Fish-in-hole: rationally positioning palladium into traps of zeolite crystals for sinter-resistant catalysts

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.

In Situ Reconstruction of Active Heterointerface for Hydrocarbon Combustion through Thermal Aging over Strontium-Modified Co3O4 Nanocatalyst with Good Sintering Resistance

The issue of catalyst deactivation due to sintering has gained significant attention alongside the rapid advancement of thermal catalysts. In this work, a simple Sr modification strategy was applied to achieve highly active Co3O4-based nanocatalyst for catalytic combustion of hydrocarbons with excellent antisintering feature. With the Co1Sr0.3 catalyst achieving a 90% propane conversion temperature (T90) of only 289 °C at a w8 hly space velocity of 60,000 mL·g-1·h-1, 24 °C lower than that of pure Co3O4. Moreover, the sintering resistance of Co3O4 catalysts was greatly improved by SrCO3 modification, and the T90 over Co1Sr0.3 just increased from 289 to 337 °C after thermal aging at 750 °C for 100 h, while that over pure Co3O4 catalysts increased from 313 to 412 °C. Through strontium modification, a certain amount of SrCO3 was introduced on the Co3O4 catalyst, which can serve as a physical barrier during the thermal aging process and further formation of Sr-Co perovskite nanocrystals, thus preventing the aggregation growth of Co3O4 nanocrystals and generating new active SrCoO2.52-Co3O4 heterointerface. In addition, propane durability tests of the Co1Sr0.3 catalysts showed strong water vapor resistance and stability, as well as excellent low-temperature activity and resistance to sintering in the oxidation reactions of other typical hydrocarbons such as toluene and propylene. This study provides a general strategy for achieving thermal catalysts by perfectly combining both highly low-temperature activity and sintering resistance, which will have great significance in practical applications for replacing precious materials with comparative features.

Synthesis of Pd/Carbon Hollow Spheres by the Microwave Discharge Method for Catalytic Debenzylation

Pd/C catalysts have been widely applied in the debenzylation process due to their excellent ability of hydrogenolysis. However, they have been suffering from the problems of agglomeration and loss of active components, which lead to decreased and unstable activity. Thus, it is still a challenge to achieve Pd/C catalysts with high activity and stability. Herein, we propose a strategy for preparing Pd/C catalysts on porous carbon hollow spheres by a microwave discharge method. Due to the high-temperature property and reducibility of microwave discharge, Pd precursors can be rapidly reduced, resulting in well-dispersed Pd nanoparticles with a small size on the carbon carrier. Besides, the matched mesopores in the carbon hollow spheres can anchor Pd nanoparticles and effectively reduce the agglomeration and loss of Pd nanoparticles during the catalytic reaction. As a result, the as-prepared Pd/mesoporous carbon hollow spheres exhibit high and stable activity in the debenzylation reaction.

Design of Bifunctional Nanocatalysts Based on Zeolites for Biomass Processing

Bifunctional catalysts consisting of metal-containing nanoparticles (NPs) and zeolite supports have received considerable attention due to their excellent catalytic properties in numerous reactions, including direct (biomass is a substrate) and indirect (platform chemical is a substrate) biomass processing. In this short review, we discuss major approaches to the preparation of NPs in zeolites, concentrating on methods that allow for the best interplay (synergy) between metal and acid sites, which is normally achieved for small NPs well-distributed through zeolite. We focus on the modification of zeolites to provide structural integrity and controlled acidity, which can be accomplished by the incorporation of certain metal ions or elements. The other modification avenue is the adjustment of zeolite morphology, including the creation of numerous defects for the NP entrapment and designed hierarchical porosity for improved mass transfer. In this review, we also provide examples of synergy between metal and acid sites and emphasize that without density functional theory calculations, many assumptions about the interactions between active sites remain unvalidated. Finally, we describe the most interesting examples of direct and indirect biomass (waste) processing for the last five years.

Novel PEPPSI-Type NHC Pd(II) Metallosurfactants on the Base of 1H-Imidazole-4,5-dicarboxylic Acid: Synthesis and Catalysis in Water-Organic Media

Carrying out organic reactions in water has attracted much attention. Catalytic reactions in water with metallosurfactants, which have both a metallocenter and the surface activity necessary for solubilizing hydrophobic reagents, are of great demand. Herein we proposed new approach to the synthesis of NHC PEPPSI metallosurfactants based on the sequential functionalization of imidazole 4,5-dicarboxylic acid with hydrophilic oligoethylene glycol and lipophilic alkyl fragments. Complexes of different lipophilicity were obtained, and their catalytic activity was studied in model reduction and Suzuki-Miyaura reactions. A comparison was made with the commercial PEPPSI-type catalytic systems designed by Organ. It was found that the reduction reaction in an aqueous solution of the metallosurfactant with the tetradecyl lipophilic fragment was three times more active than the commercially available PEPPSI complexes, which was associated with the formation of stable monodisperse aggregates detected by DLS and TEM.

