Nano-Array Integrated Structured Catalysts: A New Paradigm upon Conventional Wash-Coated Monolithic Catalysts?

Enhancing sorption kinetics by oriented and single crystalline array-structured ZSM-5 film on monoliths

To enhance the reaction kinetics without sacrificing activity in porous materials, one potential solution is to utilize the anisotropic distribution of pores and channels besides enriching active centers at the reactive surfaces. Herein, by designing a unique distribution of oriented pores and single crystalline array structures in the presence of abundant acid sites as demonstrated in the ZSM-5 nanorod arrays grown on monoliths, both enhanced dynamics and improved capacity are exhibited simultaneously in propene capture at low temperature within a short duration. Meanwhile, the ZSM-5 array also helps mitigate the long-chain HCs and coking formation due to the enhanced diffusion of reactants in and reaction products out of the array structures. Further integrating the ZSM-5 array with Co3O4 nanoarray enables comprehensive propene removal throughout a wider temperature range. The array structured film design could offer energy-efficient solutions to overcome both sorption and reaction kinetic restrictions in various solid porous materials for various energy and chemical transformation applications.

Low Heat Capacity 3D Hollow Microarchitected Reactors for Thermal and Fluid Applications

Lightweight reactor materials that simultaneously possess low heat capacity and large surface area are desirable for various applications such as catalytic supports, heat exchangers, and biological scaffolds. However, they are challenging to satisfy this criterion originating from their structural property in most porous cellular solids. Microlattices have great potential to resolve this issue in directing transport phenomena because of their hierarchically ordered design and controllable geometrical features such as porosity, specific surface, and tortuosity. In this study, we report hollow ceramic microlattices comprising a 10 μm thick hollow nickel oxide beam in an octet-truss architecture with low heat capacity and high specific surface area. Our microarchitected reactors exhibited a low heat capacity for a rapid thermal response with a small Biot number (Bi << 1) and large intertwined surface area for homogeneous flow mixing and chemical reactions, which made them ideal candidates for various energy applications. The hollow ceramic microlattice was fabricated by digital light three-dimensional (3D) printing, composite electroless plating, polymer removal, and subsequent thermal annealing. The transient thermal response and fluidic properties of the 3D-printed microstructures were experimentally investigated using a small-scale thermal and fluid test system, and analytically interpreted using simplified models. Our findings indicate that hollow microarchitected reactors provide a promising platform for developing multifunctional materials for thermal and fluid applications.

Synergistic promotion of transition metal ion-exchange in TiO2 nanoarray-based monolithic catalysts for the selective catalytic reduction of NOx with NH3

The improved performance of the multi-component Cu–Ce–Mn/TNA catalysts over the mono-metallic catalysts demonstrated the synergistic promotion of multi-transition-metal-doped nanoarray catalysts for efficient NO abatement.

3D NiCo-Layered double Hydroxide@Ni nanotube networks as integrated free-standing electrodes for nonenzymatic glucose sensing

Nickel cobalt layered double hydroxide (NiCo-LDH)-based materials have recently emerged as catalysts for important electrochemical applications. However, they frequently suffer from low electrical conductivity and agglomeration, which in turn impairs their performance. Herein, we present a catalyst design based on integrated, self-supported nickel nanotube networks (Ni-NTNWs) loaded with NiCo-LDH nanosheets, which represents a binder-free, hierarchically nanostructured electrode architecture combining continuous conduction paths and openly accessible macropores of low tortuosity with an ultrahigh density of active sites. Similar to macroscale metallic foams, the NTNWs serve as three-dimensionally interconnected, robust frameworks for the deposition of active material, but are structured in the submicron range. Our synthesis is solely based on scalable approaches, namely templating with commercial track-etched membranes, electroless plating, and electrodeposition. Morphological and compositional characterization proved the successful decoration of the inner and outer nanotube surfaces with a conformal NiCo-LDH layer. Ni-NTNW electrodes and hydroxide-decorated variants showed excellent performance in glucose sensing. The highest activity was achieved for the catalyst augmented with NiCo-LDH nanosheets, which surpassed the modification with pure Ni(OH)₂. Despite its low thickness of 20 µm, the optimized catalyst layer provided an outstanding sensitivity of 4.6 mA mM^-1 cm^-2, a low detection limit of 0.2 µM, a fast response time of 5.3 s, high selectivity and stability, and two linear ranges covering four orders of magnitude, up to 2.5 mM analyte. As such, derivatized interconnected metal nano-networks represent a promising design paradigm for highly miniaturized yet effective catalyst electrodes and electrochemical sensors.

