Dry reforming of methane by stable Ni-Mo nanocatalysts on single-crystalline MgO

Simultaneous production of syngas and carbon nanotubes from CO2/CH4 mixture over high-performance NiMo/MgO catalyst

Direct conversion of biogas via the integrative process of dry reforming of methane (DRM) and catalytic methane decomposition (CDM) has received a great attention as a promising green catalytic process for simultaneous production of syngas and carbon nanotubes (CNTs). In this work, the effects of reaction temperature of 700-1100 °C and CH4/CO2 ratio of biogas were investigated over NiMo/MgO catalyst in a fixed bed reactor under industrial feed condition of pure biogas. The reaction at 700 °C showed a rapid catalyst deactivation within 3 h due to the formation of amorphous carbon on catalyst surface. At higher temperature of 800-900 °C, the catalyst can perform the excellent performance for producing syngas and carbon nanotubes. Interestingly, the smallest diameter and the highest graphitization of CNTs was obtained at high temperature of 1000 °C, while elevating temperature to 1100 °C leads to agglomeration of Ni particles, resulting in a larger size of CNTs. The reaction temperature exhibits optimum at 800 °C, providing the highest CNTs yield with high graphitization, high syngas purity up to 90.04% with H2/CO ratio of 1.1, and high biogas conversion (XCH4 = 86.44%, XCO2 = 95.62%) with stable performance over 3 h. The typical composition biogas (CH4/CO2 = 1.5) is favorable for the integration process, while the CO2 rich biogas caused a larger grain size of catalyst and a formation of molybdenum oxide nanorods (MoO3). The long-term stability of NiMo/MgO catalyst at 800 °C showed a stable trend (> 20 h). The experimental findings confirm that NiMo/MgO can perform the excellent activity and high stability at the optimum condition, allowing the process to be more promising for practical applications.

Formation of a Porous Crystalline Mg1-xAl2Oy Overlayer on Metal Catalysts via Controlled Solid-State Reactions for High-temperature Stable Catalysis

Catalyst deactivation by sintering and coking is a long-standing issue in metal-catalyzed harsh high-temperature hydrocarbon reactions. Ultrathin oxide coatings of metal nanocatalysts have recently appeared attractive to address this issue, while the porosity of the overlayer is difficult to control to preserve the accessibility of embedded metal nanoparticles, thus often leading to a large decrease in activity. Here, we report that a nanometer-thick alumina coating of MgAl2O4-supported metal catalysts followed by high-temperature reduction can transform a nonporous amorphous alumina overlayer into a porous Mg1-xAl2Oy crystalline spinel structure with a pore size of 2-3 nm and weakened acidity. The high porosity stems from the restrained Mg migration from the MgAl2O4 support to the alumina overlayer through solid-state reactions at high temperatures. The resulting Ni/MgAl2O4 and Pt/MgAl2O4 catalysts with a porous crystalline Mg1-xAl2Oy overlayer achieved remarkably high stability while preserving much higher activity than the corresponding alumina-coated Ni and Pt catalysts on MgO and Al2O3 supports in the reactions of dry reforming of methane and propane dehydrogenation, respectively.

Pulsed laser induced plasma and thermal effects on molybdenum carbide for dry reforming of methane

Dry reforming of methane (DRM) is a highly endothermic process, with its development hindered by the harsh thermocatalytic conditions required. We propose an innovative DRM approach utilizing a 16 W pulsed laser in combination with a cost-effective Mo2C catalyst, enabling DRM under milder conditions. The pulsed laser serves a dual function by inducing localized high temperatures and generating *CH plasma on the Mo2C surface. This activates CH4 and CO2, significantly accelerating the DRM reaction. Notably, the laser directly generates *CH plasma from CH4 through thermionic emission and cascade ionization, bypassing the traditional step-by-step dehydrogenation process and eliminating the rate-limiting step of methane cracking. This method maintains a carbon-oxygen balanced environment, thus preventing the deactivation of the Mo2C catalyst due to CO2 oxidation. The laser-catalytic DRM achieves high yields of H2 (14300.8 mmol h-1 g-1) and CO (14949.9 mmol h-1 g-1) with satisfactory energy efficiency (0.98 mmol kJ-1), providing a promising alternative for high-energy-consuming catalytic systems.

Improved Selectivity and Stability in Methane Dry Reforming by Atomic Layer Deposition on Ni-CeO2-ZrO2/Al2O3 Catalysts

Ni can be used as a catalyst for dry reforming of methane (DRM), replacing more expensive and less abundant noble metal catalysts (Pt, Pd, and Rh) with little sacrifice in activity. Ni catalysts deactivate quickly under realistic DRM conditions. Rare earth oxides such as CeO2, or as CeO2-ZrO2-Al2O3 (CZA), are supports that improve both the activity and stability of Ni DRM systems due to their redox activity. However, redox-active supports can also enhance the undesired reverse water gas shift (RWGS) reaction, reducing the hydrogen selectivity. In this work, Ni on CZA was coated with an ultrathin Al2O3 overlayer using atomic layer deposition (ALD) to study the effects of the overlayer on catalyst activity, stability, and H2/CO ratio. A low-conversion screening method revealed improved DRM activity and lower coking rate upon the addition of the Al2O3 ALD overcoat, and improvements were subsequently confirmed in a high-conversion reactor at long times onstream. The overcoated samples gave an H2/CO ratio of ∼1 at high conversion, much greater than uncoated catalysts, and no evidence of deactivation. Characterization of used (but still active) catalysts using several techniques suggests that active Ni is in formal oxidation state >0, Ni-Ce-Al is most likely present as a mixed oxide at the surface, and a nominal thickness of 0.5 nm for the Al2O3 overcoat is optimal.

