Remarkable improvement in low temperature performance of model three-way catalysts through solution atomic layer deposition

Robust Ru/Ce@Co Catalyst with an Optimized Support Structure for Propane Oxidation

Short carbon chain alkanes, as typical volatile organic compounds (VOCs), have molecular structural stability and low molecular polarity, leading to an enormous challenge in the catalytic oxidation of propane. Although Ru-based catalysts exhibit a surprisingly high activity for the catalytic oxidation of propane to CO2 and H2O, active RuOx species are partially oxidized and sintered during the oxidation reaction, leading to a decrease in catalytic activity and significantly inhibiting their application in industrial processes. Herein, the Ru/Ce@Co catalyst is synthesized with a specific structure, in which cerium dioxide is dispersed in a thin layer on the surface of Co3O4, and Ru nanoparticles fall preferentially on cerium oxide with high dispersity. Compared with the Ru/CeO2 and Ru/Co3O4 catalysts, the Ru/Ce@Co catalyst demonstrates excellent catalytic activity and stability for the oxidation of propane, even under severe operating conditions, such as recycling reaction, high space velocity, a certain degree of moisture, and high temperature. Benefiting from this particular structure, the Ru/Ce@Co (5:95) catalyst with more Ce3+ species leads to the Ru species being anchored more firmly on the CeO2 surface with a low-valent state and has a strong potential for adsorption and activation of propane and oxygen, which is beneficial for RuOx species with high activity and stability. This work provides a novel strategy for designing high-efficiency Ru-based catalysts for the catalytic combustion of short carbon alkanes.

Ru-Cu Nanoheterostructures for Efficient Hydrogen Evolution Reaction in Alkaline Water Electrolyzers

Combining multiple species working in tandem for different hydrogen evolution reaction (HER) steps is an effective strategy to design HER electrocatalysts. Here, we engineered a hierarchical electrode for the HER composed of amorphous-TiO2/Cu nanorods (NRs) decorated with cost-effective Ru-Cu nanoheterostructures (Ru mass loading = 52 μg/cm2). Such an electrode exhibits a stable, over 250 h, low overpotential of 74 mV at -200 mA/cm2 for the HER in 1 M NaOH. The high activity of the electrode is attributed, by structural analysis, operando X-ray absorption spectroscopy, and first-principles simulations, to synergistic functionalities: (1) mechanically robust, vertically aligned Cu NRs with high electrical conductivity and porosity provide fast charge and gas transfer channels; (2) the Ru electronic structure, regulated by the size of Cu clusters at the surface, facilitates the water dissociation (Volmer step); (3) the Cu clusters grown atop Ru exhibit a close-to-zero Gibbs free energy of the hydrogen adsorption, promoting fast Heyrovsky/Tafel steps. An alkaline electrolyzer (AEL) coupling the proposed cathode and a stainless-steel anode can stably operate in both continuous (1 A/cm2 for over 200 h) and intermittent modes (accelerated stress tests). A techno-economic analysis predicts the minimal overall hydrogen production cost of US$2.12/kg in a 1 MW AEL plant of 30 year lifetime based on our AEL single cell, hitting the worldwide targets (US$2-2.5/kgH2).

Selective Reduction of NO into N2 Catalyzed by Rh1-Doped Cluster Anions RhCe2O3-5. J Am Chem Soc 2023;145:18658-18667. [PMID: 37572057 DOI: 10.1021/jacs.3c06565]

Catalytic conversion of toxic nitrogen oxide (NO) and carbon monoxide (CO) into nitrogen (N2) and carbon dioxide (CO2) is imperative under the weight of the increasingly stringent emission regulations, while a fundamental understanding of the nature of the active site to selectively drive N2 generation is elusive. Herein, in combination with state-of-the-art mass-spectrometric experiments and quantum-chemical calculations, we demonstrated that the rhodium-cerium oxide clusters RhCe2O3-5- can catalytically drive NO reduction by CO and give rise to N2 and CO2. This finding represents a sharp improvement in cluster science where N2O is commonly produced in the rarely established examples of catalytic NO reduction mediated with gas-phase clusters. We demonstrated the importance of the unique chemical environment in the RhCe2O3- cluster to guide the substantially improved N2 selectivity: a triatomic Lewis "acid-base-acid" Ceδ+-Rhδ--Ceδ+ site is proposed to strongly adsorb two NO molecules as well as the N2O intermediate that is attached on the Rh atom and can facilely dissociate to form N2 assisted by both Ce atoms.

