Porous Silicon Carbide (SiC): A Chance for Improving Catalysts or Just Another Active-Phase Carrier?

There is an obvious gap between efforts dedicated to the control of chemicophysical and morphological properties of catalyst active phases and the attention paid to the search of new materials to be employed as functional carriers in the upgrading of heterogeneous catalysts. Economic constraints and common habits in preparing heterogeneous catalysts have narrowed the selection of active-phase carriers to a handful of materials: oxide-based ceramics (e.g. Al₂O₃, SiO₂, TiO₂, and aluminosilicates-zeolites) and carbon. However, these carriers occasionally face chemicophysical constraints that limit their application in catalysis. For instance, oxides are easily corroded by acids or bases, and carbon is not resistant to oxidation. Therefore, these carriers cannot be recycled. Moreover, the poor thermal conductivity of metal oxide carriers often translates into permanent alterations of the catalyst active sites (i.e. metal active-phase sintering) that compromise the catalyst performance and its lifetime on run. Therefore, the development of new carriers for the design and synthesis of advanced functional catalytic materials and processes is an urgent priority for the heterogeneous catalysis of the future. Silicon carbide (SiC) is a non-oxide semiconductor with unique chemicophysical properties that make it highly attractive in several branches of catalysis. Accordingly, the past decade has witnessed a large increase of reports dedicated to the design of SiC-based catalysts, also in light of a steadily growing portfolio of porous SiC materials covering a wide range of well-controlled pore structure and surface properties. This review article provides a comprehensive overview on the synthesis and use of macro/mesoporous SiC materials in catalysis, stressing their unique features for the design of efficient, cost-effective, and easy to scale-up heterogeneous catalysts, outlining their success where other and more classical oxide-based supports failed. All applications of SiC in catalysis will be reviewed from the perspective of a given chemical reaction, highlighting all improvements rising from the use of SiC in terms of activity, selectivity, and process sustainability. We feel that the experienced viewpoint of SiC-based catalyst producers and end users (these authors) and their critical presentation of a comprehensive overview on the applications of SiC in catalysis will help the readership to create its own opinion on the central role of SiC for the future of heterogeneous catalysis.

Preparation and Investigation of Pd and Bimetallic Pd-Sn Nanocrystals on γ-Al2O3

One of the key factors for producing highly dispersed controlled nanoparticles is the method used for metal deposition. The decomposition of metal-organic precursors is a good method for deposition of metal nanoparticles with very small sizes and narrow size distributions on the surface of various supports. The preparation process of Pd and bimetallic Pd-Sn nanoparticles supported onto γ-Al2O3 is considered. The samples were prepared by diffusional co-impregnation of the γ-Al2O3 support by using organometallic Pd(acac)2 and Sn(acac)2Cl2 precursors. To achieve the formation of Pd and bimetallic Pd-Sn nanoparticles on the support surface, the synthesized samples were then subjected to thermal decomposition under Ar (to decompose the organometallic bound to the surface while keeping the formed nanoparticles small) followed by an oxidation in O2 (to eliminate the organic compounds remaining on the surface) and a reduction in H2 (to reduce the nanoparticles oxidized during the previous step). A combination of methods (ICP-OES, TPR-H2, XPS, TEM/EDX) was used to compare the physical-chemical properties of the synthesized Pd and bimetallic Pd-Sn nanoparticles supported on the γ-Al2O3. The three samples exhibit narrow size distribution with a majority on nanoparticles between 3 and 5 nm. Local EDX measurements clearly showed that the nanoparticles are bimetallic with the expected chemical composition and the measured global composition by ICP-OES. The surface composition and electronic properties of Pd and Sn on the γ-Al2O3 support were investigated by XPS, in particular the chemical state of palladium and tin after each step of thermal decomposition treatments (oxidation, reduction) by the XPS method has been carried out. The reducibility of the prepared bimetallic nanoparticles was measured by hydrogen temperature programmed reduction (TPR-H2). The temperature programmed reduction TPR-H2 experiments have confirmed the existence of strong surface interactions between Pd and Sn, as evidenced by hydrogen spillover of Pd to Sn (Pd-assisted reduction of oxygen precovered Sn). These results lead us to propose a mechanism for the formation of the bimetallic nanoparticles.

Bimetallic PdAg nanoparticle arrays from monolayer films of diblock copolymer micelles

The self-assembly technique provides a highly efficient route to generate well-ordered structures on a nanometer scale. In this paper, well-ordered arrays of PdAg alloy nanoparticles on flat substrates with narrow distributions of particle size (6-7 nm) and interparticle spacing (about 60 nm) were synthesized by the block copolymer micelle approach. A home-made PS-b-P4VP diblock copolymer was prepared to obtain a micellar structure in toluene. Pd and Ag salts were then successfully loaded in the micellar core of the PS-b-P4VP copolymer. A self-assembled monolayer of the loaded micelles was obtained by dipping the flat substrate in the solution. At this stage, the core of the micelles was still loaded with the metal precursor rather than with a metal. Physical and chemical reducing methods were used to reduce the metal salts embedded in the P4VP core into PdAg nanoparticles. HRTEM and EDX indicated that Pd-rich PdAg alloy nanoparticles were synthesized by chemical or physical reduction; UV-visible spectroscopy observations confirmed that metallic PdAg nanoparticles were quickly formed after chemical reduction; XPS measurements revealed that the PdAg alloy nanoparticles were in a metallic state after a short time of exposure to O2 plasma and after hydrazine reduction.