Atomically dispersed MoNi alloy catalyst for partial oxidation of methane

The catalytic partial oxidation of methane (POM) presents a promising technology for synthesizing syngas. However, it faces severe over-oxidation over catalyst surface. Attempts to modify metal surfaces by incorporating a secondary metal towards C-H bond activation of CH4 with moderate O* adsorption have remained the subject of intense research yet challenging. Herein, we report that high catalytic performance for POM can be achieved by the regulation of O* occupation in the atomically dispersed (AD) MoNi alloy, with over 95% CH4 conversion and 97% syngas selectivity at 800 °C. The combination of ex-situ/in-situ characterizations, kinetic analysis and DFT (density functional theory) calculations reveal that Mo-Ni dual sites in AD MoNi alloy afford the declined O2 poisoning on Ni sites with rarely weaken CH4 activation for partial oxidation pathway following the combustion reforming reaction (CRR) mechanism. These results underscore the effectiveness of CH4 turnovers by the design of atomically dispersed alloys with tunable O* adsorption.

Rh/InGaN1-xOx nanoarchitecture for light-driven methane reforming with carbon dioxide toward syngas

Light-driven dry reforming of methane toward syngas presents a proper solution for alleviating climate change and for the sustainable supply of transportation fuels and chemicals. Herein, Rh/InGaN1-xOx nanowires supported by silicon wafer are explored as an ideal platform for loading Rh nanoparticles, thus assembling a new nanoarchitecture for this grand topic. In combination with the remarkable photo-thermal synergy, the O atoms in Rh/InGaN1-xOx can significantly lower the apparent activation energy of dry reforming of methane from 2.96 eV downward to 1.70 eV. The as-designed Rh/InGaN1-xOx NWs nanoarchitecture thus demonstrates a measurable syngas evolution rate of 180.9 mmol gcat-1 h-1 with a marked selectivity of 96.3% under concentrated light illumination of 6 W cm-2. What is more, a high turnover number (TON) of 4182 mol syngas per mole Rh has been realized after six reuse cycles without obvious activity degradation. The correlative 18O isotope labeling experiments, in-situ irradiated X-ray photoelectron spectroscopy (ISI-XPS) and in-situ diffuse reflectance Fourier transform infrared spectroscopy characterizations, as well as density functional theory calculations reveal that under light illumination, Rh/InGaN1-xOx NWs facilitate releasing *CH3 and H+ from CH4 by holes, followed by H2 evolution from H+ reduction with electrons. Subsequently, the O atoms in Rh/InGaN1-xOx can directly participate in CO generation by reacting with the *C species from CH4 dehydrogenation and contributes to the coke elimination, in concurrent formation of O vacancies. The resultant O vacancies are then replenished by CO2, showing an ideal chemical loop. This work presents a green strategy for syngas production via light-driven dry reforming of methane.

Unveiling the Mechanism of Plasma-Catalyzed Oxidation of Methane to C2+ Oxygenates over Cu/UiO-66-NH2

Nonthermal plasma (NTP) offers the potential for converting CH4 with CO2 into liquid products under mild conditions, but controlling liquid selectivity and manipulating intermediate species remain significant challenges. Here, we demonstrate the effectiveness of the Cu/UiO-66-NH2 catalyst in promising the conversion of CH4 and CO2 into oxygenates within a dielectric barrier discharge NTP reactor under ambient conditions. The 10% Cu/UiO-66-NH2 catalyst achieved an impressive 53.4% overall liquid selectivity, with C2+ oxygenates accounting for ∼60.8% of the total liquid products. In situ plasma-coupled Fourier-transform infrared spectroscopy (FTIR) suggests that Cu facilitates the cleavage of surface adsorbed COOH species (*COOH), generating *CO and enabling its migration to the surface of Cu particles. This surface-bound *CO then undergoes C-C coupling and hydrogenation, leading to ethanol production. Further analysis using CO diffuse reflection FTIR and 1H nuclear magnetic resonance spectroscopy indicates that in situ generated surface *CO is more effective than gas-phase CO (g) in promoting C-C coupling and C2+ liquid formation. This work provides valuable mechanistic insights into C-C coupling and C2+ liquid production during plasma-catalytic CO2 oxidation of CH4 under ambient conditions. These findings hold broader implications for the rational design of more efficient catalysts for this reaction, paving the way for advancements in sustainable fuel and chemical production.

Distributed electrified heating for efficient hydrogen production

This study introduces a distributed electrified heating approach that is able to innovate chemical engineering involving endothermic reactions. It enables rapid and uniform heating of gaseous reactants, facilitating efficient conversion and high product selectivity at specific equilibrium. Demonstrated in catalyst-free CH4 pyrolysis, this approach achieves stable production of H2 (530 g h-1 L reactor -1) and carbon nanotube/fibers through 100% conversion of high-throughput CH4 at 1150 °C, surpassing the results obtained from many complex metal catalysts and high-temperature technologies. Additionally, in catalytic CH4 dry reforming, the distributed electrified heating using metallic monolith with unmodified Ni/MgO catalyst washcoat showcased excellent CH4 and CO2 conversion rates, and syngas production capacity. This innovative heating approach eliminates the need for elongated reactor tubes and external furnaces, promising an energy-concentrated and ultra-compact reactor design significantly smaller than traditional industrial systems, marking a significant advance towards more sustainable and efficient chemical engineering society.

