Sintering-Resistant Nanoparticles in Wide-Mouthed Compartments for Sustained Catalytic Performance

Unveiling the Stability of Encapsulated Pt Catalysts Using Nanocrystals and Atomic Layer Deposition

Platinum exhibits desirable catalytic properties, but it is scarce and expensive. Optimizing its use in key applications such as emission control catalysis is important to reduce our reliance on such a rare element. Supported Pt nanoparticles (NPs) used in emission control systems deactivate over time because of particle growth in sintering processes. In this work, we shed light on the stability against sintering of Pt NPs supported on and encapsulated in Al2O3 using a combination of nanocrystal catalysts and atomic layer deposition (ALD) techniques. We find that small amounts of alumina overlayers created by ALD on preformed Pt NPs can stabilize supported Pt catalysts, significantly reducing deactivation caused by sintering, as previously observed by others. Combining theoretical and experimental insights, we correlate this behavior to the decreased propensity of oxidized Pt species to undergo Ostwald ripening phenomena because of the physical barrier imposed by the alumina overlayers. Furthermore, we find that highly stable catalysts can present an abundance of under-coordinated Pt sites after restructuring of both Pt particles and alumina overlayers at a high temperature (800 °C) in C3H6 oxidation conditions. The enhanced stability significantly improves the Pt utilization efficiency after accelerated aging treatments, with encapsulated Pt catalysts reaching reaction rates more than two times greater than those of a control supported Pt catalyst.

Dynamic Copper Site Redispersion through Atom Trapping in Zeolite Defects

Single-site copper-based catalysts have shown remarkable activity and selectivity for a variety of reactions. However, deactivation by sintering in high-temperature reducing environments remains a challenge and often limits their use due to irreversible structural changes to the catalyst. Here, we report zeolite-based copper catalysts in which copper oxide agglomerates formed after reaction can be repeatedly redispersed back to single sites using an oxidative treatment in air at 550 °C. Under different environments, single-site copper in Cu-Zn-Y/deAlBeta undergoes dynamic changes in structure and oxidation state that can be tuned to promote the formation of key active sites while minimizing deactivation through Cu sintering. For example, single-site Cu2+ reduces to Cu1+ after catalyst pretreatment (270 °C, 101 kPa H2) and further to Cu0 nanoparticles under reaction conditions (270-350 °C, 7 kPa EtOH, 94 kPa H2) or accelerated aging (400-450 °C, 101 kPa H2). After regeneration at 550 °C in air, agglomerated CuO was dispersed back to single sites in the presence and absence of Zn and Y, which was verified by imaging, in situ spectroscopy, and catalytic rate measurements. Ab initio molecular dynamics simulations show that solvation of CuO monomers by water facilitates their transport through the zeolite pore, and condensation of the CuO monomer with a fully protonated silanol nest entraps copper and reforms the single-site structure. The capability of silanol nests to trap and stabilize copper single sites under oxidizing conditions could extend the use of single-site copper catalysts to a wider variety of reactions and allows for a simple regeneration strategy for copper single-site catalysts.

Nested Metal Catalysts: Metal Atoms and Clusters Stabilized by Confinement with Accessibility on Supports

Supported catalysts that are important in technology prominently include atomically dispersed metals and metal clusters. When the metals are noble, they are typically unstable-susceptible to sintering-especially under reducing conditions. Embedding the metals in supports such as organic polymers, metal oxides, and zeolites confers stability on the metals but at the cost of catalytic activity associated with the lack of accessibility of metal bonding sites to reactants. An approach to stabilizing noble metal catalysts while maintaining their accessibility involves anchoring them in molecular-scale nests that are in or on supports. The nests include zeolite pore mouths, zeolite surface cups (half-cages), raft-like islands of oxophilic metals bonded to metal oxide supports, clusters of non-noble metals (e.g., hosting noble metals as single-atom alloys), and nanoscale metal oxide islands that selectively bond to the catalytic metals, isolating them from the support. These examples illustrate a trend toward precision in the synthesis of solid catalysts, and the latter two classes of nested catalysts offer realistic prospects for economical large-scale application.