Reverse oxygen spillover triggered by CO adsorption on Sn-doped Pt/TiO2 for low-temperature CO oxidation

The spillover of oxygen species is fundamentally important in redox reactions, but the spillover mechanism has been less understood compared to that of hydrogen spillover. Herein Sn is doped into TiO₂ to activate low-temperature (<100 °C) reverse oxygen spillover in Pt/TiO₂ catalyst, leading to CO oxidation activity much higher than that of most oxide-supported Pt catalysts. A combination of near-ambient-pressure X-ray photoelectron spectroscopy, in situ Raman/Infrared spectroscopies, and ab initio molecular dynamics simulations reveal that the reverse oxygen spillover is triggered by CO adsorption at Pt²⁺ sites, followed by bond cleavage of Ti-O-Sn moieties nearby and the appearance of Pt⁴⁺ species. The O in the catalytically indispensable Pt-O species is energetically more favourable to be originated from Ti-O-Sn. This work clearly depicts the interfacial chemistry of reverse oxygen spillover that is triggered by CO adsorption, and the understanding is helpful for the design of platinum/titania catalysts suitable for reactions of various reactants.

Progress on metal-support interactions in Pd-based catalysts for automobile emission control

The interactions between metals and oxide supports, so-called metal-support interactions (MSI), are of great importance in heterogeneous catalysis. Pd-based automotive exhaust control catalysts, especially Pd-based three-way catalysts (TWCs), have received considerable research attention owing to its prominent oxidation activity of HCs/CO, as well as excellent thermal stability. For Pd-based TWCs, the dispersion, chemical state and thermal stability of Pd species, which are crucial to the catalytic performance, are closely associated with interactions between metal nanoparticles and their supporting matrix. Progress on the research about MSI and utilization of MSI in advanced Pd-based three-way catalysts are reviewed here. Along with the development of advanced synthesis approaches and engine control technology, the study on MSI would play a notable role in further development of catalysts for automobile exhaust control.

Isolating Contiguous Ir Atoms and Forming Ir-W Intermetallics with Negatively Charged Ir for Efficient NO Reduction by CO

The lack of efficient catalysts with a wide working temperature window and vital O₂ and SO₂ resistance for selective catalytic reduction of NO by CO (CO-SCR) largely hinders its implementation. Here, a novel Ir-based catalyst with only 1 wt% Ir loading is reported for efficient CO-SCR. In this catalyst, contiguous Ir atoms are isolated into single atoms, and Ir-W intermetallic nanoparticles are formed, which are supported on ordered mesoporous SiO₂ (KIT-6). Notably, this catalyst enables complete NO conversion to N₂ at 250 °C in the presence of 1% O₂ and has a wide temperature window (250-400 °C), outperforming the comparison samples with Ir isolated-single-atomic-sites and Ir nanoparticles, respectively. Also, it possesses a high SO₂ tolerance. Both experimental results and theoretical calculations reveal that single Ir atoms are negatively charged, dramatically enhancing the NO dissociation, while the Ir-W intermetallic nanoparticles accelerate the reduction of the N₂ O and NO₂ intermediates by CO.