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

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

Suppressing Metal Leaching and Sintering in Hydroformylation Reaction by Modulating the Coordination of Rh Single Atoms with Reactants

Hydroformylation reaction is one of the largest homogeneously catalyzed industrial processes yet suffers from difficulty and high cost in catalyst separation and recovery. Heterogeneous single-atom catalysts (SACs), on the other hand, have emerged as a promising alternative due to their high initial activity and reasonable regioselectivity. Nevertheless, the stability of SACs against metal aggregation and leaching during the reaction has rarely been addressed. Herein, we elucidate the mechanism of Rh aggregation and leaching by investigating the structural evolution of Rh1@silicalite-1 SAC in response to different adsorbates (CO, H2, alkene, and aldehydes) by using diffuse reflectance infrared Fourier transform spectroscopy, X-ray adsorption fine structure, and scanning transmission electron microscopy techniques and kinetic studies. It is discovered that the aggregation and leaching of Rh are induced by the strong adsorption of CO and aldehydes on Rh, as well as the reduction of Rh3+ by CO/H2 which weakens the binding of Rh with support. In contrast, alkene effectively counteracts this effect by the competitive adsorption on Rh atoms with CO/aldehyde, and the disintegration of Rh clusters. Based on these results, we propose a strategy to conduct the reaction under conditions of high alkene concentration, which proves to be able to stabilize Rh single atom against aggregation and/or leaching for more than 100 h time-on-stream.

Local Structures of Ex-Solved Nanoparticles Identified by Machine-Learned Potentials

In this study, we identify the local structures of ex-solved nanoparticles using machine-learned potentials (MLPs). We develop a method for training machine-learned potentials by sampling local structures of heterointerface configurations as a training set with its efficacy tested on the Ni/MgO system, illustrating that the error in interface energy is only 0.004 eV/Å2. Using the developed scheme, we train an MLP for the Ni/La0.5Ca0.5TiO3 ex-solution system and identify the local structures for both exo- and endo-type particles. The established model aligns well with the experimental observations, accurately predicting a nucleation size of 0.45 nm. Lastly, the density functional theory calculations on the established atomistic model verify that the kinetic barrier for the dry reforming of methane are substantially reduced by 0.49 eV on the ex-solved catalysts compared to that on the impregnated catalysts. Our findings offer insights into the local structures, growth mechanisms, and underlying origin of the catalytic properties of ex-solved nanoparticles.

Single-Atom Alloys Materials for CO2 and CH4 Catalytic Conversion

The catalytic conversion of greenhouse gases CH4 and CO2 constitutes an effective approach for alleviating the greenhouse effect and generating valuable chemical products. However, the intricate molecular characteristics characterized by high symmetry and bond energies, coupled with the complexity of associated reactions, pose challenges for conventional catalysts to attain high activity, product selectivity, and enduring stability. Single-atom alloys (SAAs) materials, distinguished by their tunable composition and unique electronic structures, confer versatile physicochemical properties and modulable functionalities. In recent years, SAAs materials demonstrate pronounced advantages and expansive prospects in catalytic conversion of CH4 and CO2. This review begins by introducing the challenges entailed in catalytic conversion of CH4 and CO2 and the advantages offered by SAAs. Subsequently, the intricacies of synthesis strategies employed for SAAs are presented and characterization techniques and methodologies are introduced. The subsequent section furnishes a meticulous and inclusive overview of research endeavors concerning SAAs in CO2 catalytic conversion, CH4 conversion, and synergy CH4 and CO2 conversion. The particular emphasis is directed toward scrutinizing the intricate mechanisms underlying the influence of SAAs on reaction activity and product selectivity. Finally, insights are presented on the development and future challenges of SAAs in CH4 and CO2 conversion reactions.

Structured Catalysts and Catalytic Processes: Transport and Reaction Perspectives

The structure of catalysts determines the performance of catalytic processes. Intrinsically, the electronic and geometric structures influence the interaction between active species and the surface of the catalyst, which subsequently regulates the adsorption, reaction, and desorption behaviors. In recent decades, the development of catalysts with complex structures, including bulk, interfacial, encapsulated, and atomically dispersed structures, can potentially affect the electronic and geometric structures of catalysts and lead to further control of the transport and reaction of molecules. This review describes comprehensive understandings on the influence of electronic and geometric properties and complex catalyst structures on the performance of relevant heterogeneous catalytic processes, especially for the transport and reaction over structured catalysts for the conversions of light alkanes and small molecules. The recent research progress of the electronic and geometric properties over the active sites, specifically for theoretical descriptors developed in the recent decades, is discussed at the atomic level. The designs and properties of catalysts with specific structures are summarized. The transport phenomena and reactions over structured catalysts for the conversions of light alkanes and small molecules are analyzed. At the end of this review, we present our perspectives on the challenges for the further development of structured catalysts and heterogeneous catalytic processes.

Methane-H2S Reforming Catalyzed by Carbon and Metal Sulfide Stabilized Sulfur Dimers

H2S reforming of methane (HRM) provides a potential strategy to directly utilize sour natural gas for the production of COx-free H2 and sulfur chemicals. Several carbon allotropes were found to be active and selective for HRM, while the additional presence of transition metals led to further rate enhancements and outstanding stability (e.g., Ru supported on carbon black). Most metals are transformed to sulfides, but the carbon supports prevent sintering under the harsh reaction conditions. Supported by theoretical calculations, kinetic and isotopic investigations with representative catalysts showed that H2S decomposition and the recombination of surface H atoms are quasi-equilibrated, while the first C-H bond scission is the kinetically relevant step. Theory and experiments jointly establish that dynamically formed surface sulfur dimers are responsible for methane activation and catalytic turnovers on sulfide and carbon surfaces that are otherwise inert without reaction-derived active sites.

