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Ando A, Hirano T, Cao KLA, Septiani EL, Tanabe E, Ragadhita R, Nandiyanto ABD, Ogi T. Design and internal structure analysis of submicron aggregated and porous three-way catalyst particles synthesized via spray drying for enhanced CO conversion. J Colloid Interface Sci 2025; 686:277-288. [PMID: 39899912 DOI: 10.1016/j.jcis.2025.01.243] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/01/2024] [Revised: 01/23/2025] [Accepted: 01/26/2025] [Indexed: 02/05/2025]
Abstract
The development of efficient three-way catalysts (TWCs) is crucial for reducing vehicle emissions and addressing environmental concerns. However, the widespread application of TWCs is limited by their reliance on expensive precious metals and challenges in optimizing catalytic performance at low temperatures. To address these limitations, this study presents a novel approach to designing and characterizing submicron spherical aggregated TWC particles and porous structured TWC particles, which were synthesized using a spray drying method. The objectives of this research focus on optimizing the particle size of aggregated TWC particles, analyzing the internal porous architecture of porous TWC particles, and evaluating their catalytic performance in CO conversion. The synthesis process allowed precise control over the particle size of aggregated TWC particles by adjusting the concentration of colloidal TWC nanoparticles, revealing that smaller aggregated particles (520 nm) exhibited superior CO conversion efficiency compared to larger particles (1,180 nm) due to enhanced gas accessibility. Cross-sectional and three-dimensional elemental mapping analyses of porous TWC particles provided insights into the homogeneity of elemental distribution and interconnected pore networks, critical for efficient gas transport. Furthermore, the effect of CO gas flow rate on catalytic performance was systematically investigated, demonstrating that lower gas flow rates enhanced CO conversion efficiency at reduced temperatures due to prolonged gas-catalyst contact time. This work demonstrates a clear correlation between particle size of aggregated TWC particles and their catalytic efficiency, as well as highlights the influence of gas flow rates on the catalytic activity of porous TWC particles.
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Affiliation(s)
- Ai Ando
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Tomoyuki Hirano
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Kiet Le Anh Cao
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Eka Lutfi Septiani
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Eishi Tanabe
- Hiroshima Prefectural Technology Research Institute, 3-13-26 Kagamiyama, Higashi Hiroshima, Hiroshima 739-0046, Japan
| | - Risti Ragadhita
- Program Studi Teknik Kimia, Universitas Pendidikan Indonesia, Jl. Setiabudhi No. 229, Bandung, West Java 40154, Indonesia
| | - Asep Bayu Dani Nandiyanto
- Program Studi Teknik Kimia, Universitas Pendidikan Indonesia, Jl. Setiabudhi No. 229, Bandung, West Java 40154, Indonesia
| | - Takashi Ogi
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan.
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2
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Zhang Y, Du J, Shan Y, Wang F, Liu J, Wang M, Liu Z, Yan Y, Xu G, He G, Shi X, Lian Z, Yu Y, Shan W, He H. Toward synergetic reduction of pollutant and greenhouse gas emissions from vehicles: a catalysis perspective. Chem Soc Rev 2025; 54:1151-1215. [PMID: 39687940 DOI: 10.1039/d4cs00140k] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/18/2024]
Abstract
It is a great challenge for vehicles to satisfy the increasingly stringent emission regulations for pollutants and greenhouse gases. Throughout the history of the development of vehicle emission control technology, catalysts have always been in the core position of vehicle aftertreatment. Aiming to address the significant demand for synergistic control of pollutants and greenhouse gases from vehicles, this review provides a panoramic view of emission control technologies and key aftertreatment catalysts for vehicles using fossil fuels (gasoline, diesel, and natural gas) and carbon-neutral fuels (hydrogen, ammonia, and green alcohols). Special attention will be given to the research advancements in catalysts, including three-way catalysts (TWCs), NOx selective catalytic reduction (SCR) catalysts, NOx storage-reduction (NSR) catalysts, diesel oxidation catalysts (DOCs), soot oxidation catalysts, ammonia slip catalysts (ASCs), methane oxidation catalysts (MOCs), N2O abatement catalysts (DeN2O), passive NOx adsorbers (PNAs), and cold start catalysts (CSCs). The main challenges for industrial applications of these catalysts, such as insufficient low-temperature activity, product selectivity, hydrothermal stability, and poisoning resistance, will be examined. In addition, the future development of synergistic control of vehicle pollutants and greenhouse gases will be discussed from a catalysis perspective.
