Coaxial 3D Printing of Zeolite-Based Core-Shell Monolithic Cu-SSZ-13@SiO2 Catalysts for Diesel Exhaust Treatment

Core-shell catalysts with functional shells can increase the activity and stability of the catalysts in selective catalytic reduction of NOx with ammoniax. However, the conventional approaches based on multistep fabrication for core-shell structures encounter persistent restrictions regarding strict synthesis conditions and limited design flexibility. Herein, a facile coaxial 3D printing strategy is for the first time developed to construct zeolite-based core-shell monolithic catalysts with interconnected honeycomb structures, in which the hydrophilic noncompact silica serves as shell and Cu-SSZ-13 zeolite acts as core. Compared to a Cu-SSZ-13 monolith which suffers from the interfacial diffusion, the SiO2 shell layer can increase the accessibility of active sites over Cu-SSZ-13@SiO2, resulting in a 10-20% higher NO conversion at200-550 °C under 300 000 cm3 g-1 h-1. Meanwhile, a thicker SiO2 shell enhances the hydrothermal stability of the aged catalyst by inhibiting the dealumination and the formation of CuOx. Other representative monolithic catalysts with different topological zeolites as shell and diverse metal oxides as the core can be also realized by this coaxial 3D printing. This strategy allows multiple porous materials to be directly integrated, which allows for flexible design and fabrication of various core-shell monolithic catalysts with customized functionalities.

A Hierarchical Metal-Organic Framework Composite Aerogel Catalyst Containing Integrated Acid, Base, and Metal Sites for the One-Pot Catalytic Synthesis of Cyclic Carbonates

Catalysis has played a decisive role in the development of unique chemical reactions to produce important chemicals. However, conventional stepwise synthetic routes that rely on individual catalysts to promote each step often suffer from ponderous processes for the isolation of intermediates that result in massive material losses and large economic expenditures. In addition, traditional powder forms of these catalysts suffer from poor processability and recoverability. Herein, we designed and prepared a hierarchical metal-organic framework (MOF) composite monolithic catalyst IL-Au@UiO-66-NH2/CMC that contains integrated acid (Zr4+), base (ionic liquid (IL)), and metal sites (Au nanoparticles (NPs)) to promote the one-pot preparation of cyclic carbonates from styrene derivatives and CO2. Highly dispersed Au NPs, IL 1-aminoethyl-3-methylimidazolium bromide ([C2NH2 MIM] [Br]), and MOF-positioned Lewis acid sites within this composite aerogel are separately responsible for catalyzing selective epoxidation of the styrene derivatives and the subsequent cycloaddition reaction of CO2 with intermediate styrene oxides. Importantly, inclusion of the imidazolium-based IL effectively modulates the size and chemical microenvironment of the Au NPs via electrostatic protection, leading to catalyst stability and its selective oxidation of styrene. Benefiting from the rapid mass transfer and high exposure of active sites within the pore-rich hierarchical nanostructure, IL-Au@UiO-66-NH2/CMC promotes high conversion (90.5%) of the styrene and selectivity (80.5%) for styrene carbonate (SC) formation in the one-pot process, a performance level that far exceeds those of related catalysts containing only Au NPs or IL (the selectivity of SC < 42%). Furthermore, the composite aerogel catalyst can be readily separated and recycled at least five times without a remarkable loss of activity and selectivity. The controllable integration of various active components in the hierarchical MOF composite aerogel herein should serve as the foundation for the design of multifunctional monolithic catalysts for other valuable tandem processes.

In situfabrication of Cu-Mn-O nanostructure catalysts on Ti mesh and their catalytic property optimization for low-temperature and stable CO oxidation

A series of interlaced 'tripe-shaped' nanoflake catalysts made of CuMn2O4werein situprepared on Ti mesh substrate through the associated methods of plasma electrolyte oxidation and hydrothermal technique. The surface morphology, elemental distribution and chemical state, phase composition and microstructure of CuMn2O4nanostructures prepared under different conditions were systemically investigated. To evaluate the catalytic activity, the CO oxidation as a probe reaction was used, and the results showed that 12h-Cu1Mn2-300 (hydrothermal reaction at 150 °C for 12 h, Cu/Mn = 1/2 in initial precursor, heat treatment temperature at 300 °C) exhibited the best CO oxidation capability withT100= 150 °C owe to the formation of uniform CuMn2O4nanosheet layersin situgrown on flexible Ti mesh and the synergistic effect of Cu and Mn species in spinel CuMn2O4, which makes it more active towards CO oxidation than pure copper/manganese oxides.