Synthesis of Highly Tunable Alloy Nanocatalyst through Heterogeneous Doping Method

The combination of supported metal nanoparticles and functional host oxides catalyze many major industrial reactions. However, uniform dispersion and ideal chemical configuration of such nanoparticles, which determines the catalytic activity, are often difficult to achieve. In this study, a unique combination is proposed of heterogeneous doping and ex-solution for the fabrication of Pt-Ni alloy nanoparticles on CeO₂ . By manipulating the reducing conditions, both the particle size and composition are precisely controlled, thereby achieving a highly dispersed and stable alloy nanocatalyst. The unique behavior of controlled alloy composition is elucidated through classical diffusion and precipitation kinetics with elemental analysis of the grain boundaries. Finally, Pt-Ni alloy nanocatalysts are successfully tuned showcasing a breakthrough performance compared to single element catalyst in reverse water gas shift reaction with superior stability and reproducibility.

Solid-State Reaction Synthesis of Nanoscale Materials: Strategies and Applications

Nanomaterials (NMs) with unique structures and compositions can give rise to exotic physicochemical properties and applications. Despite the advancement in solution-based methods, scalable access to a wide range of crystal phases and intricate compositions is still challenging. Solid-state reaction (SSR) syntheses have high potential owing to their flexibility toward multielemental phases under feasibly high temperatures and solvent-free conditions as well as their scalability and simplicity. Controlling the nanoscale features through SSRs demands a strategic nanospace-confinement approach due to the risk of heat-induced reshaping and sintering. Here, we describe advanced SSR strategies for NM synthesis, focusing on mechanistic insights, novel nanoscale phenomena, and underlying principles using a series of examples under different categories. After introducing the history of classical SSRs, key theories, and definitions central to the topic, we categorize various modern SSR strategies based on the surrounding solid-state media used for nanostructure growth, conversion, and migration under nanospace or dimensional confinement. This comprehensive review will advance the quest for new materials design, synthesis, and applications.

One-Step Solvothermal Synthesis of Ni Nanoparticle Catalysts Embedded in ZrO2 Porous Spheres to Suppress Carbon Deposition in Low-Temperature Dry Reforming of Methane

Ni nanoparticle catalysts embedded in ZrO₂ porous spheres and ZrO₂ porous composite spheres, SiO₂-ZrO₂, MgO-ZrO₂, and Y₂O₃-ZrO₂, with 83-115 nm diameter and 167-269 m²/g specific surface area were prepared by a one-pot and one-step solvothermal reaction from precursor solutions consisting of Ni(NO₃)₂‧6H₂O, Zr(OⁿBu)₄, and acetylacetone in moist ethanol combined with either Si(OEt)₄, magnesium acetylacetate, or Y(OⁱPr)₃. The obtained Ni catalysts have high specific surface areas of 130-196 m²/g, even after high-temperature reduction by H₂ at 450 °C for 2 h. They were utilized as catalysts for low-temperature dry reforming of methane (DRM) at 550 °C to suppress carbon deposition on Ni nanoparticles. The Ni catalysts embedded in SiO₂-ZrO₂ and Y₂O₃-ZrO₂ demonstrated high catalytic activity and long stability in the reaction. Moreover, carbon deposition on Ni nanoparticles in the DRM reaction was effectively suppressed in when using the SiO₂-ZrO₂ and Y₂O₃-ZrO₂ composites.

Highly Active CuO/KCC−1 Catalysts for Low-Temperature CO Oxidation

Copper catalysts have been extensively studied for CO oxidation at low temperatures. Previous findings on the stability of such catalysts, on the other hand, revealed that they deactivated badly under extreme circumstances. Therefore, in this work, a series of KCC−1-supported copper oxide catalysts were successfully prepared by impregnation method, of which 5% CuO/KCC−1 exhibited the best activity: CO could be completely converted at 120 °C. The 5% CuO/KCC−1 catalyst exhibited better thermal stability, which is mainly attributed to the large specific surface area of KCC−1 that facilitates the high dispersion of CuO species, and because the dendritic layered walls can lengthen the movement distances from particle-to-particle, thus helping to slow down the tendency of active components to sinter. In addition, the 5% CuO/KCC−1 has abundant mesoporous and surface active oxygen species, which are beneficial to the mass transfer and promote the adsorption of CO and the decomposition of Cu+–CO species, thus improving the CO oxidation performance of the catalyst.