Highly Efficient and Selective Photocatalytic Nonoxidative Coupling of Methane to Ethylene over Pd-Zn Synergistic Catalytic Sites

Photocatalytic nonoxidative coupling of CH4 to multicarbon (C2+) hydrocarbons (e.g., C2H4) and H2 under ambient conditions provides a promising energy-conserving approach for utilization of carbon resource. However, as the methyl intermediates prefer to undergo self-coupling to produce ethane, it is a challenging task to control the selective conversion of CH4 to higher value-added C2H4. Herein, we adopt a synergistic catalysis strategy by integrating Pd-Zn active sites on visible light-responsive defective WO3 nanosheets for synergizing the adsorption, activation, and dehydrogenation processes in CH4 to C2H4 conversion. Benefiting from the synergy, our model catalyst achieves a remarkable C2+ compounds yield of 31.85 μmol·g-1·h-1 with an exceptionally high C2H4 selectivity of 75.3% and a stoichiometric H2 evolution. In situ spectroscopic studies reveal that the Zn sites promote the adsorption and activation of CH4 molecules to generate methyl and methoxy intermediates with the assistance of lattice oxygen, while the Pd sites facilitate the dehydrogenation of methoxy to methylene radicals for producing C2H4 and suppress overoxidation. This work demonstrates a strategy for designing efficient photocatalysts toward selective coupling of CH4 to higher value-added chemicals and highlights the importance of synergistic active sites to the synergy of key steps in catalytic reactions.

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.

Zeolites and Related Materials as Catalyst Supports for Hydrocarbon Oxidation Reactions

Catalytic oxidation is a key technology for the conversion of petroleum-based feedstocks into useful chemicals (e.g., adipic acid, caprolactam, glycols, acrylates, and vinyl acetate) since this chemical transformation is always involved in synthesis processes. Millions of tons of these compounds are annually produced worldwide and find applications in all areas of chemical industries, ranging from pharmaceutical to large-scale commodities. The traditional industrial methods to produce large amounts of those compounds involve over-stoichiometric quantities of toxic inorganic reactants and homogeneous catalysts that operate at high temperature, originating large amounts of effluents, often leading to expensive downstream processes, along with nonrecovery of valuable catalysts that are loss within the reactant effluent. Due to the increasingly stringent environmental legislation nowadays, there is considerable pressure to replace these antiquate technologies, focusing on heterogeneous catalysts that can operate under mild reactions conditions, easily recovered, and reused. Parallelly, recent advances in the synthesis and characterization of metal complexes and metal clusters on support surfaces have brought new insights to catalysis and highlight ways to systematic catalysts design. This review aims to provide a comprehensive bibliographic examination over the last 10 years on the development of heterogeneous catalysts, i.e., organometallic complexes or metal clusters immobilized in distinct inorganic supports such as zeolites, hierarchical zeolites, silicas, and clays. The methodologies used to prepare and/or modify the supports are critically reviewed, as well as the methods used for the immobilization of the active species. The applications of the heterogenized catalysts are presented, and some case-studies are discussed in detail.

OUP accepted manuscript

The rational design synthesis of zeolite catalysts with effective, environmentally benign and atom-economic routes is a major topic in the field of microporous materials, as it would avoid the high labor cost and inefficiency of traditional trial-and-error methods in developing new structures and dispel environmental concerns regarding the industrial mass production of zeolites. Catalytic applications of zeolite materials have expanded from conventional single functionalities, such as solid acids or selective oxidation catalysts to bi/multifunctionalities through combination with metals or metal oxides. This is a response to new requirements from petrochemical and fine chemical industries, such as precise control of product distribution, conversion of low-carbon resources for chemical production, and solutions to increasingly severe environmental problems related to CO₂ and NO_x. Thus, based on the systematic knowledge of zeolite chemistry and science that researchers have acquired in the past half-century and the development requirements, remarkable progress has been made in zeolite synthesis and catalysis in the past 10 years. This includes the manipulation of zeolitic monolayers derived from layered zeolites and germanosilicates to construct novel zeolite materials and effective and green zeolite syntheses as well as the synergistic interaction of zeolites and metal/metal oxides with different space distributions in the conversion of low-carbon resources. With many zeolite catalysts and catalytic processes being developed, our understanding of the close relationship between zeolite synthesis, structure and catalytic properties has deepened. Researchers are gradually approaching the goal of rationally designing zeolite catalysts with precisely controlled activity and selectivity for particular applications.