Ion-Exchange Loading Promoted Stability of Platinum Catalysts Supported on Layered Protonated Titanate-Derived Titania Nanoarrays

Supported metal catalysts are one of the major classes of heterogeneous catalysts, which demand good stability in both the supports and catalysts. Herein, layered protonated titanate-derived TiO₂ (LPT-TiO₂) nanowire arrays were synthesized to support platinum catalysts using different loading processes. The Pt ion-exchange loading on pristine LPTs followed by thermal annealing resulted in superior Pt catalysts supported on the LPT-TiO₂ nanoarrays with excellent hydrothermal stability and catalytic performance toward CO and NO oxidations as compared to the Pt catalysts through wet-impregnation on the anatase TiO₂ (ANT-TiO₂) nanoarrays resulted from thermal annealing of LPT nanoarrays. Both loading processes resulted in highly dispersed Pt nanoparticles (NPs) with average sizes smaller than 1 nm at their pristine states. However, after hydrothermal aging at 800 °C for 50 h, highly dispersed Pt NPs were only retained on the ion-exchanged LPT-TiO₂ nanoarrays with the support structure consisting of a mixture of 74% anatase and 26% rutile TiO₂. For the wet-impregnation loading directly on anatase TiO₂ nanoarrays derived from LPT, the Pt catalysts experienced severe agglomeration after hydrothermal aging, with the nanoarray supports consisting of 86% anatase and 14% rutile TiO₂. Spectroscopy analysis suggested that Pt²⁺ cations intercalated into the interlayers of the titanate frameworks through ion-exchange impregnation procedure, which altered the chemical and electronic structures of the catalysts, resulting in the shifts of the electronic binding energy, Raman bands, and optical energy bandgap. The ion-exchangeable nature of LPT nanoarrays clearly provides a structural modification in Pt-doped LPT that has resulted in a strong interaction between the Pt catalysts and LPT-TiO₂ nanoarray supports, leading to the enhanced hydrothermal stability of the catalysts. Considering the wide applications of the LPT and TiO₂ nanomaterials as supports for catalysts, this finding provides a new pathway to design highly stable supported metal catalysts for different reactions.

Metal Nanotube/Nanowire-Based Unsupported Network Electrocatalysts

Combining 1D metal nanotubes and nanowires into cross-linked 2D and 3D architectures represents an attractive design strategy for creating tailored unsupported catalysts. Such materials complement the functionality and high surface area of the nanoscale building blocks with the stability, continuous conduction pathways, efficient mass transfer, and convenient handling of a free-standing, interconnected, open-porous superstructure. This review summarizes synthetic approaches toward metal nano-networks of varying dimensionality, including the assembly of colloidal 1D nanostructures, the buildup of nanofibrous networks by electrospinning, and direct, template-assisted deposition methods. It is outlined how the nanostructure, porosity, network architecture, and composition of such materials can be tuned by the fabrication conditions and additional processing steps. Finally, it is shown how these synthetic tools can be employed for designing and optimizing self-supported metal nano-networks for application in electrocatalysis and related fields.

Direct Synthesis of Conformal Layered Protonated Titanate Nanoarray Coatings on Various Substrate Surfaces Boosted by Low-Temperature Microwave-Assisted Hydrothermal Synthesis

Layered protonated titanates (LPTs) are promising support materials for catalytic applications because their high surface area and cation exchange capacity provide the possibility of achieving a high metal dispersion. However, the reported LPT nanomaterials are mainly limited to free-standing nanoparticles (NPs) and usually require high temperature and pressure conditions with extended reaction time. In this work, a high-throughput microwave-assisted hydrothermal method was developed for the direct synthesis of conformal LPT nanoarray coatings onto the three-dimensional honeycomb monoliths as well as other substrate surfaces at low temperature (75-95 °C) and pressure (1 atm). Using TiCl₃ as the titanium source, H₂O₂ as the oxidant, and hydrochloric acid as the pH controller, a peroxotitanium complex (PTC) was formed and identified to play an essential role for the formation of LPT nanoarrays. The gaseous O₂ released during the decomposition of PTC promotes the mass transfer of the precursors, making this method applicable to substrates with complex geometries. With the optimized conditions, a growth rate of 42 nm/min was achieved on cordierite monolith substrates. When loaded with Pt NPs, the LPT nanoarray-based monolithic catalysts showed excellent low-temperature catalytic activity for CO and hydrocarbon oxidation as well as satisfactory hydrothermal stability and mechanical robustness. The low temperature and pressure requirements of this facile hydrothermal method overcome the size- and pressure-seal restrictions of the reactors, making it feasible for scaled production of LPT nanoarray-based devices for various applications.