Hierarchical zeolite-encapsulated metal nanoparticles for heterogeneous catalysis

Zeolites, characterized by their highly porous structure, have become integral to modern industry and environmental science due to their broad applications in adsorption, separation, and catalysis. Recent advancements in zeolite synthesis, particularly through hydrothermal methods and the incorporation of metal nanoparticles, have significantly expanded their utility. This review delves into the innovative strategies for encapsulating metal nanoparticles within zeolite matrices, enhancing catalytic reactions' efficiency, selectivity, and durability. Challenges such as nanoparticle agglomeration and catalyst deactivation are addressed through hierarchical zeolite encapsulation, which provides a novel route for the development of multifunctional materials. By examining methods ranging from in situ encapsulation to post-synthetic recrystallization, this review highlights the versatility and potential of metal@zeolite catalysts in various applications, including organic synthesis, pollutant treatment, and energy conversion. The review underscores the importance of optimizing the interaction between metal nanoparticles and the zeolite framework to achieve superior catalytic performance, offering new directions for research in catalytic science and industrial process optimization.

Catalytic-Level Identification of Prepared Pt/HY, Pt-Zn/HY, and Pt-Rh/HY Nanocatalysts on the Reforming Reactions of N-Heptane

The operation of reforming catalysts in a fixed bed reactor undergoes a high level of interaction between the operating parameters and the reaction mechanism. Understanding such an interaction reduces the catalyst deactivation rate. In the present work, three kinds of nanocatalysts (i.e., Pt/HY, Pt-Zn/HY, and Pt-Rh/HY) were synthesized. The catalysts’ performances were evaluated for n-heptane reactions in the fixed bed reactor. The operating conditions applied were the following: 1 bar pressure, WHSV of 4, hydrogen/n-heptane ratio of 4, and the reaction temperatures of 425, 450, 475, 500, and 525 °C. The optimal reaction temperature for all three types of nanocatalysts to produce high-quality isomers and aromatic hydrocarbons was 500 °C. Accordingly, the nanocatalyst Pt-Zn/HY provided the highest catalytic selectivity for the desired hydrocarbons. Moreover, the Pt-Zn/HY-nanocatalyst showed more resistance against catalyst deactivation in comparison with the other two types of nanocatalysts (Pt/HY and Pt-Rh/HY). This work offers more understanding for the application of nanocatalysts in the reforming process in petroleum refineries with high performance and economic feasibility.

Metal Sites in Zeolites: Synthesis, Characterization, and Catalysis

Zeolites with ordered microporous systems, distinct framework topologies, good spatial nanoconfinement effects, and superior (hydro)thermal stability are an ideal scaffold for planting diverse active metal species, including single sites, clusters, and nanoparticles in the framework and framework-associated sites and extra-framework positions, thus affording the metal-in-zeolite catalysts outstanding activity, unique shape selectivity, and enhanced stability and recyclability in the processes of Brønsted acid-, Lewis acid-, and extra-framework metal-catalyzed reactions. Especially, thanks to the advances in zeolite synthesis and characterization techniques in recent years, zeolite-confined extra-framework metal catalysts (denoted as metal@zeolite composites) have experienced rapid development in heterogeneous catalysis, owing to the combination of the merits of both active metal sites and zeolite intrinsic properties. In this review, we will present the recent developments of synthesis strategies for incorporating and tailoring of active metal sites in zeolites and advanced characterization techniques for identification of the location, distribution, and coordination environment of metal species in zeolites. Furthermore, the catalytic applications of metal-in-zeolite catalysts are demonstrated, with an emphasis on the metal@zeolite composites in hydrogenation, dehydrogenation, and oxidation reactions. Finally, we point out the current challenges and future perspectives on precise synthesis, atomic level identification, and practical application of the metal-in-zeolite catalyst system.

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.

Highly stable Pt-Co bimetallic catalysts prepared by atomic layer deposition for selective hydrogenation of cinnamaldehyde

Pt-Co bimetallic catalysts were deposited onγ-Al₂O₃nanoparticles by atomic layer deposition (ALD) and were used for selective hydrogenation of cinnamaldehyde (CAL) to cinnamyl alcohol (COL). High resolution transmission electron microscopy, hydrogen temperature-programmed reduction, x-ray diffraction, and x-ray photoelectron spectroscopy were used to identify the strong interaction between Pt and Co. The obtained catalysts with an optimal Pt/Co ratio achieved a COL selectivity of 81.2% with a CAL conversion of 95.2% under mild conditions (i.e., 10 bar H₂and 80 °C). During the CAL hydrogenation, the addition of Co on Pt significantly improved the activity and selectivity due to the synergetic effects of Pt-Co bimetallic catalysts, resulted from the transfer of electrons from Co to Pt, which can stabilize the carbonyl groups. The obtained Pt-Co bimetallic catalysts also showed excellent stability due to the strong interaction between the metal nanoparticles and the alumina support. Negligible losses in the activity and selectivity were observed during the recycling experiments, showing the potential for practical applications.