High-Entropy-Alloy Nanocrystal Based Macro- and Mesoporous Materials

High-entropy-alloy (HEA) nanoparticles are attractive for several applications in catalysis and energy. Great efforts are currently devoted to establish composition-property relationships to improve catalytic activity or selectivity. Equally importantly, developing practical fabrication methods for shaping HEA-based materials into complex architectures is a key requirement for their utilization in catalysis. However, shaping nano-HEAs into hierarchical structures avoiding demixing or collapse remains a great challenge. Herein, we overcome this issue by introducing a simple soft-chemistry route to fabricate ordered macro- and mesoporous materials based on HEA nanoparticles, with high surface area, thermal stability, and catalytic activity toward CO oxidation. The process is based on spray-drying from an aqueous solution containing five different noble metal precursors and polymer latex beads. Upon annealing, the polymer plays a double role: templating and reducing agent enabling formation of HEA nanoparticle-based porous networks at only 350 °C. The formation mechanism and the stability of the macro- and mesoporous materials were investigated by a set of in situ characterization techniques; notably, in situ transmission electron microscopy unveiled that the porous structure is stable up to 800 °C. Importantly, this process is green, scalable, and versatile and could be potentially extended to other classes of HEA materials.

Catalysis of Alloys: Classification, Principles, and Design for a Variety of Materials and Reactions

Alloying has long been used as a promising methodology to improve the catalytic performance of metallic materials. In recent years, the field of alloy catalysis has made remarkable progress with the emergence of a variety of novel alloy materials and their functions. Therefore, a comprehensive disciplinary framework for catalytic chemistry of alloys that provides a cross-sectional understanding of the broad research field is in high demand. In this review, we provide a comprehensive classification of various alloy materials based on metallurgy, thermodynamics, and inorganic chemistry and summarize the roles of alloying in catalysis and its principles with a brief introduction of the historical background of this research field. Furthermore, we explain how each type of alloy can be used as a catalyst material and how to design a functional catalyst for the target reaction by introducing representative case studies. This review includes two approaches, namely, from materials and reactions, to provide a better understanding of the catalytic chemistry of alloys. Our review offers a perspective on this research field and can be used encyclopedically according to the readers' individual interests.

Dispersion and stability mechanism of Pt nanoparticles on transition-metal oxides

The heterogeneous catalysts of Pt/transition-metal oxides are typically synthesized through calcination at 500 °C, and Pt nanoparticles are uniformly and highly dispersed when hydrogen peroxide (H₂O₂) is applied before calcination. The influence of H₂O₂ on the dispersion and the stability of Pt nanoparticles on titania-incorporated fumed silica (Pt/Ti-FS) supports was examined using X-ray absorption fine structure (XAFS) measurements at the Pt L₃ and Ti K edges as well as density functional theory (DFT) calculations. The local structural and chemical properties around Pt and Ti atoms of Pt/Ti-FS with and without H₂O₂ treatment were monitored using in-situ XAFS during heating from room temperature to 500 °C. XAFS revealed that the Pt nanoparticles of H₂O₂-Pt/Ti-FS are highly stable and that the Ti atoms of H₂O₂-Pt/Ti-FS support form into a distorted-anatase TiO₂. DFT calculations showed that Pt atoms bond more stably to oxidized-TiO₂ surfaces than they do to bare- and reduced-TiO₂ surfaces. XAFS measurements and DFT calculations clarified that the presence of extra oxygen atoms due to the H₂O₂ treatment plays a critical role in the strong bonding of Pt atoms to TiO₂ surfaces.

Dual-Site Single-Atom Catalysts with High Performance for Three-Way Catalysis

In response to growing levels of air pollution and emission regulations, novel three-way catalysts (TWCs) with high efficiency are highly coveted. Herein, a multi-step heating strategy to fabricate a unique dual-site catalyst composed of strongly coupled Pt and Pd atoms located in neighboring positions on the surface of CeO₂ is demonstrated. Outstanding three-way catalytic performance is demonstrated, especially for NO elimination. Based on comprehensive investigations, the enhancement is attributed to the strong interactions between the neighboring Pt and Pd atoms, which can separately serve as active sites for CO and NO adsorption, efficiently reducing the energy barrier and accelerating the reaction rate. These findings not only contribute to designing and constructing next-generation catalysts, but also provide a promising opportunity to improve fuel efficiency and control emissions.