Confined Generation of Homogeneously Dispersed Au and SnO2 Nanoparticles in Layered Silicate as Synergistic Catalysts

With the aid of the confined conversion of layered silicate RUB-15, homogeneously dispersed Au and SnO₂ nanoparticles (NPs) were generated in the confined layer space of RUB-15. The Au-SnO₂/SiO₂ composite was obtained with the structure that ultrafine Au and SnO₂ NPs were supported on SiO₂ lamellas. Benefited by the Sn(II)-assisted in situ reduction strategy, Au NPs were highly uniformed and evenly distributed in/on the RUB-15. This Au-SnO₂/SiO₂ composite was employed as a catalyst to the reduction of 4-nitrophenol showing excellent catalytic activity. The catalytic rate constant at room temperature was calculated to be 6.64 min^-1, which was dramatically higher than that of Au/SiO₂ composite produced by reduction with hydrazine hydrate on the same support of layered silicate RUB-15. The interaction between Au and SnO₂ NPs increased the electron density around Au NPs, which was demonstrated to be an essential factor to the excellent catalytic activity of the Au-SnO₂/SiO₂ composite. The simple and universal synthesis method afforded precise control over the size/spatial arrangement of Au and SnO₂ NPs on SiO₂ lamellas. The high activity of the Au-SnO₂/SiO₂ composite demonstrated that the strategy used in this study has good potential application prospect. Furthermore, this work provided new perspective on the catalysis mechanism to the metal/semiconductor synergistic catalyst system.

Boosting the sintering resistance of platinum–alumina catalyst via a morphology-confined phosphate-doping strategy

The size-dependent metal–support interaction, high surface area, and, above all, the support morphology-confined effect contribute to a good sintering-resistant catalyst.

Recent advances in zeolite-encapsulated metal catalysts: A suitable catalyst design for catalytic biomass conversion

Metal clusters and nanoparticles, which have been used to tune the acidity of zeolite support, are beneficial for promoting the catalytic performance of various reaction processes, including biomass conversion. However, catalytic instabilities resulting from metal coalescence, sintering and leaching are major problems that need to be resolved. Therefore, metal encapsulation within the zeolite structure has been proposed as a feasible solution for this issue, particularly for biomass conversions that require high temperatures. In this current review, recent developments in metal confinement techniques are described along with experimental examples of biomass upgrading reactions. The present and future perspectives of zeolite-encapsulated metal catalysts in biomass conversions are also given.

Catalytic Performance of Toluene Combustion over Pt Nanoparticles Supported on Pore-Modified Macro-Meso-Microporous Zeolite Foam

Herein, to investigate the pore effect on toluene catalytic oxidation activity, novel supports for Pt nanoparticles-ZSM-5 foam (ZF) fabricated using polyurethane foam (PUF) templates and pore-modified ZSM-5 foam (ZF-D) treated by acid etching, comparing with conventional ZSM-5 and pore-modified ZSM-5 (ZSM-5-D), were successfully synthesized. Pt nanoparticles were loaded on series ZSM-5 supports by the impregnation method. The Pt loaded on ZF-D (Pt/ZF-D) showed the highest activity of toluene catalytic combustion (i.e., T₉₀ = 158 °C), with extraordinary stability and an anti-coking ability. Based on various catalysts characterizations, the unique macropores of ZF facilitated the process of acid etching as compared to conventional ZSM-5. The mesopores volume of ZF-D significantly increased due to acid etching, which enlarged toluene adsorption capacity and led to a better Pt distribution since some Pt nanoparticles were immobilized into some mesopores. Specifically, the microporous distribution was centered in the range of 0.7-0.8 nm close to the molecular diameter of toluene (ca. 0.67 nm), which was key to the increasing toluene diffusion rate due to pore levitation effect of catalysts and accessibility of metal. Furthermore, the reducibility of Pt nanoparticles was improved on Pt/ZF-D, which enhanced the activity of toluene catalytic oxidation.

Synthesis and Catalytic Properties of Porous Metal Silica Materials Templated and Functionalized by Extended Coordination Cages

A practically applicable strategy is developed to rationally immobilize easily accessed and highly dispersed redox-active metal oxides into porous metal silica (PMS) materials templated and functionalized by porous metal-ligand moieties. On the basis of this strategy, the highly active porous catalyst PMS-1 is successfully targeted for aerobic oxidation of cyclohexane with conversion up to 14.6%, which is much superior to the current industrially adopted catalysts (less than 4% cyclohexane conversion) that use harsh conditions. This promising approach to explore highly active heterogeneous catalysts for inert C-H bond activation should lead to the further discovery of numerous industrially useful catalysts for the oxidation of inert hydrocarbon raw materials.