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Affiliation(s)
- Yan Zhang
- Fujian Key Laboratory of Atmospheric Ozone Pollution Prevention, Institute of Urban Environment, Chinese Academy of Sciences, Xiamen 361021, China
- Zhejiang Key Laboratory of Pollution Control for Port-Petrochemical Industry, Ningbo Urban Environment Observation and Research Station, Institute of Urban Environment, Chinese Academy of Sciences, Ningbo, 315800, China.
| | - Jinpeng Du
- Research Center for Eco-Environmental Sciences, Chinese Academy of Sciences, Beijing 100085, China.
| | - Yulong Shan
- Research Center for Eco-Environmental Sciences, Chinese Academy of Sciences, Beijing 100085, China.
| | - Fei Wang
- Faculty of Environmental Science and Engineering, Kunming University of Science and Technology, Kunming 650500, China
| | - Jingjing Liu
- Research Center for Eco-Environmental Sciences, Chinese Academy of Sciences, Beijing 100085, China.
| | - Meng Wang
- Fujian Key Laboratory of Atmospheric Ozone Pollution Prevention, Institute of Urban Environment, Chinese Academy of Sciences, Xiamen 361021, China
- Zhejiang Key Laboratory of Pollution Control for Port-Petrochemical Industry, Ningbo Urban Environment Observation and Research Station, Institute of Urban Environment, Chinese Academy of Sciences, Ningbo, 315800, China.
| | - Zhi Liu
- Research Center for Eco-Environmental Sciences, Chinese Academy of Sciences, Beijing 100085, China.
| | - Yong Yan
- Ganjiang Innovation Academy, Chinese Academy of Sciences, Ganzhou 341000, China
| | - Guangyan Xu
- Research Center for Eco-Environmental Sciences, Chinese Academy of Sciences, Beijing 100085, China.
| | - Guangzhi He
- Research Center for Eco-Environmental Sciences, Chinese Academy of Sciences, Beijing 100085, China.
| | - Xiaoyan Shi
- Research Center for Eco-Environmental Sciences, Chinese Academy of Sciences, Beijing 100085, China.
| | - Zhihua Lian
- Fujian Key Laboratory of Atmospheric Ozone Pollution Prevention, Institute of Urban Environment, Chinese Academy of Sciences, Xiamen 361021, China
| | - Yunbo Yu
- Research Center for Eco-Environmental Sciences, Chinese Academy of Sciences, Beijing 100085, China.
- Ganjiang Innovation Academy, Chinese Academy of Sciences, Ganzhou 341000, China
| | - Wenpo Shan
- Fujian Key Laboratory of Atmospheric Ozone Pollution Prevention, Institute of Urban Environment, Chinese Academy of Sciences, Xiamen 361021, China
- Zhejiang Key Laboratory of Pollution Control for Port-Petrochemical Industry, Ningbo Urban Environment Observation and Research Station, Institute of Urban Environment, Chinese Academy of Sciences, Ningbo, 315800, China.
| | - Hong He
- Fujian Key Laboratory of Atmospheric Ozone Pollution Prevention, Institute of Urban Environment, Chinese Academy of Sciences, Xiamen 361021, China
- Research Center for Eco-Environmental Sciences, Chinese Academy of Sciences, Beijing 100085, China.
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3
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Kautsar DB, Le PH, Ando A, Tanabe E, Cao KLA, Septiani EL, Hirano T, Ogi T. Enhancing CO oxidation performance by controlling the interconnected pore structure in porous three-way catalyst particles. NANOSCALE 2025; 17:2841-2851. [PMID: 39835367 DOI: 10.1039/d4nr03770g] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/22/2025]
Abstract
Highly ordered porous structured particles comprising three-way catalyst (TWC) nanoparticles have attracted attention because of their remarkable catalytic performance. However, the conditions for controlling their pore arrangement to form interconnected pore structures remain unclear. In particular, the correlation between framework thickness (distance between pores) or macroporosity and the diffusion of gaseous reactants to achieve a high catalytic performance has not been extensively discussed. Here, the interconnected pore structure was successfully controlled by adjusting the precursor components (i.e., template particle concentration) via a template-assisted spray process. A cross-sectional image analysis was conducted to comprehensively examine the internal structure and porous properties (framework thickness and macroporosity) of the porous TWC particles. In addition, we propose mathematical equations to predict the framework thickness and macroporosity, as well as determine the critical conditions that caused the formation of interconnected pores and broken structures in the porous TWC particles. The evaluation of CO oxidation performance revealed that porous TWC particles with an interconnected pore structure, thin framework, and high macroporosity exhibited a high catalytic performance owing to the effective diffusion and utilization of their internal parts. The study findings provide valuable insights into the design of porous TWC particles with interconnected pore structures to enhance exhaust gas emission control in real-world applications.