Wood-Derived Monolithic Catalysts with the Ability of Activating Water Molecules for Oxygen Electrocatalysis

Oxygen reduction reaction (ORR) is the key reaction on cathode of rechargeable zinc-air batteries (ZABs). However, the lack of protons in alkaline conditions limits the rate of ORR. Herein, an activating water strategy is proposed to promote oxygen electrocatalytic activity by enhancing the proton production from water dissociation. FeP nanoparticles (NPs) are coupled on N-doped wood-derived catalytically active carbon (FeP-NWCC) to associate bifunctional active sites. In alkaline, FeP-NWCC possesses outstanding catalytic activities toward ORR (E_1/2  = 0.86 V) and Oxygen evolution reaction (OER) (overpotential is 310 mV at 10 mA cm^-2 ). The liquid ZABs assembled by FeP-NWCC deliver superior peak power density (144 mW cm^-2 ) and cycle stability (over 450 h). The quasi-solid-state ZABs based on FeP-NWCC also display excellent performances. Theoretical calculation illustrates that the superb bifunctional performance of FeP-NWCC results from the elevated dissociation efficiency of water via FeP NPs to assist the oxygen catalytic process. The strategy of activating water provides a new perspective for the design of ORR/OER bifunctional catalysts. This work is a model for the application of forest biomass.

3D Printing in Heterogeneous Catalysis-The State of the Art

This paper describes the process of additive manufacturing and a selection of three-dimensional (3D) printing methods which have applications in chemical synthesis, specifically for the production of monolithic catalysts. A review was conducted on reference literature for 3D printing applications in the field of catalysis. It was proven that 3D printing is a promising production method for catalysts.

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.

Fe-Doped CoP Nanoarray: A Monolithic Multifunctional Catalyst for Highly Efficient Hydrogen Generation

An Fe-doped CoP nanoarray behaves as a robust 3D monolithic multifunctional catalyst for electrolytic and hydrolytic hydrogen evolution with high activity. Its two-electrode electrolyzer needs a cell voltage of only 1.60 V for 10 mA cm^-2 water-splitting current. It also catalyzes effectively NaBH₄ hydrolysis with a low activation energy of ≈39.6 kJ mol^-1 and a hydrogen generation rate of 6.06 L min^-1 g^-1 .

Manganese Oxide Nanoarray-Based Monolithic Catalysts: Tunable Morphology and High Efficiency for CO Oxidation

A generic one-pot hydrothermal synthesis route has been successfully designed and utilized to in situ grow uniform manganese oxide nanorods and nanowires onto the cordierite honeycomb monolithic substrates, forming a series of nanoarray-based monolithic catalysts. During the synthesis process, three types of potassium salt oxidants have been used with different reduction potentials, i.e., K2Cr2O7, KClO3, and K2S2O8, denoted as HM-DCM, HM-PCR, and HM-PSF, respectively. The different reduction potentials of the manganese source (Mn(2+)) and oxidants induced the formation of manganese oxide nanoarrays with different morphology, surface area, and reactivity of carbon monoxide (CO) oxidation. K2Cr2O7 and KClO3 can induce sharp and long nanowires with slow growth rates due to their low reduction potentials. In comparison, the nanoarrays of HM-PSF presented shorter nanorods but displayed an efficient 90% CO oxidation conversion at 200 °C (T90) without noble-metal loading. Reducibility tests for the three monolithic catalysts by hydrogen temperature-programmed reduction revealed an activation energy order of HM-PSF > HM-DCM > HM-PCR for CO oxidation. The characterizations of oxygen temperature-programmed desorption and X-ray photoelectron spectroscopy indicated the abundant surface-adsorbed oxygen and lattice oxygen contributing to the superior reactivity of HM-PSF. The straightforward synthetic process showed a scalable, low-cost, and template-free method to fabricate manganese oxide nanoarray monolithic catalysts for exhaust treatment.