New Strategies for the Preparation of Sinter-Resistant Metal-Nanoparticle-Based Catalysts

Supported metal nanoparticles are widely used as catalysts in the industrial production of chemicals, but still suffer from deactivation because of metal leaching and sintering at high temperature. In recent years, serious efforts have been devoted to developing new strategies for stabilizing metal nanoparticles. Recent developments for preparing sinter-resistant metal-nanoparticle catalysts via strong metal-support interactions, encapsulation with oxide or carbon layers and within mesoporous materials, and fixation in zeolite crystals, are briefly summarized. Furthermore, the current challenges and future perspectives for the preparation of highly efficient and extraordinarily stable metal-nanoparticle-based catalysts, and suggestions regarding the mechanisms involved in sinter resistance, are proposed.

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.

Highly dispersed nickel catalysts via a facile pyrolysis generated protective carbon layer

Highly dispersed nickel catalysts were synthesized by simple Ni(acac)2 impregnation followed by pyrolysis of organic ligands, which produces a protective carbon coating on the Ni nanoparticles, reducing the metal mobility and sintering. The synthesized catalyst shows high thermal stability and enhanced CO methanation activity compared to the catalyst prepared by the traditional impregnation/calcination method.

A new cluster-based chalcogenide zeolite analogue with a large inter-cluster bridging angle

A new cluster-based chalcogenide zeolite analogue with a large inter-cluster bridging angle.

Ultrasmall Metal Nanoparticles Confined within Crystalline Nanoporous Materials: A Fascinating Class of Nanocatalysts

Crystalline nanoporous materials with uniform porous structures, such as zeolites and metal-organic frameworks (MOFs), have proven to be ideal supports to encapsulate ultrasmall metal nanoparticles (MNPs) inside their void nanospaces to generate high-efficiency nanocatalysts. The nanopore-encaged metal catalysts exhibit superior catalytic performance as well as high stability and catalytic shape selectivity endowed by the nanoporous matrix. In addition, the synergistic effect of confined MNPs and nanoporous frameworks with active sites can further promote the catalytic activities of the composite catalysts. Herein, recent progress in nanopore-encaged metal nanocatalysts is reviewed, with a special focus on advances in synthetic strategies for ultrasmall MNPs (<5 nm), clusters, and even single atoms confined within zeolites and MOFs for various heterogeneous catalytic reactions. In addition, some advanced characterization methods to elucidate the atomic-scale structures of the nanocatalysts are presented, and the current limitations of and future opportunities for these fantastic nanocatalysts are also highlighted and discussed. The aim is to provide some guidance for the rational synthesis of nanopore-encaged metal catalysts and to inspire their further applications to meet the emerging demands in catalytic fields.

Encapsulation of Metal Nanoparticle Catalysts Within Mesoporous Zeolites and Their Enhanced Catalytic Performances: A Review

Metal nanoparticles (NPs) exhibit desired activities in various catalytic reactions. However, the aggregation and sintering of metal NPs usually cause the loss of catalytic performance in practical reaction processes. Encapsulation of catalytically active metal NPs on/within a high-surface-area inorganic support partially resolve such concerns. Microporous zeolites, owing to their rigid frameworks and porous structural features, have been considered as one of ideal inorganic supports. Metal NPs can be easily encapsulated and stabilized within zeolitic frameworks to prevent unwished aggregation during the catalysis. Unfortunately, sole microporous nanochannels (generally <1 nm) in conventional zeolites are not easy to be accessed. The introduction of another set of nanochannel (e.g., mesopore), known as mesoporous zeolites, can greatly improve the mass-transfer efficiency, which is structurally beneficial for most catalytic reactions. The coexistence of micropores and mesopores in inorganic supports provides the synergetic advantages of both fine confinement effect for metal NPs and easy diffusion for organic reactants/intermediates/products. This review focuses on the recent advances in the design and synthesis of mesoporous zeolites-encapsulated metal NP catalysts as well as their desired catalytic performances (activity and stability) in organic reactions. We first discuss the advantages of mesoporous zeolites as the supports and present general strategies for the construction of mesoporous zeolites. Then, the preparation methods on how to encapsulate NP catalysts within both microporous and mesoporous zeolites are clearly demonstrated. Third, some recent important cases on catalytic applications are presented to verify structural advantages of mesoporous zeolite supports. Within the conclusion, the perspectives on future developments in metal NP catalysts encapsulated within mesoporous zeolites are lastly discussed.