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Affiliation(s)
- Duhaul Biqal Kautsar
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi Hiroshima, Hiroshima 739-8527, Japan.
| | - Phong Hoai Le
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi Hiroshima, Hiroshima 739-8527, Japan.
| | - Ai Ando
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi Hiroshima, Hiroshima 739-8527, Japan.
| | - Eishi Tanabe
- Hiroshima Prefectural Institute of Industrial Science and Technology, 3-10-31 Kagamiyama, Higashi Hiroshima, Hiroshima 739-0046, Japan
| | - Kiet Le Anh Cao
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi Hiroshima, Hiroshima 739-8527, Japan.
| | - Eka Lutfi Septiani
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi Hiroshima, Hiroshima 739-8527, Japan.
| | - Tomoyuki Hirano
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi Hiroshima, Hiroshima 739-8527, Japan.
| | - Takashi Ogi
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi Hiroshima, Hiroshima 739-8527, Japan.
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4
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Septiani EL, Ogi T. Advances in Aerosol Nanostructuring: Functions and Control of Next-Generation Particles. LANGMUIR : THE ACS JOURNAL OF SURFACES AND COLLOIDS 2024; 40:26789-26799. [PMID: 39546762 DOI: 10.1021/acs.langmuir.4c02867] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/17/2024]
Abstract
Nanostructured particles (NSPs), with their remarkable properties at the nanoscale, possess key functions required for unlocking a sustainable future. Fabricating these particles using aerosol methods and spraying processes enables precise control over the particle morphology, structure, composition, and crystallinity during in-flight transformation. In this Perspective, the significant impact of NSPs on technological advancement for energy and environmental applications is discussed. Furthermore, incorporating in situ/operando assessment techniques alongside machine and deep learning is explored. Finally, the future development trends and the perspective on the advancing NSPs synthesis via aerosol process are elaborated for further driving innovations for supersmart and carbon-neutral society.
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Affiliation(s)
- Eka Lutfi Septiani
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Takashi Ogi
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
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5
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Hirano T, Tsuboi T, Ho TTN, Tanabe E, Takano A, Kataoka M, Ogi T. Macroporous Structures of Nb-SnO 2 Particles as a Catalyst Support Induce High Porosity and Performance in Polymer Electrolyte Fuel Cell Catalyst Layers. NANO LETTERS 2024; 24:10426-10433. [PMID: 39140557 DOI: 10.1021/acs.nanolett.4c01150] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 08/15/2024]
Abstract
Macroporous niobium-doped tin oxide (NTO) is introduced as a robust alternative to conventional carbon-based catalyst supports to improve the durability and performance of polymer electrolyte fuel cells (PEFCs). Metal oxides like NTO are more stable than carbon under PEFC operational conditions, but they can compromise gas diffusion and water management because of their denser structures. To address this tradeoff, we synthesized macroporous NTO particles using a flame-assisted spray-drying technique employing poly(methyl methacrylate) as a templating agent. X-ray diffraction analysis and scanning electron microscopy confirmed the preservation of crystallinity and revealed a macroporous morphology with larger pore volumes and diameters than those in flame-made NTO nanoparticles, as revealed by mercury porosimetry. The macroporous NTO particles exhibited enhanced maximum current density and reduced gas diffusion resistance relative to commercial carbon supports. Our findings establish a foundation for integrating macroporous NTO structures into PEFCs to optimize durability and performance.
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Affiliation(s)
- Tomoyuki Hirano
- Chemical Engineering Program, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Takama Tsuboi
- Chemical Engineering Program, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Thi Thanh Nguyen Ho
- Chemical Engineering Program, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Eishi Tanabe
- Hiroshima Prefectural Institute of Industrial Science and Technology, 3-10-31 Kagamiyama, Higashi Hiroshima, Hiroshima 739-0046, Japan
| | - Aoi Takano
- Cataler Corporation, 7800 Chihama, Kakegawa, Shizuoka 437-1492, Japan
| | - Mikihiro Kataoka
- Cataler Corporation, 7800 Chihama, Kakegawa, Shizuoka 437-1492, Japan
| | - Takashi Ogi
- Chemical Engineering Program, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
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6
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Groppe P, Reichstein J, Carl S, Cuadrado Collados C, Niebuur BJ, Zhang K, Apeleo Zubiri B, Libuda J, Kraus T, Retzer T, Thommes M, Spiecker E, Wintzheimer S, Mandel K. Catalyst Supraparticles: Tuning the Structure of Spray-Dried Pt/SiO 2 Supraparticles via Salt-Based Colloidal Manipulation to Control their Catalytic Performance. SMALL (WEINHEIM AN DER BERGSTRASSE, GERMANY) 2024; 20:e2310813. [PMID: 38700050 DOI: 10.1002/smll.202310813] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/23/2023] [Revised: 04/10/2024] [Indexed: 05/05/2024]
Abstract
The structure of supraparticles (SPs) is a key parameter for achieving advanced functionalities arising from the combination of different nanoparticle (NP) types in one hierarchical entity. However, whenever a droplet-assisted forced assembly approach is used, e.g., spray-drying, the achievable structure is limited by the inherent drying phenomena of the method. In particular, mixed NP dispersions of differently sized colloids are heavily affected by segregation during the assembly. Herein, the influence of the colloidal arrangement of Pt and SiO2 NPs within a single supraparticulate entity is investigated. A salt-based electrostatic manipulation approach of the utilized NPs is proposed to customize the structure of spray-dried Pt/SiO2 SPs. By this, size-dependent separation phenomena of NPs during solvent evaporation, that limit the catalytic performance in the reduction of 4-nitrophenol, are overcome by achieving even Pt NP distribution. Additionally, the textural properties (pore size and distribution) of the SiO2 pore framework are altered to improve the mass transfer within the material leading to increased catalytic activity. The suggested strategy demonstrates a powerful, material-independent, and universally applicable approach to deliberately customize the structure and functionality of multi-component SP systems. This opens up new ways of colloidal material combinations and structural designs in droplet-assisted forced assembly approaches like spray-drying.
