Design and synthesis of heterogeneous catalysts: the thermolytic molecular precursor approach

Design strategies for the molecular level synthesis of supported catalysts

Supported catalysts, metal or oxide catalytic centers constructed on an underlying solid phase, are making an increasingly important contribution to heterogeneous catalysis. For example, in industry, supported catalysts are employed in selective oxidation, selective reduction, and polymerization reactions. Supported structures increase the thermal stability, dispersion, and surface area of the catalyst relative to the neat catalytic material. However, structural and mechanistic characterization of these catalysts presents a formidable challenge because traditional preparations typically afford complex mixtures of structures whose individual components cannot be isolated. As a result, the characterization of supported catalysts requires a combination of advanced spectroscopies for their characterization, unlike homogeneous catalysts, which have relatively uniform structures and can often be characterized using standard methods. Moreover, these advanced spectroscopic techniques only provide ensemble averages and therefore do not isolate the catalytic function of individual components within the mixture. New synthetic approaches are required to more controllably tailor supported catalyst structures. In this Account, we review advances in supported catalyst synthesis and characterization developed in our laboratories at Northwestern University. We first present an overview of traditional synthetic methods with a focus on supported vanadium oxide catalysts. We next describe approaches for the design and synthesis of supported polymerization and hydrogenation catalysts, using anchoring techniques which provide molecular catalyst structures with exceptional activity and high percentages of catalytically significant sites. We then highlight similar approaches for preparing supported metal oxide catalysts using atomic layer deposition and organometallic grafting. Throughout this Account, we describe the use of incisive spectroscopic techniques, including high-resolution solid state NMR, UV-visible diffuse reflectance (DRS), UV-Raman, and X-ray absorption spectroscopies to characterize supported catalysts. We demonstrate that it is possible to tailor and isolate defined surface species using a molecularly oriented approach. We anticipate that advances in catalyst design and synthesis will lead to a better understanding of catalyst structure and function and, thus, to advances in existing catalytic processes and the development of new technologies.

Enhancement of epoxidation efficiencies for Ta-SBA15 catalysts. The influence of modification with -EMe3 (E = Si, Ge, Sn) groups

Site-isolated Ta(V) centers were introduced onto the surface of a mesoporous SBA-15 support via the thermolytic molecular precursor method. After thermal treatment under oxygen, the resulting Si-OH and Ta-OH sites of TaSBA15-O(2)were modified with a series of trimethyl group 14 species, Me(3)E-, by treatment with Me(3)E-NMe(2) (E = Si, Ge, Sn) reagents. The resulting surface-modified catalysts (Me(3)E)(cap)TaSBA15 exhibit a significantly increased rate of cyclohexene epoxidation with H(2)O(2) as an oxidant, and provided a decreased amount of allylic oxidation products with respect to the unmodified material, TaSBA15-O(2). The rate of nonproductive H(2)O(2) decomposition, as monitored via (1)H NMR spectroscopy, significantly decreased after the surface modification. The structure of the TaSBA15 catalysts and potential Ta(V) epoxidation intermediates (formed upon treatment of Ta(V) materials with H(2)O(2)) were probed using UV-visible absorbance and diffuse-reflectance UV-visible spectroscopy. A Ta(V)(η(2)-O(2)) intermediate species is proposed for the TaSBA15-O(2), (Me(3)Si)(cap)TaSBA15, and (Me(3)Ge)(cap)TaSBA15 catalysts, while intermediate species for the (Me(3)Sn)(cap)TaSBA15 catalysts could not be characterized.

Zeolite-supported rhodium complexes and clusters: switching catalytic selectivity by controlling structures of essentially molecular species

Precise synthesis and characterization of site-isolated rhodium complexes and extremely small rhodium clusters supported on zeolite HY allow control of the catalyst selectivity in the conversion of ethene to n-butene or ethane, respectively, as a result of tuning the structure of the active sites at a molecular level.