High-Pressure Electro-Fenton Driving CH4 Conversion by O2 at Room Temperature

Electrochemical conversion of CH4 to easily transportable and value-added liquid fuels is highly attractive for energy-efficient CH4 utilization, but it is challenging due to the low reactivity and solubility of CH4 in the electrolyte. Herein, we report a high-pressure electro-Fenton (HPEF) strategy to establish a hetero-homogeneous process for the electrocatalytic conversion of CH4 by O2 at room temperature. In combination with elevation of reactant pressure to accelerate reaction kinetics, it delivers an unprecedented HCOOH productivity of 11.5 mmol h-1 gFe-1 with 220 times enhancement compared to that under ambient pressure. Remarkably, an HCOOH Faradic efficiency of 81.4% can be achieved with an ultralow cathodic overpotential of 0.38 V. The elevated pressure not only promotes the electrocatalytic reduction of O2 to H2O2 but also increases the reaction collision probability between CH4 and •OH, which is in situ generated from the Fe2+-facilitated decomposition of H2O2.

Challenging thermodynamics: combining immiscible elements in a single-phase nano-ceramic

The Hume-Rothery rules governing solid-state miscibility limit the compositional space for new inorganic material discovery. Here, we report a non-equilibrium, one-step, and scalable flame synthesis method to overcome thermodynamic limits and incorporate immiscible elements into single phase ceramic nanoshells. Starting from prototype examples including (NiMg)O, (NiAl)Ox, and (NiZr)Ox, we then extend this method to a broad range of Ni-containing ceramic solid solutions, and finally to general binary combinations of elements. Furthermore, we report an "encapsulated exsolution" phenomenon observed upon reducing the metastable porous (Ni0.07Al0.93)Ox to create ultra-stable Ni nanoparticles embedded within the walls of porous Al2O3 nanoshells. This nanoconfined structure demonstrated high sintering resistance during 640 h of catalysis of CO2 reforming of methane, maintaining constant 96% CH4 and CO2 conversion at 800 °C and dramatically outperforming conventional catalysts. Our findings could greatly expand opportunities to develop novel inorganic energy, structural, and functional materials.

Photodriven Methane Conversion on Transition Metal Oxide Catalyst: Recent Progress and Prospects

Methane as the main component in natural gas is a promising chemical raw material for synthesizing value-added chemicals, but its harsh chemical conversion process often causes severe energy and environment concerns. Photocatalysis provides an attractive path to active and convert methane into various products under mild conditions with clean and sustainable solar energy, although many challenges remain at present. In this review, recent advances in photocatalytic methane conversion are systematically summarized. As the basis of methane conversion, the activation of methane is first elucidated from the structural basis and activation path of methane molecules. The study is committed to categorizing and elucidating the research progress and the laws of the intricate methane conversion reactions according to the target products, including photocatalytic methane partial oxidation, reforming, coupling, combustion, and functionalization. Advanced photocatalytic reactor designs are also designed to enrich the options and reliability of photocatalytic methane conversion performance evaluation. The challenges and prospects of photocatalytic methane conversion are also discussed, which in turn offers guidelines for methane-conversion-related photocatalyst exploration, reaction mechanism investigation, and advanced photoreactor design.

Intermetallic Ni3Ga1 Catalyst for Efficient Ammonia Reforming of Light Alkane

Ammonia reforming of light alkane is conventionally employed for HCN production where coproduct H2 is burned for heating owing to the high reaction temperature (1200 °C) of such a highly endothermic process. Here, we show that a Ni3Ga1 intermetallic compound (IMC) catalyst is highly efficient for such a reaction, realizing efficient conversion of C1-C3 alkanes at 575-750 °C. This makes it feasible for on-purpose COx-free H2 production assuming that ammonia, as an H2 carrier, is ubiquitously available from renewable energy. At 650 °C and an alkane/ammonia ratio of 1/2, ethane and propane conversion of ∼20% and methane conversion of 13% were obtained (with nearly 100% HCN selectivity for methane and ethane) over the unsupported Ni3Ga1 IMC, which also shows high stability due to the absence of coke deposition. This breakthrough is achieved by employing a stoichiometric Ni3Ga1 mixed oxalate solid solution as the precursor for the Ni3Ga1 IMC.

General Synthesis of High-Entropy Oxide Nanofibers

The discovery of high-entropy oxides (HEOs) in 2015 has provided a family of potential solid catalysts, due to their tunable components, abundant defects or lattice distorts, excellent thermal stability (ΔG↓ = ΔH - TΔS↑), and so on. When facing the heterogeneous catalysis by HEOs, the micrometer bulky morphology and low surface areas (e.g., <10 m2 g-1) by traditional synthesis methods obstructed their way. In this work, an electrospinning method to fabricate HEO nanofibers with diameters of 50-100 nm was demonstrated. The key point lay in the formation of one-dimensional filamentous precursors, during which the uniform dispersion of five metal species with disordered configuration would help to crystallize into single-phase HEOs at lower temperatures: inverse spinel (Cr0.2Mn0.2Co0.2Ni0.2Fe0.2)3O4 (400 °C), perovskite La(Mn0.2Cu0.2Co0.2Ni0.2Fe0.2)O3 (500 °C), spinel Ni0.2Mg0.2Cu0.2Mn0.2Co0.2)Al2O4 (550 °C), and cubic Ni0.2Mg0.2Cu0.2Zn0.2Co0.2O (750 °C). As a proof-of-concept, (Ni3MoCoZn)Al12O24 nanofiber exhibited good activity (CH4 Conv. > 96%, CO2 Conv. > 99%, H2/CO ≈ 0.98), long-time stability (>100 h) for the dry reforming of methane (DRM) at 700 °C without coke deposition, better than control samples (Ni3MoCoZn)Al12O24-Coprecipitation-700 (CH4 Conv. < 3%, CO2 Conv. < 7%). The reaction mechanism of DRM was studied by in situ infrared spectroscopy, CO2-TPD, and CO2/CH4-TPSR. This electrospinning method provides a synthetic route for HEO nanofibers for target applications.