Quantification of critical particle distance for mitigating catalyst sintering

Supported metal nanoparticles are of universal importance in many industrial catalytic processes. Unfortunately, deactivation of supported metal catalysts via thermally induced sintering is a major concern especially for high-temperature reactions. Here, we demonstrate that the particle distance as an inherent parameter plays a pivotal role in catalyst sintering. We employ carbon black supported platinum for the model study, in which the particle distance is well controlled by changing platinum loading and carbon black supports with varied surface areas. Accordingly, we quantify a critical particle distance of platinum nanoparticles on carbon supports, over which the sintering can be mitigated greatly up to 900 °C. Based on in-situ aberration-corrected high-angle annular dark-field scanning transmission electron and theoretical studies, we find that enlarging particle distance to over the critical distance suppress the particle coalescence, and the critical particle distance itself depends sensitively on the strength of metal-support interactions.

Deactivation of supported metal catalysts via thermally induced sintering is a major concern in the catalysis community. Here, the authors demonstrate that enlarging particle distance to over the critical distance could suppress the particle coalescence greatly up to 900 °C.

Size-controlled nanocrystals reveal spatial dependence and severity of nanoparticle coalescence and Ostwald ripening in sintering phenomena

A major aim in the synthesis of nanomaterials is the development of stable materials for high-temperature applications. Although the thermal coarsening of small and active nanocrystals into less active aggregates is universal in material deactivation, the atomic mechanisms governing nanocrystal growth remain elusive. By utilizing colloidally synthesized Pd/SiO2 powder nanocomposites with controlled nanocrystal sizes and spatial arrangements, we unravel the competing contributions of particle coalescence and atomic ripening processes in nanocrystal growth. Through the study of size-controlled nanocrystals, we can uniquely identify the presence of either nanocrystal dimers or smaller nanoclusters, which indicate the relative contributions of these two processes. By controlling and tracking the nanocrystal density, we demonstrate the spatial dependence of nanocrystal coalescence and the spatial independence of Ostwald (atomic) ripening. Overall, we prove that the most significant loss of the nanocrystal surface area is due to high-temperature atomic ripening. This observation is in quantitative agreement with changes in the nanocrystal density produced by simulations of atomic exchange. Using well-defined colloidal materials, we extend our analysis to explain the unusual high-temperature stability of Au/SiO2 materials up to 800 °C.

Exceptionally stable sol-immobilization derived Pd/SBA-15 catalysts for methane combustion

Pd/SBA-15-SI catalysts are more efficient for methane combustion than Pd/SBA-15-IWI catalysts due to anti-sintering property of the catalysts.

Spiky-shaped niobium pentoxide nano-architecture: highly stable and recoverable Lewis acid catalyst

Niobium pentoxide particles with a complex three-dimensional (3D) nanostructure consisting of a spiky structure have been developed as recyclable and recoverable Lewis acid catalysts. The morphology of the niobium pentoxide was successfully controlled from 1D to 3D via a bridging-ligand-assisted hydrothermal treatment, without changing the crystal structure. Compared with dispersed one-dimensional (1D) niobium pentoxide nanorods with a major-axis length and minor-axis length of 20 nm and 5-8 nm, respectively, the spiky-shaped niobium pentoxide composed of 300 nm spherical cores and nanorods with a minor-axis length of 5 nm maintained its surface nanostructure even after calcination at 400 °C in air. The 400 °C-calcined spiky particles exhibited the highest production rate of 2-((4-methoxyphenyl)amino)-2-phenylacetonitrile (0.115 mmol m^-2) in a Strecker reaction, resulting in a nanoscale and ordered surface structure of spiky particles that simultaneously exhibit high specific reactivity and high structural stability. Acid site analysis and Raman spectroscopy revealed that stable nanorods that grew in the (001) orientation functioned as Lewis acid catalysts and that the origin of the acidity was a flexible Nb-O polyhedral structure in the single-nanoscale (<10 nm) niobium oxide rods. This study proposes that the spiky-shaped niobium pentoxide exhibits sintering resistivity and high activity and has potential applications as a recoverable and recyclable solid acid catalyst.