Design and use of nanostructured single-site heterogeneous catalysts for the selective transformation of fine chemicals

Nanostructured single-site heterogeneous catalysts possess the advantages of classical solid catalysts, in terms of easy recovery and recycling, together with a defined tailored chemical and steric environment around the catalytically active metal site. The use of inorganic oxide supports with selected shape and porosity at a nanometric level may have a relevant impact on the regio- and stereochemistry of the catalytic reaction. Analogously, by choosing the optimal preparation techniques to obtain spatially isolated and well-characterised active sites, it is possible to achieve performances that are comparable to (or, in the most favourable cases, better than) those obtained with homogeneous systems. Such catalysts are therefore particularly suitable for the transformation of highly-functionalised fine chemicals and some relevant examples where high chemo-, regio- and stereoselectivity are crucial will be described.

Single-Site Heterogeneous Catalysts

Intellectually, the advantages that flow from the availability of single-site heterogeneous catalysts (SSHC) are many. They facilitate the determination of the kinetics and mechanism of catalytic turnover-both experimentally and computationally-and make accessible the energetics of various intermediates (including short-lived transition states). These facts in turn offer a rational strategic principle for the design of new catalysts and the improvement of existing ones. It is generally possible to prepare soluble molecular fragments that circumscribe the single-site, thus enabling a direct comparison to be made, experimentally, between the catalytic performance of the same active site when functioning as a heterogeneous (continuous solid) as well as a homogeneous (dispersed molecular) catalyst. This approach also makes it possible to modify the immediate atomic environment as well as the central atomic structure of the active site. From the practical standpoint, SSHC exhibit very high selectivities leading to the production of sharply defined molecular products, just as do their homogeneous analogues. Given that mesoporous silicas with very large internal surface areas are ideal supports for SSHC, and that more than a quarter of the elements of the Periodic Table may be grafted as active sites onto such silicas, there is abundant scope for creating new catalytic opportunities.

Rigid Nanoscopic Containers for Highly Dispersed, Stable Metal and Bimetal Nanoparticles with Both Size and Site Control

We demonstrate a novel strategy for the preparation of mesoporous silica-supported, highly dispersed, stable metal and bimetal nanoparticles with both size and site control. The supporting mesoporous silica, functionalized by polyaminoamine (PAMAM) dendrimers, is prepared by repeated Michael addition with methyl acrylates (MA) and amidation reaction with ethylenediamine (EDA), by using aminopropyl-functionalized mesoporous silica as the starting material. The encapsulation of metal nanoparticles within the dendrimer-propagated mesoporous silica is achieved by the chemical reduction of metal-salt-impregnated dendrimer-mesoporous silica by using aqueous hydrazine. The site control of the metal or bimetal nanoparticles is accomplished by the localization of inter- or intradendrimeric nanoparticles within the mesoporous silica tunnels. The size of the encapsulated nanoparticles is controlled by their confinement to the nanocavity of the dendrimer and the mesopore. For Cu and Pd, particles locate at the lining of mesoporous tunnels, and have diameters of less than 2.0 nm. For Pd/Pt, particles locate at the middle of mesoporous tunnels and have diameters in the range of 2.0-4.2 nm. The Pd and Pd/Pt nanoparticles are very stable in air, whereas the Cu nanoparticles are stable only in an inert atmosphere.

UV−Vis Microspectroscopy: Probing the Initial Stages of Supported Metal Oxide Catalyst Preparation

A UV-vis microspectroscopy methodology for monitoring the speciation and macrodistribution of catalyst-precursor species inside catalyst-support bodies at the initial stages of catalyst preparation has been developed. The setup is based upon optical-fiber technology and allows spatially resolved analysis of bisected catalyst bodies. The potential of this tool is demonstrated by two pore-volume impregnation studies involving Ni2+ d-d transition bands and Cr6+ charge-transfer bands.