Challenging Conditions for Gasoline Particulate Filters (GPFs)

The emission limit of non-volatile particles (i.e., particles that do not evaporate at 350 °C) with size >23 nm, in combination with the real driving emissions (RDE) regulation in 2017, resulted in the introduction of gasoline particulate filters (GPFs) in all light-duty vehicles with gasoline direct injection engines in Europe. Even though there are studies that have examined the particulate emissions at or beyond the current RDE boundary conditions, there is a lack of studies combining most or all worst cases (i.e., conditions that increase the emissions). In this study, we challenged a fresh (i.e., no accumulation of soot or ash) “advanced” prototype GPF at different temperatures (down to −9 °C), aggressive drive cycles and hard accelerations (beyond the RDE limits), high payload (up to 90%), use of all auxiliaries (air conditioning, heating of the seats and the rear window), and cold starts independently or simultaneously. Under hot engine conditions, the increase of the particulate emissions due to higher payload and lower ambient temperature was 30–90%. The cold start at low ambient temperature, however, had an effect on the emissions of up to a factor of 20 for particles >23 nm or 300 when considering particles <23 nm. We proposed that the reason for these high emissions was the incomplete combustion and the low efficiency of the three-way oxidation catalyst. This resulted in a high concentration of species that were in the gaseous phase at the high temperature of the close-coupled GPF and thus could not be filtered by the GPF. As the exhaust gas cooled down, these precursor species formed particles that could not be evaporated at 350 °C (the temperature of the particle number system). These results highlight the importance of the proper calibration of the engine out emissions at all conditions, even when a GPF is installed.

Opportunities and challenges in the development of advanced materials for emission control catalysts

Advances in engine technologies are placing additional demands on emission control catalysts, which must now perform at lower temperatures, but at the same time be robust enough to survive harsh conditions encountered in engine exhaust. In this Review, we explore some of the materials concepts that could revolutionize the technology of emission control systems. These include single-atom catalysts, two-dimensional materials, three-dimensional architectures, core@shell nanoparticles derived via atomic layer deposition and via colloidal synthesis methods, and microporous oxides. While these materials provide enhanced performance, they will need to overcome many challenges before they can be deployed for treating exhaust from cars and trucks. We assess the state of the art for catalysing reactions related to emission control and also consider radical breakthroughs that could potentially completely transform this field.

Improved Pd/CeO2 Catalysts for Low-Temperature NO Reduction: Activation of CeO2 Lattice Oxygen by Fe Doping

Developing better three-way catalysts with improved low-temperature performance is essential for cold start emission control. Density functional theory in combination with microkinetics simulations is used to predict reactivity of CO/NO/H2 mixtures on a small Pd cluster on CeO2(111). At low temperatures, N2O formation occurs via a N2O2 dimer over metallic Pd3. Part of the N2O intermediate product re-oxidizes Pd, limiting NO conversion and requiring rich conditions to obtain high N2 selectivity. High N2 selectivity at elevated temperatures is due to N2O decomposition on oxygen vacancies. Doping CeO2 by Fe is predicted to lead to more oxygen vacancies and a higher N2 selectivity, which is validated by the lower onset of N2 formation for a Pd catalyst supported on Fe-doped CeO2 prepared by flame spray pyrolysis. Activating ceria surface oxygen by transition metal doping is a promising strategy to improve the performance of three-way catalysts.

Single atom catalysis poised to transition from an academic curiosity to an industrially relevant technology

During the past decade, initial skepticism rapidly changed into widespread recognition of the role of single atoms in heterogeneous catalysts. The next decade could usher in the era of industrial applications as manufacturing of durable single atom catalysts is perfected.

The Hydrothermal Stability and the Properties of Non- and Strongly-Interacting Rh Species over Rh/γ, θ-Al2O3 Catalysts

The present work reports the effects of γ-, θ-phase of alumina on the hydrothermal stability and the properties of non- and strongly-interacting Rh species of the Rh/Al2O3 catalysts. Comparing to γ-Al2O3, θ-Al2O3 can not only reduce the amount of occluded Rh but also better stabilize Rh during hydrothermal aging treatment. When the aging time was prolonged to 70 h, all the non-interacting Rh was transformed into strongly-interacting Rh and occluded Rh. The XPS results indicated that non- and strongly-interacting Rh might exist in the form of Rh/Rh3+ and Rh4+, respectively. CO-NO reaction was chosen as a probe reaction to research more information about non- and strongly-interacting Rh. The two Rh species had similar apparent activation energy (Eapp) of 170 kJ/mol, which indicated that non- and strongly-interacting Rh follow the same reaction path. The non-interacting Rh was removed from aged samples by the acid-treated method, and obtained results showed that only 2.5% and 4.0% non-interacting Rh was maintained in aged Rh/γ-Al2O3 and Rh/θ-Al2O3.