A Comprehensive Review of the Applications of Hierarchical Zeolite Nanosheets and Nanoparticle Assemblies in Light Olefin Production

Light olefins including ethylene, propylene and butylene are important building blocks in petrochemical industries to produce various chemicals such as polyethylene, polypropylene, ethylene oxide and cumene. Traditionally, light olefins are produced via a steam cracking process operated at an extremely high temperature. The catalytic conversion, in which zeolites have been widely used, is an alternative pathway using a lower temperature. However, conventional zeolites, composed of a pure microporous structure, restrict the diffusion of large molecules into the framework, resulting in coke formation and further side reactions. To overcome these problems, hierarchical zeolites composed of additional mesoporous and/or macroporous structures have been widely researched over the past decade. In this review, the recent development of hierarchical zeolite nanosheets and nanoparticle assemblies together with opening up their applications in various light olefin productions such as catalytic cracking, ethanol dehydration to ethylene, methanol to olefins (MTO) and other reactions will be presented.

Highly dispersed cobalt Fischer–Tropsch synthesis catalysts supported on γ-Al2O3, CNTs, and graphene nanosheet using chemical vapor deposition

Highly dispersed 15.0 wt% cobalt catalysts were prepared on γ-Al2O3, carbon nanotubes (CNTs), and graphene nanosheet (GNS) using chemical vapor deposition (CVD) procedure. The physico-chemical properties of the catalysts were studied by inductively coupled plasma (ICP), Brunauer–Emmett–Teller (BET), X-ray powder diffraction (XRD), field-emission scanning electron microscopy (FESEM), and temperature-programmed reduction (TPR) techniques, and the Fischer–Tropsch synthesis (FTS) performance of the catalysts was assessed at 220 °C, 18 bar, H2/CO = 2 and feed flow rate of 45 ml/min g cat. Based on BET results, Co/GNS catalyst provided highest surface area in comparison to the other catalysts. XRD and FESEM results revealed that CVD method prepared smaller particles on GNS compared to the other supports and resulted in the most dispersed metal particles on GNS according to H2-chemisorption results. The performance of Co/Al2O3 catalyst prepared by CVD method was compared with conventional 15 wt% Co/Al2O3 catalyst prepared by impregnation method. The Co/Al2O3 catalyst prepared with CVD method showed 5.3% higher %CO conversion and 2.1% lower C5+ selectivity as compared with the Co/Al2O3 catalysts prepared by impregnation method. Among three catalysts prepared by CVD, Co/GNS showed higher %CO conversion of 78.4% and C5+ selectivity of 70.3%. Co/γ-Al2O3 catalyst showed higher stability.

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.

Transformation of Stöber Silica Spheres to Hollow Hierarchical Single-Crystal ZSM-5 Zeolites with Encapsulated Metal Nanocatalysts for Selective Catalysis

The activity of zeolite-supported nanocatalysts is dependent on both the dispersion, size, and location of metal nanoparticles around the zeolite and the size and pore structure of the zeolite. In this study, a synthetic approach was developed to encapsulate metal catalysts within hollow interiors of single-crystal ZSM-5. Briefly, Stöber silica spheres were synthesized and then transformed to single-crystal nano-ZSM-5 (Si/Al = 60), followed by growth of embedded metal nanoparticles and subsequently creation of a nanosized (30-50 nm shell thickness) hollow hierarchical zeolite structure. Metal nanoparticles such as Co, Cu, Cu-Zn, Fe, and Ni can be supported on the inner wall of the hollow zeolite and the surrounding satellite mesopores, without any particles present on the external zeolite surface. When evaluated as a catalyst for the Fischer-Trøpsch reaction, the Fe@h-ZSM5 catalyst shows high activity, sintering and coking resistance (50% longer stability than Fe@ZSM5), and secondary cracking reactions in the acid sites in the ZSM-5 shell, which reduce C₅₊ hydrocarbon selectivity and increase smaller-chain hydrocarbon selectivity. In addition, when Pt was further deposited inside the hollow structure, shape-selective alkene hydrogenation was demonstrated. These configured nanoscale zeolite catalysts have potential applications for reactions that involve supported metal nanoparticle catalysis, shape selectivity, or secondary cracking reactions.

