. The β-Mo₂C/C obtained showed activity and stability for the dry reforming of methane at 800 °C and 8 bar. In situ XANES/XRD evaluation of the catalyst under DRM reaction conditions combined with high resolution TEM analysis revealed the evolution of β-Mo₂C/C to Mo₂C_xO_y/C. Notably, the gradual oxidation of β-Mo₂C/C to Mo₂C_xO_y/C correlates directly with the increased activity of the competing reverse water gas shift reaction.

Ni-Based catalysts supported on natural clay of attapulgite applied in the dry reforming of methane reaction

With the increase of the global average temperature year after year, dry reforming of methane to synthetic gas as a way to deal with reaction between greenhouse gases CO₂ and CH₄, therefore, has become a research focus.