Synthesis of core@shell catalysts guided by Tammann temperature

Designing high-performance thermal catalysts with stable catalytic sites is an important challenge. Conventional wisdom holds that strong metal-support interactions can benefit the catalyst performance, but there is a knowledge gap in generalizing this effect across different metals. Here, we have successfully developed a generalizable strong metal-support interaction strategy guided by Tammann temperatures of materials, enabling functional oxide encapsulation of transition metal nanocatalysts. As an illustrative example, Co@BaAl2O4 core@shell is synthesized and tracked in real-time through in-situ microscopy and spectroscopy, revealing an unconventional strong metal-support interaction encapsulation mechanism. Notably, Co@BaAl2O4 exhibits exceptional activity relative to previously reported core@shell catalysts, displaying excellent long-term stability during high-temperature chemical reactions and overcoming the durability and reusability limitations of conventional supported catalysts. This pioneering design and widely applicable approach has been validated to guide the encapsulation of various transition metal nanoparticles for environmental tolerance functionalities, offering great potential to advance energy, catalysis, and environmental fields.

A review on high-pressure heterogeneous catalytic processes for gas-phase CO2 valorization

This review discusses the importance of mitigating CO2 emissions by valorizing CO2 through high-pressure catalytic processes. It focuses on various key processes, including CO2 methanation, reverse water-gas shift, methane dry reforming, methanol, and dimethyl ether synthesis, emphasizing pros and cons of high-pressure operation. CO2 methanation, methanol synthesis, and dimethyl ether synthesis reactions are thermodynamically favored under high-pressure conditions. However, in the case of methane dry reforming and reverse water-gas shift, applying high pressure, results in decreased selectivity toward desired products and an increase in coke production, which can be detrimental to both the catalyst and the reaction system. Nevertheless, high-pressure utilization proves industrially advantageous for cost reduction when these processes are integrated with Fischer-Tropsch or methanol synthesis units. This review also compiles recent advances in heterogeneous catalysts design for high-pressure applications. By examining the impact of pressure on CO2 valorization and the state of the art, this work contributes to improving scientific understanding and optimizing these processes for sustainable CO2 management, as well as addressing challenges in high-pressure CO2 valorization that are crucial for industrial scaling-up. This includes the development of cost-effective and robust reactor materials and the development of low-cost catalysts that yield improved selectivity and long-term stability under realistic working environments.

Metal Alloys-Structured Electrocatalysts: Metal-Metal Interactions, Coordination Microenvironments, and Structural Property-Reactivity Relationships

Metal alloys-structured electrocatalysts (MAECs) have made essential contributions to accelerating the practical applications of electrocatalytic devices in renewable energy systems. However, due to the complex atomic structures, varied electronic states, and abundant supports, precisely decoding the metal-metal interactions and structure-activity relationships of MAECs still confronts great challenges, which is critical to direct the future engineering and optimization of MAECs. Here, this timely review comprehensively summarizes the latest advances in creating the MAECs, including the metal-metal interactions, coordination microenvironments, and structure-activity relationships. First, the fundamental classification, design, characterization, and structural reconstruction of MAECs are outlined. Then, the electrocatalytic merits and modulation strategies of recent breakthroughs for noble and non-noble metal-structured MAECs are thoroughly discussed, such as solid solution alloys, intermetallic alloys, and single-atom alloys. Particularly, unique insights into the bond interactions, theoretical understanding, and operando techniques for mechanism disclosure are given. Thereafter, the current states of diverse MAECs with a unique focus on structural property-reactivity relationships, reaction pathways, and performance comparisons are discussed. Finally, the future challenges and perspectives for MAECs are systematically discussed. It is believed that this comprehensive review can offer a substantial impact on stimulating the widespread utilization of metal alloys-structured materials in electrocatalysis.

Highly Efficient and Stable Methane Dry Reforming Enabled by a Single-Site Cationic Ni Catalyst

Zeolite-supported nickel (Ni) catalysts have been extensively studied for the dry reforming of methane (DRM). It is generally believed that prior to or during the reaction, Ni is reduced to a metallic state to act as the catalytic site. Here, we employed a ligand-protected synthesis method to achieve a high degree of Ni incorporation into the framework of the MFI zeolite. The incorporated Ni species retained their cationic nature during the DRM reaction carried out at 600 °C, exhibiting higher apparent catalytic activity and significantly greater catalytic stability in comparison to supported metallic Ni particles at the same loading. From theoretical and experimental evidence, we conclude that the incorporation of Ni into the zeolite framework leads to the formation of metal-oxygen (Niδ+-O(2-ξ)-) pairs, which serve as catalytic active sites, promoting the dissociation of C-H bonds in CH4 through a mechanism distinct from that of metallic Ni. The conversion of CH4 on cationic Ni single sites follows the CHx oxidation pathway, which is characterized by the rapid transformation of partial cracking intermediates CHx*, effectively inhibiting coke formation. The presence of the CHx oxidation pathway was experimentally validated by identifying the reaction intermediates. These new mechanistic insights elucidate the exceptional performance of the developed Ni-MFI catalyst and offer guidance for designing more efficient and stable Ni-based DRM catalysts.