Taming the stability of Pd active phases through a compartmentalizing strategy toward nanostructured catalyst supports

The design and synthesis of robust sintering-resistant nanocatalysts for high-temperature oxidation reactions is ubiquitous in many industrial catalytic processes and still a big challenge in implementing nanostructured metal catalyst systems. Herein, we demonstrate a strategy for designing robust nanocatalysts through a sintering-resistant support via compartmentalization. Ultrafine palladium active phases can be highly dispersed and thermally stabilized by nanosheet-assembled γ-Al₂O₃ (NA-Al₂O₃) architectures. The NA-Al₂O₃ architectures with unique flowerlike morphologies not only efficiently suppress the lamellar aggregation and irreversible phase transformation of γ-Al₂O₃ nanosheets at elevated temperatures to avoid the sintering and encapsulation of metal phases, but also exhibit significant structural advantages for heterogeneous reactions, such as fast mass transport and easy access to active sites. This is a facile stabilization strategy that can be further extended to improve the thermal stability of other Al₂O₃-supported nanocatalysts for industrial catalytic applications, in particular for those involving high-temperature reactions.

The design and synthesis of robust sintering-resistant nanocatalysts for high-temperature oxidation reactions remains challenging, even though the strategy of metal-support interactions has been extensively used. Here, the authors demonstrate an alternative strategy for designing robust nanocatalysts through a sintering-resistant support.

Self-assembly as a key player for materials nanoarchitectonics

The development of science and technology of advanced materials using nanoscale units can be conducted by a novel concept involving combination of nanotechnology methodology with various research disciplines, especially supramolecular chemistry. The novel concept is called 'nanoarchitectonics' where self-assembly processes are crucial in many cases involving a wide range of component materials. This review of self-assembly processes re-examines recent progress in materials nanoarchitectonics. It is composed of three main sections: (1) the first short section describes typical examples of self-assembly research to outline the matters discussed in this review; (2) the second section summarizes self-assemblies at interfaces from general viewpoints; and (3) the final section is focused on self-assembly processes at interfaces. The examples presented demonstrate the strikingly wide range of possibilities and future potential of self-assembly processes and their important contribution to materials nanoarchitectonics. The research examples described in this review cover variously structured objects including molecular machines, molecular receptors, molecular pliers, molecular rotors, nanoparticles, nanosheets, nanotubes, nanowires, nanoflakes, nanocubes, nanodisks, nanoring, block copolymers, hyperbranched polymers, supramolecular polymers, supramolecular gels, liquid crystals, Langmuir monolayers, Langmuir-Blodgett films, self-assembled monolayers, thin films, layer-by-layer structures, breath figure motif structures, two-dimensional molecular patterns, fullerene crystals, metal-organic frameworks, coordination polymers, coordination capsules, porous carbon spheres, mesoporous materials, polynuclear catalysts, DNA origamis, transmembrane channels, peptide conjugates, and vesicles, as well as functional materials for sensing, surface-enhanced Raman spectroscopy, photovoltaics, charge transport, excitation energy transfer, light-harvesting, photocatalysts, field effect transistors, logic gates, organic semiconductors, thin-film-based devices, drug delivery, cell culture, supramolecular differentiation, molecular recognition, molecular tuning, and hand-operating (hand-operated) nanotechnology.