Insight into different performance of Pt/KL catalysts for n-alkane (C6-C8) aromatization: catalytic role of zeolite channels

Zeolite channel architecture was vital to catalytic activity and products distribution during the naphtha reforming, which could be effectively utilized by designing the locations of active sites. Herein, uniformly dispersed...

Atomic-Scale Designing of Zeolite Based Catalysts by Atomic Layer Deposition

Zeolite-supported catalysts have been widely used in the field of heterogeneous catalysis. Atomic-scale governing the metal or acid sites on zeolites still encounters great challenge in controllable synthesis and developing of novel catalysts. Atomic layer deposition (ALD), owing to its unique character of self-limiting surface reactions, becomes one of the most promising and controllable strategies to tailor the metallic deposition sites in atomic scale precisely. In this review, we present a comprehensive summary and viewpoint of recent research in designing and engineering the structural of zeolite-based catalysts via ALD method. A prior focus is laid on the deposition of metals on the zeolites with emphasis on the isolated states of metals, followed by introducing the selected metals into channels of zeolites associates with identifying the location of metals in and/or out of the channels. Subsequently, detailed analysis of tailoring the acid sites of different zeolites is provided. Assisted synthesis of zeolite and the regioselective deposition of metal on special sites to modify the structures of zeolites are also critically discussed. We further summarize the challenges of ALD with respect to engineering the active sites in heterogeneous zeolite-based catalysts and provide the perspectives on the development in this field.

Elucidating the restructuring-induced highly active bimetallic Pt–Co/KL catalyst for the aromatization of n-heptane

The restructured bimetallic Pt–Co/KL catalyst promotes the aromatization of n-heptane.

Creation of gallium acid and platinum metal sites in bifunctional zeolite hydroisomerization and hydrocracking catalysts by atomic layer deposition

Active sites in bifunctional zeolite catalysts were engineered using atomic layer deposition (ALD). Gallium acid and platinum metal sites were introduced to zeolites via ALD and investigated for a hydroconversion reaction.

Highly Dispersed Single-Atom Pt and Pt Clusters in the Fe-Modified KL Zeolite with Enhanced Selectivity for n-Heptane Aromatization

Conversion of straight-chain paraffins into aromatics is particularly attractive but extremely challenging in the oil refining industry. Constructing the Pt-supported catalysts with high aromatic selectivity is vital. Here, we report a strategy to use Fe-modified KL zeolites to improve the Pt atom utilization efficiency and anchor them inside KL zeolite channels via atomic-layer deposition technique. A combination of highly dispersed single-atom Pt and electron-rich Pt clusters is fabricated on the KL zeolite through the creation of proper nucleation sites. The resulted catalyst (PtFe-1/KL) exhibits excellent performance for the n-heptane aromatization (90.1% aromatic selectivity) with an apparent activation energy of 131 kJ/mol and much enhanced stability at a relatively lower temperature (420 °C). Experimental analysis and density functional theory calculation demonstrate that the single-atom Pt might play a key role in the initial dehydrogenation of n-heptane to 1-heptene, and the superior stable Pt clusters encapsulated inside Fe-decorated KL zeolite channels accelerate the 1-heptene dehydrocyclization to aromatics. The synergetic interaction between single-atom Pt and Pt clusters enables the PtFe-1/KL catalyst to be one of the most effective n-heptane aromatization catalysts reported to date.

Numerical Simulation and Experimental Study on Commercial Diesel Reforming Over an Advanced Pt/Rh Three-Way Catalyst

Hydrocarbon fuel reforming has been proven useful for producing hydrogen that is utilized on road vehicles, but it is associated with reaction mechanism and catalyst characterization. In this study, a reduced mechanism for n-heptane/toluene reforming over an advanced Pt/Rh TWC is adopted to investigate the effects of the reaction conditions on H2 and CO concentrations. The physical and chemical properties of the advanced catalyst are examined using SEM, XRD and XPS analyses. The contrasted experiments are conducted to study the composition variation tendency of the reforming reactor gas product. The results show that the POX reaction is most likely to occur considering the stoichiometric ratio of H2/CO, and other reactions are SR or ATR. The coke formation and carbon deposition occur on the catalyst surface, and the diffraction peaks corresponding to the metallic Pt are observed, while no obvious peaks characteristic of Rh are detected. The characteristics of the concentration trend of n-heptane/toluene reforming can represent H2 and CO yield features of diesel reforming in a way; nevertheless, the difference of the average H2 and CO concentration is remarkable.