Balancing elementary steps enables coke-free dry reforming of methane

Balancing kinetics, a crucial priority in catalysis, is frequently achieved by sacrificing activity of elementary steps to suppress side reactions and enhance catalyst stability. Dry reforming of methane (DRM), a process operated at high temperature, usually involves fast C-H activation but sluggish carbon removal, resulting in coke deposition and catalyst deactivation. Studies focused solely on catalyst innovation are insufficient in addressing coke formation efficiently. Herein, we develop coke-free catalysts that balance kinetics of elementary steps for overall thermodynamics optimization. Beginning from a highly active cobalt aluminum oxide (CoAl2O4) catalyst that is susceptible to severe coke formation, we substitute aluminum (Al) with gallium (Ga), reporting a CoAl0.5Ga1.5O4-R catalyst that performs DRM stably over 1000 hours without observable coke deposition. We find that Ga enhances DRM stability by suppressing C-H activation to balance carbon removal. A series of coke-free DRM catalysts are developed herein by partially substituting Al from CoAl2O4 with other metals.

Dry reforming of methane over gallium-based supported catalytically active liquid metal solutions

Gallium-rich supported catalytically active liquid metal solutions (SCALMS) were recently introduced as a new way towards heterogeneous single atom catalysis. SCALMS were demonstrated to exhibit a certain resistance against coking during the dehydrogenation of alkanes using Ga-rich alloys of noble metals. Here, the conceptual catalytic application of SCALMS in dry reforming of methane (DRM) is tested with non-noble metal (Co, Cu, Fe, Ni) atoms in the gallium-rich liquid alloy. This study introduces SCALMS to high-temperature applications and an oxidative reaction environment. Most catalysts were shown to undergo severe oxidation during DRM, while Ga-Ni SCALMS retained a certain level of activity. This observation is explained by a kinetically controlled redox process, namely oxidation to gallium oxide species and re-reduction via H2 activation over Ni. Consequentially, this redox process can be shifted to the metallic side when using increasing concentrations of Ni in Ga, which strongly suppresses coke formation. Density-functional theory (DFT) based ab initio molecular dynamics (AIMD) simulations were performed to confirm the increased availability of Ni at the liquid alloy-gas interface. However, leaching of gallium via the formation of volatile oxidic species during the hypothesised redox cycles was identified indicating a critical instability of Ga-Ni SCALMS for prolonged test durations.

PdCu nanoalloy decorated photocatalysts for efficient and selective oxidative coupling of methane in flow reactors

Methane activation by photocatalysis is one of the promising sustainable technologies for chemical synthesis. However, the current efficiency and stability of the process are moderate. Herein, a PdCu nanoalloy (~2.3 nm) was decorated on TiO2, which works for the efficient, stable, and selective photocatalytic oxidative coupling of methane at room temperature. A high methane conversion rate of 2480 μmol g-1 h-1 to C2 with an apparent quantum efficiency of ~8.4% has been achieved. More importantly, the photocatalyst exhibits the turnover frequency and turnover number of 116 h-1 and 12,642 with respect to PdCu, representing a record among all the photocatalytic processes (λ > 300 nm) operated at room temperature, together with a long stability of over 112 hours. The nanoalloy works as a hole acceptor, in which Pd softens and weakens C-H bond in methane and Cu decreases the adsorption energy of C2 products, leading to the high efficiency and long-time stability.

Light-Reinforced Key Intermediate for Anticoking To Boost Highly Durable Methane Dry Reforming over Single Atom Ni Active Sites on CeO2

Dry reforming of methane (DRM) has been investigated for more than a century; the paramount stumbling block in its industrial application is the inevitable sintering of catalysts and excessive carbon emissions at high temperatures. However, the low-temperature DRM process still suffered from poor reactivity and severe catalyst deactivation from coking. Herein, we proposed a concept that highly durable DRM could be achieved at low temperatures via fabricating the active site integration with light irradiation. The active sites with Ni-O coordination (NiSA/CeO2) and Ni-Ni coordination (NiNP/CeO2) on CeO2, respectively, were successfully constructed to obtain two targeted reaction paths that produced the key intermediate (CH3O*) for anticoking during DRM. In particular, the operando diffuse reflectance infrared Fourier transform spectroscopy coupling with steady-state isotopic transient kinetic analysis (operando DRIFTS-SSITKA) was utilized and successfully tracked the anticoking paths during the DRM process. It was found that the path from CH3* to CH3O* over NiSA/CeO2 was the key path for anticoking. Furthermore, the targeted reaction path from CH3* to CH3O* was reinforced by light irradiation during the DRM process. Hence, the NiSA/CeO2 catalyst exhibits excellent stability with negligible carbon deposition for 230 h under thermo-photo catalytic DRM at a low temperature of 472 °C, while NiNP/CeO2 shows apparent coke deposition behavior after 0.5 h in solely thermal-driven DRM. The findings are vital as they provide critical insights into the simultaneous achievement of low-temperature and anticoking DRM process through distinguishing and directionally regulating the key intermediate species.

Highly Efficient Solar-Driven Dry Reforming of Methane on a Rh/LaNiO3 Catalyst through a Light-induced Metal-To-Metal Charge Transfer Process

As an energy-saving and green method, solar-driven dry reforming of methane (DRM) is expected to introduce new activation processes and prevent sintering and coking of the catalysts. However, it still lacks an efficient way to coordinate the regulation of activation of reactants and lattice oxygen migration. In this study, Rh/LaNiO3 is designed as a highly efficient photothermal catalyst for solar-driven DRM, which performs production rates of 452.3 mmol h-1  gRh -1 for H2 and 527.6 mmol h-1  gRh -1 for CO2 under a light intensity of 1.5 W cm-2 , with an excellent stability. Moreover, a remarkable light-to-chemical energy efficiency (LTCEE) of 10.72% is achieved under a light intensity of 3.5 W cm-2 . The characterizations of surface electronic and chemical properties and theoretical analysis demonstrate that strong adsorption for CH4 and CO2 , light-induced metal-to-metal charge transfer (MMCT) process and high oxygen mobility together bring Rh/LaNiO3 excellent performance for solar-driven DRM.