Nanoarchitectonic-Based Material Platforms for Environmental and Bioprocessing Applications

The challenges of pollution, environmental science, and energy consumption have become global issues of broad societal importance. In order to address these challenges, novel functional systems and advanced materials are needed to achieve high efficiency, low emission, and environmentally friendly performance. A promising approach involves nanostructure-level controls of functional material design through a novel concept, nanoarchitectonics. In this account article, we summarize nanoarchitectonic approaches to create nanoscale platform structures that are potentially useful for environmentally green and bioprocessing applications. The introduced platforms are roughly classified into (i) membrane platforms and (ii) nanostructured platforms. The examples are discussed together with the relevant chemical processes, environmental sensing, bio-related interaction analyses, materials for environmental remediation, non-precious metal catalysts, and facile separation for biomedical uses.

Well-dispersed Ni or MnO nanoparticles on mesoporous carbons: preparation via carbonization of bimetallic MOF-74s for highly reactive redox catalysts

A series of metal-organic framework-74s (MOF-74s), composed of two different metallic species (Zn/Ni or Zn/Mn in various compositions), were synthesized, and Ni or MnO-doped carbonaceous materials were first prepared by pyrolysis of the MOFs under an inert environment for catalytic applications. These MOF-derived nanomaterials (MDNMs), obtained by pyrolysis of MOF-74s, were characterized thoroughly to understand their phase, porosity, particle size, dispersion, and composition. With increasing Zn content in the bimetallic MOF-74s, the porosity of the MDNMs increased but the size and content of Ni or MnO in the MDNMs decreased monotonously. One MDNM(75Zn25Mn), prepared from MOF-74(75%Zn/25%Mn), showed noticeably higher activity in the oxidation of benzyl alcohol as compared with not only the MDNM(xZnyMn)s but also MnOx-loaded carbon or loaded γ-alumina (or, MDNM(75Zn25Mn) showed ∼54 times turnover frequency (TOF) to that of MnO/activated carbon). MDNM(75Zn25Mn) was also effective in the oxidative removal of dibenzothiophene from a model fuel. Moreover, MDNM(75Zn25Ni), prepared from MOF-74(75%Zn/25%Ni), had the highest TOF in the reduction of 4-nitrophenol among various MDNM(xZnyNi)s. The highest activity of MDNM(75Zn25Mn) and MDNM(75Zn25Ni), even with the lowest Mn and Ni contents in the respective MDNMs, for oxidation and reduction in several cycles might be due to the well-dispersed MnO (and Ni) and high porosity with mesopores. Therefore, it can be suggested that pyrolysis of mixed-metal MOFs such as MOF-74s can be a facile way to obtain highly effective and recyclable heterogeneous catalysts, with well-dispersed active species in very small sizes, for various organic reactions.

Catalytic activity of nickel nanoparticles stabilized by adsorbing polymers for enhanced carbon sequestration

This work shows the potential of nickel (Ni) nanoparticles (NPs) stabilized by polymers for accelerating carbon dioxide (CO₂) dissolution into saline aquifers. The catalytic characteristics of Ni NPs were investigated by monitoring changes in diameter of CO₂ microbubbles. An increase in ionic strength considerably reduces an electrostatic repulsive force in pristine Ni NPs, thereby decreasing their catalytic potential. This study shows how cationic dextran (DEX), nonionic poly(vinyl pyrrolidone) (PVP), and anionic carboxy methylcellulose (CMC) polymers, the dispersive behaviors of Ni NPs can be used to overcome the negative impact of salinity on CO₂ dissolution. The cationic polymer, DEX was less adsorbed onto NPs surfaces, thereby limiting the Ni NPs’ catalytic activity. This behavior is due to a competition for Ni NPs’ surface sites between the cation and DEX under high salinity. On the other hand, the non/anionic polymers, PVP and CMC could be relatively easily adsorbed onto anchoring sites of Ni NPs by the monovalent cation, Na⁺. Considerable dispersion of Ni NPs by an optimal concentration of the anionic polymers improved their catalytic capabilities even under unfavorable conditions for CO₂ dissolution. This study has implications for enhancing geologic sequestration into deep saline aquifers for the purposes of mitigating atmospheric CO₂ levels.