Copper Bronze Catalyzed Heck Reaction in Ionic Liquids

Heck reaction of aryl iodides and activated aryl bromides catalyzed by copper bronze in tetrabutylammonium bromide as solvent and tetrabutylammonium acetate as base was developed. The effective catalysts are Cu nanoparticles deriving from the reaction of iodobenzene with copper bronze. These nanoparticles are very stable in tetraalkylammonium salts, are easily recycled, and can be stored for months without a loss of catalytic efficiency. [reaction: see text]

Transformations of molecules and secondary building units to materials: a bottom-up approach

A variety of complex inorganic solids with open-framework and other fascinating architectures, involving silicate, phosphate, and other anions, have been synthesized under hydrothermal conditions. The past few years have also seen the successful synthesis and characterization of several molecular compounds that can act as precursors to form open-framework and other materials, some of them resembling secondary building units (SBUs). Transformations of rationally synthesized molecular compounds to materials constitute an important new direction in both structural inorganic chemistry and materials chemistry and enable possible pathways for the rational design of materials. In this article, we indicate the potential of such a bottom-up approach, by briefly examining the transformations of molecular silicates and phosphates. We discuss stable organosilanols and silicate secondary building units, phosphorous acids and phosphate secondary building units, di- and triesters of phosphoric acids, and molecular phosphate clusters and polymers. We also examine the transformations of metal dialkyl phosphates and molecular metal phosphates.

Atomic Level Control over Surface Species via a Molecular Precursor Approach: Isolated Cu(I) Sites and Cu Nanoparticles Supported on Mesoporous Silica

A nonaqueous molecular precursor grafting approach was employed for the generation of well-defined surface structures featuring Cu on a mesoporous silica support. X-ray absorption measurements (XANES and EXAFS) were used to determine that [CuOSi(OtBu)3]4 provided 100% isolated Cu(I) sites upon grafting (without thermal treatment), whereas [CuOtBu]4 gave isolated species with most of the original Cu-O-Cu linkages intact, but in a more relaxed straight chain form. Upon heating under inert conditions, the vast majority of Cu in the materials from [CuOSi(OtBu)3]4 remained as isolated Cu(I) sites (up to 88% isolation), with significant stabilization provided from the -OSi(OtBu)3 ligands. In stark contrast, approximately 100% of the Cu in the materials generated from [CuOtBu]4 was readily reduced upon heating, forming isolated Cu metal particles with an average diameter of 0.7 nm.

Molecular zinc phosphonates: synthesis and X-ray crystal structures of [{(ZnMe)4(THF)2}{tBuPO3}2] and [{(ZnEt)3(Zn(THF))3}{tBuPO3}4{μ3-OEt}]

The reactions of zinc alkyls with tert-butylphosphonic acid in 2 : 1 and 1 : 1 molar ratios afforded [[(ZnMe)(4-)(THF)2][tBuPO3]2] (2) and [[(ZnEt)3(Zn(THF))3][tBuPO3]4[mu3-OEt]] (3), respectively. Compounds 2 and 3 have been fully characterised by means of spectroscopic and analytical methods. Single-crystal X-ray diffraction studies revealed that zinc phosphonates 2 and 3 are tetra- and hexa-nuclear, respectively. This is in contrast to the dodecanuclear zinc phosphonate [[Zn2(THF)2(ZnEt)6Zn4(mu4-O)][(tBuPO3)8]] (1) obtained in a 1.5 : 1 reaction between zinc alkyls and tBuP(O)(OH)2.

Synthesis and characterization of {(diene)Rh[μ-OSi(OtBu)3]}2, a precursor to silica-bound rhodium

Reaction of [(diene)RhCl]2 with 2 equiv of KOSi(OtBu)3 afforded [(diene)Rh[mu-OSi(OtBu)3]]2, where diene=cod (1) and nbd (2). Multinuclear NMR studies reveal that 1 and 2 have a dimeric structure with bridging tris(tert-butoxy)siloxy ligands. These dimers are folded along the O...O axis. Complexes and reacted with PR3(R=Me, Ph) to give monomeric products, the formulae of which depend on the amount of PR3 added ((diene)Rh[OSi(OtBu)3](PR3) and Rh[OSi(OtBu)3](PMe3)3). The behavior of 1 towards water and methanol is discussed. Thermogravimetric analyses (TGAs) of 1 and 2 reveal rather sharp conversions to rhodium-containing materials. Thermolysis of 1 in toluene at 180 degrees C resulted in formation of a black precipitate, which contained rhodium nanoparticles with an average diameter of 22 nm, as determined by powder X-ray diffraction (PXRD), after calcination at 300 degrees C for 1 h.