Synthesis of nanoparticles via microfluidic devices and integrated applications

In recent years, nanomaterials have attracted the research intervention of experts in the fields of catalysis, energy, biomedical testing, and biomedicine with their unrivaled optical, chemical, and biological properties. From basic metal and oxide nanoparticles to complex quantum dots and MOFs, the stable preparation of various nanomaterials has always been a struggle for researchers. Microfluidics, as a paradigm of microscale control, is a remarkable platform for online stable synthesis of nanomaterials with efficient mass and heat transfer in microreactors, flexible blending of reactants, and precise control of reaction conditions. We describe the process of microfluidic preparation of nanoparticles in the last 5 years in terms of microfluidic techniques and the methods of microfluidic manipulation of fluids. Then, the ability of microfluidics to prepare different nanomaterials, such as metals, oxides, quantum dots, and biopolymer nanoparticles, is presented. The effective synthesis of some nanomaterials with complex structures and the cases of nanomaterials prepared by microfluidics under extreme conditions (high temperature and pressure), the compatibility of microfluidics as a superior platform for the preparation of nanoparticles is demonstrated. Microfluidics has a potent integration capability to combine nanoparticle synthesis with real-time monitoring and online detection, which significantly improves the quality and production efficiency of nanoparticles, and also provides a high-quality ultra-clean platform for some bioassays.

Mechanistic Insights into Radical-Induced Selective Oxidation of Methane over Nonmetallic Boron Nitride Catalysts

Boron-based nonmetallic materials (such as B₂O₃ and BN) emerge as promising catalysts for selective oxidation of light alkanes by O₂ to form value-added products, resulting from their unique advantage in suppressing CO₂ formation. However, the site requirements and reaction mechanism of these boron-based catalysts are still in vigorous debate, especially for methane (the most stable and abundant alkane). Here, we show that hexagonal BN (h-BN) exhibits high selectivities to formaldehyde and CO in catalyzing aerobic oxidation of methane, similar to Al₂O₃-supported B₂O₃ catalysts, while h-BN requires an extra induction period to reach a steady state. According to various structural characterizations, we find that active boron oxide species are gradually formed in situ on the surface of h-BN, which accounts for the observed induction period. Unexpectedly, kinetic studies on the effects of void space, catalyst loading, and methane conversion all indicate that h-BN merely acts as a radical generator to induce gas-phase radical reactions of methane oxidation, in contrast to the predominant surface reactions on B₂O₃/Al₂O₃ catalysts. Consequently, a revised kinetic model is developed to accurately describe the gas-phase radical feature of methane oxidation over h-BN. With the aid of in situ synchrotron vacuum ultraviolet photoionization mass spectroscopy, the methyl radical (CH₃^•) is further verified as the primary reactive species that triggers the gas-phase methane oxidation network. Theoretical calculations elucidate that the moderate H-abstraction ability of predominant CH₃^• and CH₃OO^• radicals renders an easier control of the methane oxidation selectivity compared to other oxygen-containing radicals generally proposed for such processes, bringing deeper understanding of the excellent anti-overoxidation ability of boron-based catalysts.

Effects of Operating Parameters and Feed Gas Compositions on the Dry Reforming of Methane over the Ni/Al2O3 Catalyst

The effects of operating parameters such as reaction temperature, space velocity, and feed gas composition on the performance of the methane dry-reforming reaction (DRM) over the Ni/Al2O3 catalyst are systemically investigated. The Ni/Al2O3 catalyst, which is synthesized by conventional wet impregnation, showed well-developed mesoporosity with well-dispersed Ni nanoparticles. CH4 and CO2 conversions over the Ni/Al2O3 catalyst are dramatically increased as both the reaction temperature is increased, and space velocity is decreased. The feed gas composition, especially the CO2/CH4 ratio, significantly influences the DRM performance, catalyst deactivation and the reaction behavior of side reactions. When the CO2-rich gas composition (CO2/CH4 > 1) was used, a reverse water gas shift (RWGS) reaction significantly occurred, leading to the consumption of hydrogen produced from DRM. The CH4-rich gas composition (CO2/CH4 < 1) induces severe carbon depositions followed by a reverse Boudouard reaction, resulting in catalytic activity drastically decreasing at the beginning followed by a stable conversion. The catalyst after the DRM reaction with a different feed ratio was analyzed to investigate the amount and structure of carbon deposited on the catalyst. In this study, we suggested that the optimal DRM reaction conditions can achieve stable performances in terms of conversion, hydrogen production and long-term stability.

Maximizing Active Fe Species in ZSM-5 Zeolite Using Organic-Template-Free Synthesis for Efficient Selective Methane Oxidation

The selective oxidation of CH₄ in the aqueous phase to produce valuable chemicals has attracted considerable attention due to its mild reaction conditions and simple process. As the most widely studied catalyst for this reaction, Fe-ZSM-5 demonstrates high intrinsic activity and selectivity; however, Fe-ZSM-5 prepared using conventional methods has a limited number of active Fe sites, resulting in low CH₄ conversion per unit mass of the catalyst. This study reports a facile organic-template-free synthesis strategy that enables the incorporation of more Fe into the zeolite framework with a higher dispersion degree compared to conventional synthesis methods. Because framework Fe incorporated in this way is more readily transformed into isolated extra-framework Fe species under thermal treatment, the overall effect is that Fe-ZSM-5 prepared using this method (Fe-HZ5-TF) has 3 times as many catalytically active sites as conventional Fe-ZSM-5. When used for the selective oxidation of CH₄ with 0.5 M H₂O₂ at 75 °C, Fe-HZ5-TF produced a high C₁ oxygenate yield of 109.4 mmol g_cat^-1 h^-1 (a HCOOH selectivity of 91.1%), surpassing other catalysts reported to date. Spectroscopic characterization and density functional theory calculations revealed that the active sites in Fe-HZ5-TF are mononuclear Fe species in the form of [(H₂O)₃Fe(IV)═O]²⁺ bound to Al pairs in the zeolite framework. This differs from conventional Fe-ZSM-5, where binuclear Fe acts as the active site. Analysis of the catalyst and product evolution during the reaction suggests a radical-driven pathway to explain CH₄ activation at the mononuclear Fe site and subsequent conversion to C₁ oxygenates.