New trends in tailoring active sites in zeolite-based catalysts

This review discusses approaches for tailoring active sites in extra-large pore, nanocrystalline, and hierarchical zeolites and their performance in emerging catalytic applications.

Zeolites as Catalysts for Fuels Refining after Indirect Liquefaction Processes

The use of zeolite catalysts for the refining of products from methanol synthesis and Fisher-Tropsch synthesis was reviewed. The focus was on fuels refining processes and differences in the application to indirect liquefaction products was compared to petroleum, which is often a case of managing different molecules. Processes covered were skeletal isomerisation of n-butenes, hydroisomerisation of n-butane, aliphatic alkylation, alkene oligomerisation, methanol to hydrocarbons, ethanol and heavier alcohols to hydrocarbons, carbonyls to hydrocarbons, etherification of alkenes with alcohols, light naphtha hydroisomerisation, catalytic naphtha reforming, hydroisomerisation of distillate, hydrocracking and fluid catalytic cracking. The zeolite types that are already industrially used were pointed out, as well as zeolite types that have future promise for specific conversion processes.

Synthesis of nano-sized LTL zeolite by addition of a Ba precursor with superior n-octane aromatization performance

Nano-sized LTL zeolites obtained by the Ba-assisted method show improved catalytic performance in n-octane aromatization reaction.

Design and Properties of Confined Nanocatalysts by Atomic Layer Deposition

Governing the process and outcome of chemical reactions is the most important aim of catalytic chemistry. The confinement of active sites inside nanosized spaces provides a powerful strategy to achieve this goal. Reacting molecules (reactants, intermediates, and products of a reaction) and nanomaterials (metal/metal-oxide nanoparticles) confined inside nanoreactors have been observed to exhibit modified behaviors and properties with respect to their unconfined counterparts. Typically, catalysts confined in zeolites, mesoporous materials, metal-organic frameworks, and nanotubes are obtained by traditional liquid-phase methods. However, excess metals or undesired solvents and other reagents must be removed. It is also difficult to precisely regulate the confined nanostructures and assemble multifunctional sites in the confined nanospaces. Atomic layer deposition (ALD) provides a controllable method to fabricate confined catalysts due to its outstanding advantages. In this Account, we describe our progress in the design and properties of confined nanocatalysts by ALD. ALD is an elegant method to directly deposit highly dispersed metal or oxide species into porous materials, including zeolites and mesoporous materials. We deposited Pt nanoclusters in the micropores of a KL zeolite with precisely controlled size by ALD. We also introduced CoO_x nanoclusters into mesoporous SBA-15. We have reported pioneering works on the synthesis of confined nanoparticles with metal-in-nanotube structures by a template-assisted ALD method. Confined Cu nanoparticles were prepared by reducing CuO nanowires coated with Al₂O₃, TiO₂, or alucone layers by ALD. Confined Cu and Au nanoparticles were also prepared starting from the corresponding metal nanowires with the assistance of sacrificial layers produced by ALD. In a more facile strategy, Au nanoparticles confined in Al₂O₃ nanotubes were produced using a sacrificial template by ALD. Furthermore, we synthesized a multiply confined Ni-based nanocatalyst through a template-assisted ALD method. We assembled multiple interfaces (Ni/Al₂O₃ and Pt/TiO₂) in a confined nanospace for tandem reactions by template-assisted ALD. The synergistic effect of two interfaces enhanced the tandem reaction, and the confined nanospace favored the instant transfer of intermediates between the two interfaces. In addition, porous TiO₂ nanotubes with spatially separated Pt and CoO_x cocatalysts were also produced by ALD. The confined catalysts can be further treated by ALD. We used ALD to modify the mesoporous SBA-15 support to precisely tune the active species-support interaction. In addition to the support, the confined metal nanoparticles can also be coated with an ultrathin oxide layer by ALD to further improve their catalytic activities. Moreover, the structure and size of the confined nanospace can be tuned precisely by ALD. Overall, ALD has exhibited noteworthy applications in and will provide new opportunities for the design and synthesis of highly effective confined catalysts.