Support Induced Effects on the Ir Nanoparticles Activity, Selectivity and Stability Performance under CO2 Reforming of Methane

The production of syngas (H₂ and CO)—a key building block for the manufacture of liquid energy carriers, ammonia and hydrogen—through the dry (CO₂−) reforming of methane (DRM) continues to gain attention in heterogeneous catalysis, renewable energy technologies and sustainable economy. Here we report on the effects of the metal oxide support (γ-Al₂O₃, alumina-ceria-zirconia (ACZ) and ceria-zirconia (CZ)) on the low-temperature (ca. 500–750 °C) DRM activity, selectivity, resistance against carbon deposition and iridium nanoparticles sintering under oxidative thermal aging. A variety of characterization techniques were implemented to provide insight into the factors that determine iridium intrinsic DRM kinetics and stability, including metal-support interactions and physicochemical properties of materials. All Ir/γ-Al₂O₃, Ir/ACZ and Ir/CZ catalysts have stable DRM performance with time-on-stream, although supports with high oxygen storage capacity (ACZ and CZ) promoted CO₂ conversion, yielding CO-enriched syngas. CZ-based supports endow Ir exceptional anti-sintering characteristics. The amount of carbon deposition was small in all catalysts, however decreasing as Ir/γ-Al₂O₃ > Ir/ACZ > Ir/CZ. The experimental findings are consistent with a bifunctional reaction mechanism involving participation of oxygen vacancies on the support’s surface in CO₂ activation and carbon removal, and overall suggest that CZ-supported Ir nanoparticles are promising catalysts for low-temperature dry reforming of methane (LT-DRM).

Emergence and Future of Exsolved Materials

Supported nanoparticle systems have received increased attention over the last decades because of their potential for high activity levels when applied to chemical conversions, although, because of their nanoscale nature, they tend to exhibit problems with long-term durability. Over the last decade, the discovery of the so-called exsolution concept has addressed many of these challenges and opened many other opportunities to material design by providing a relatively simple, single-step, synthetic pathway to produce supported nanoparticles that combine high stability against agglomeration and poisoning with high activity across multiple areas of application. Here, the trends that define the development of the exsolution concept are reviewed in terms of design, functionality, tunability, and applicability. To support this, the number of studies dedicated to both fundamental and application-related studies, as well as the types of metallic nanoparticles and host or support lattices employed, are examined. Exciting future directions of research are also highlighted.

Trends and Prospects of Bimetallic Exsolution

Supported bimetallic nanoparticles used for various chemical transformations appear to be more appealing than their monometallic counterparts, because of their unique properties mainly originating from the synergistic effects between the two different metals. Exsolution, a relatively new preparation method for supported nanoparticles, has earned increasing attention for bimetallic systems in the past decade, not only due to the high stability of the resulting nanoparticles but also for the potential to control key particle properties (size, composition, structure, morphology, etc.). In this review, we summarize the trends and advances on exsolution of bimetallic systems and provide prospects for future studies in this field.

Exsolution of Catalytically Active Iridium Nanoparticles from Strontium Titanate

The search for new functional materials that combine high stability and efficiency with reasonable cost and ease of synthesis is critical for their use in renewable energy applications. Specifically in catalysis, nanoparticles, with their high surface-to-volume ratio, can overcome the cost implications associated with otherwise having to use large amounts of noble metals. However, commercialized materials, that is, catalytic nanoparticles deposited on oxide supports, often suffer from loss of activity because of coarsening and carbon deposition during operation. Exsolution has proven to be an interesting strategy to overcome such issues. Here, the controlled emergence, or exsolution, of faceted iridium nanoparticles from a doped SrTiO₃ perovskite is reported and their growth preliminary probed by in situ electron microscopy. Upon reduction of SrIr_0.005Ti_0.995O₃, the generated nanoparticles show embedding into the oxide support, therefore preventing agglomeration and subsequent catalyst degradation. The advantages of this approach are the extremely low noble metal amount employed (∼0.5% weight) and the catalytic activity reported during CO oxidation tests, where the performance of the exsolved SrIr_0.005Ti_0.995O₃ is compared to the activity of a commercial catalyst with 1% loading (1% Ir/Al₂O₃). The high activity obtained with such low doping shows the possibility of scaling up this new catalyst, reducing the high cost associated with iridium-based materials.

Endogenous Nanoparticles Strain Perovskite Host Lattice Providing Oxygen Capacity and Driving Oxygen Exchange and CH4 Conversion to Syngas

Particles dispersed on the surface of oxide supports have enabled a wealth of applications in electrocatalysis, photocatalysis, and heterogeneous catalysis. Dispersing nanoparticles within the bulk of oxides is, however, synthetically much more challenging and therefore less explored, but could open new dimensions to control material properties analogous to substitutional doping of ions in crystal lattices. Here we demonstrate such a concept allowing extensive, controlled growth of metallic nanoparticles, at nanoscale proximity, within a perovskite oxide lattice as well as on its surface. By employing operando techniques, we show that in the emergent nanostructure, the endogenous nanoparticles and the perovskite lattice become reciprocally strained and seamlessly connected, enabling enhanced oxygen exchange. Additionally, even deeply embedded nanoparticles can reversibly exchange oxygen with a methane stream, driving its redox conversion to syngas with remarkable selectivity and long term cyclability while surface particles are present. These results not only exemplify the means to create extensive, self-strained nanoarchitectures with enhanced oxygen transport and storage capabilities, but also demonstrate that deeply submerged, redox-active nanoparticles could be entirely accessible to reaction environments, driving redox transformations and thus offering intriguing new alternatives to design materials underpinning several energy conversion technologies.

In Situ Observation of Nanoparticle Exsolution from Perovskite Oxides: From Atomic Scale Mechanistic Insight to Nanostructure Tailoring

Understanding and controlling the formation of nanoparticles at the surface of functional oxide supports is critical for tuning activity and stability for catalytic and energy conversion applications. Here, we use a latest generation environmental transmission electron microscope to follow the exsolution of individual nanoparticles at the surface of perovskite oxides, with ultrahigh spatial and temporal resolution. Qualitative and quantitative analysis of the data reveals the atomic scale processes that underpin the formation of the socketed, strain-inducing interface that confers exsolved particles their exceptional stability and reactivity. This insight also enabled us to discover that the shape of exsolved particles can be controlled by changing the atmosphere in which exsolution is carried out, and additionally, this could also produce intriguing heterostructures consisting of metal-metal oxide coupled nanoparticles. Our results not only provide insight into the in situ formation of nanoparticles but also demonstrate the tailoring of nanostructures and nanointerfaces.

Towards efficient use of noble metals via exsolution exemplified for CO oxidation

Many catalysts and in particular automotive exhaust catalysts usually consist of noble metal nanoparticles dispersed on metal oxide supports. While highly active, such catalysts are expensive and prone to deactivation by sintering and thus alternative methods for their production are being sought to ensure more efficient use of noble metals. Exsolution has been shown to be an approach to produce confined nanoparticles, which in turn are more stable against agglomeration, and, at the same time strained, displaying enhanced activity. While exsolution has been extensively investigated for relatively high metal loadings, it has yet to be explored for dilute loadings which is expected to be more challenging but more suitable for application of noble metals. Here we explore the substitution of Rh into an A-site deficient perovskite titante aiming to investigate the possibility of exsolving from dilute amounts of noble metal substituted perovskites. We show that this is possible and in spite of certain limitations, they still compete well against conventionally prepared samples with higher apparent surface loading when applied for CO oxidation.