Synergistic promotions between CO2 capture and in-situ conversion on Ni-CaO composite catalyst

The integrated CO₂ capture and conversion (iCCC) technology has been booming as a promising cost-effective approach for Carbon Neutrality. However, the lack of the long-sought molecular consensus about the synergistic effect between the adsorption and in-situ catalytic reaction hinders its development. Herein, we illustrate the synergistic promotions between CO₂ capture and in-situ conversion through constructing the consecutive high-temperature Calcium-looping and dry reforming of methane processes. With systematic experimental measurements and density functional theory calculations, we reveal that the pathways of the reduction of carbonate and the dehydrogenation of CH₄ can be interactively facilitated by the participation of the intermediates produced in each process on the supported Ni-CaO composite catalyst. Specifically, the adsorptive/catalytic interface, which is controlled by balancing the loading density and size of Ni nanoparticles on porous CaO, plays an essential role in the ultra-high CO₂ and CH₄ conversions of 96.5% and 96.0% at 650 °C, respectively.

Upgrading heterogeneous Ni catalysts with thiol modification

Precious metal catalysts are the cornerstone of many industrial processes. Replacing precious metal catalysts with earth-abundant metals is one of key challenges for the green and sustainable development of chemical industry. We report in this work a surprisingly effective strategy toward the development of cost-effective, air-stable, and efficient Ni catalysts by simple surface modification with thiols. The as-prepared catalysts exhibit unprecedentedly high activity and selectivity in the reductive amination of aldehydes/ketones. The thiol modification can not only prevent the deep oxidation of Ni surface to endow the catalyst with long shelf life in air but can also allow the reductive amination to proceed via a non-contact mechanism to selectively produce primary amines. The catalytic performance is far superior to that of precious and non-precious metal catalysts reported in the literature. The wide application scope and high catalytic performance of the developed Ni catalysts make them highly promising for the low-cost, green production of high-value amines in chemical industry.

Ni-Cu Alloy Nanoparticles Confined by Physical Encapsulation with SiO2 and Chemical Metal-Support Interaction with CeO2 for Methane Dry Reforming

Fabrication of sintering- and carbon-free Ni catalysts for methane dry reforming (MDR), which is attractive to upgrade greenhouse gases CH₄ and CO₂, is challenging. In this work, we innovatively synthesized Ni-Cu alloy nanoparticles confined by physical encapsulation and chemical metal-support interaction (MSI); the synergism of alloy effect, size effect, MSI, and confinement effect in the catalysts gave high rates of CH₄ and CO₂ of 6.98 and 7.16 mmol/(g_Nis), respectively, at 1023 K for 50 h. The rates were 2-3 times enhanced compared to those in the literature. XRD, TEM, H₂-TPR, and so forth revealed that the alloy effect, size effect, and MSI of Ni-Cu and CeO₂ enhanced the MDR activity; MSI promoted the ceria surface lattice oxygen mobility and generated more oxygen vacancies, almost completely gasifying carbon deposits; chemical confinement from MSI and physical confinement from SiO₂ nanospheres realized sintering-free alloys and CeO₂ nanoparticles. The synergistic approach provides a universal strategy for sintering- and carbon-free Ni catalyst design for MDR reaction.

Counting Point Defects at Nanoparticle Surfaces by Electron Holography

Metal oxide nanoparticles exhibit outstanding catalytic properties, believed to be related to the presence of oxygen vacancies at the particle's surface. However, little quantitative information is known about concentrations of point defects inside and at surfaces of these nanoparticles, due to the challenges in achieving an atomically resolved experimental access. By employing off-axis electron holography, we demonstrate, using MgO nanoparticles as an example, a methodology that discriminates between mobile charge induced by electron beam irradiation and immobile charge associated with deep traps induced by point defects as well as distinguishes between bulk and surface point defects. Counting the immobile charge provides a quantification of the concentration of F²⁺ centers induced by oxygen vacancies at the MgO nanocube surfaces.

The role of Mo species in Ni-Mo catalysts for dry reforming of methane

The Ni-Mo catalyst has attracted significant attention due to its excellent coke-resistance in dry reforming of methane (DRM) reaction, but its detailed mechanism is still vague. Herein, Mo-doped Ni (Ni-Mo_x) and MoO_x adsorbed Ni surfaces (MoO_x@Ni) are employed to explore the DRM reaction mechanism and the effect of coke-resistance. Due to the electron donor effect of Mo, the antibonding states below the Fermi level between Ni and C increase and the adsorption of C decrease, thereby inhibiting the carbonization of Ni. On account of the strong Mo and O interaction, more O atoms gather around Mo, which inhibits the oxidation of Ni and may promote the formation of MoO_x species on the Ni-Mo catalyst. The presence of Mo-O species promotes the carbon oxidation, forming a unique redox cycle (MoO_x ↔ MoO_x-1) similar to the Mars-van Krevelen (MvK) mechanism, explaining the excellent anti-carbon deposition effect on the Ni-Mo catalyst.