Activation of subnanometric Pt on Cu-modified CeO2 via redox-coupled atomic layer deposition for CO oxidation

Improving the low-temperature activity (below 100 °C) and noble-metal efficiency of automotive exhaust catalysts has been a continuous effort to eliminate cold-start emissions, yet great challenges remain. Here we report a strategy to activate the low-temperature performance of Pt catalysts on Cu-modified CeO2 supports based on redox-coupled atomic layer deposition. The interfacial reducibility and structure of composite catalysts have been precisely tuned by oxide doping and accurate control of Pt size. Cu-modified CeO2-supported Pt sub-nanoclusters demonstrate a remarkable performance with an onset of CO oxidation reactivity below room temperature, which is one order of magnitude more active than atomically-dispersed Pt catalysts. The Cu-O-Ce site with activated lattice oxygen anchors deposited Pt sub-nanoclusters, leading to a moderate CO adsorption strength at the interface that facilitates the low-temperature CO oxidation performance.

Surface oxygenation of multicomponent nanoparticles toward active and stable oxidation catalysts

The need for active and stable oxidation catalysts is driven by the demands in production of valuable chemicals, remediation of hydrocarbon pollutants and energy sustainability. Traditional approaches focus on oxygen-activating oxides as support which provides the oxygen activation at the catalyst-support peripheral interface. Here we report a new approach to oxidation catalysts for total oxidation of hydrocarbons (e.g., propane) by surface oxygenation of platinum (Pt)-alloyed multicomponent nanoparticles (e.g., platinum-nickel cobalt (Pt-NiCo)). The in-situ/operando time-resolved studies, including high-energy synchrotron X-ray diffraction and diffuse reflectance infrared Fourier transform spectroscopy, demonstrate the formation of oxygenated Pt-NiOCoO surface layer and disordered ternary alloy core. The results reveal largely-irregular oscillatory kinetics associated with the dynamic lattice expansion/shrinking, ordering/disordering, and formation of surface-oxygenated sites and intermediates. The catalytic synergy is responsible for reduction of the oxidation temperature by ~100 °C and the high stability under 800 °C hydrothermal aging in comparison with Pt, and may represent a paradigm shift in the design of self-supported catalysts.

Block-Co-polymer-Assisted Synthesis of All Inorganic Highly Porous Heterostructures with Highly Accessible Thermally Stable Functional Centers

Here, we propose a simple approach for the design of highly porous multicomponent heterostructures by infiltration of block-co-polymer templates with inorganic precursors in swelling solvents followed by gas-phase sequential infiltration synthesis and thermal annealing. This approach can prepare conformal coatings, free-standing membranes, and powders consisting of uniformly sized metal or metal oxide nanoparticles (NPs) well dispersed in a porous oxide matrix. We employed this new, versatile synthetic concept to synthesize catalytically active heterostructures of uniformly dispersed ∼4.3 nm PdO nanoparticles accessible through three-dimensional pore networks of the alumina support. Importantly, such materials reveal high resistance against sintering at 800 °C, even at relatively high loadings of NPs (∼10 wt %). At the same time, such heterostructures enable high mass transport due to highly interconnected nature of the pores. The surface of synthesized nanoparticles in the porous matrix is highly accessible, which enables their good catalytic performance in methane and carbon monoxide oxidation. In addition, we demonstrate that this approach can be utilized to synthesize heterostructures consisting of different types of NPs on a highly porous support. Our results show that swelling-based infiltration provides a promising route toward the robust and scalable synthesis of multicomponent structures.