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Affiliation(s)
- Philipp Groppe
- Department of Chemistry and Pharmacy, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 1, 91058, Erlangen, Germany
| | - Jakob Reichstein
- Department of Chemistry and Pharmacy, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 1, 91058, Erlangen, Germany
| | - Simon Carl
- Institute of Micro- and Nanostructure Research (IMN) & Center for Nanoanalysis and Electron Microscopy (CENEM), Interdisciplinary Center for Nanostructured Films (IZNF), Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Cauerstrasse 3, 91058, Erlangen, Germany
| | - Carlos Cuadrado Collados
- Institute of Separation Science and Technology, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 3, 91058, Erlangen, Germany
| | - Bart-Jan Niebuur
- INM - Leibniz-Institute for New Materials, Campus D2 2, 66123, Saarbrücken, Germany
| | - Kailun Zhang
- Interface Research and Catalysis, Erlangen Center for Interface Research and Catalysis (ECRC), Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 3, 91058, Erlangen, Germany
| | - Benjamin Apeleo Zubiri
- Institute of Micro- and Nanostructure Research (IMN) & Center for Nanoanalysis and Electron Microscopy (CENEM), Interdisciplinary Center for Nanostructured Films (IZNF), Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Cauerstrasse 3, 91058, Erlangen, Germany
| | - Jörg Libuda
- Interface Research and Catalysis, Erlangen Center for Interface Research and Catalysis (ECRC), Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 3, 91058, Erlangen, Germany
| | - Tobias Kraus
- INM - Leibniz-Institute for New Materials, Campus D2 2, 66123, Saarbrücken, Germany
- Colloid and Interface Chemistry, Saarland University, Campus D2 2, 66123, Saarbrücken, Germany
| | - Tanja Retzer
- Interface Research and Catalysis, Erlangen Center for Interface Research and Catalysis (ECRC), Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 3, 91058, Erlangen, Germany
| | - Matthias Thommes
- Institute of Separation Science and Technology, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 3, 91058, Erlangen, Germany
| | - Erdmann Spiecker
- Institute of Micro- and Nanostructure Research (IMN) & Center for Nanoanalysis and Electron Microscopy (CENEM), Interdisciplinary Center for Nanostructured Films (IZNF), Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Cauerstrasse 3, 91058, Erlangen, Germany
| | - Susanne Wintzheimer
- Department of Chemistry and Pharmacy, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 1, 91058, Erlangen, Germany
- Fraunhofer-Institute for Silicate Research ISC, Neunerplatz 2, 97082, Würzburg, Germany
| | - Karl Mandel
- Department of Chemistry and Pharmacy, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Egerlandstraße 1, 91058, Erlangen, Germany
- Fraunhofer-Institute for Silicate Research ISC, Neunerplatz 2, 97082, Würzburg, Germany
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Ratnasari D, Septiani EL, Dani Nandiyanto AB, Le Anh Cao K, Okuda N, Matsumoto H, Hirano T, Ogi T. Nanostructuring silica-iron core-shell particles in a one-step aerosol process. RSC Adv 2024; 14:18171-18180. [PMID: 38854827 PMCID: PMC11155725 DOI: 10.1039/d4ra01154f] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/15/2024] [Accepted: 05/30/2024] [Indexed: 06/11/2024] Open
Abstract
Silica-coated iron (Fe@SiO2) particles have attracted considerable interest as a potential powder core material due to their distinctive advantages, including higher magnetic saturation and enhanced electrical resistance. In this study, the submicron-sized core-shell Fe@SiO2 particles were successfully synthesized in a single step via an aerosol process using a spray pyrolysis method assisted by a swirler connector for the first time. Changing the reducing agent concentration (supplied H2) and tuning the number of core (Fe) particles were investigated to achieve the desired Fe@SiO2 particles. The results indicated that an excessive number of cores led to the appearance of FeO crystals due to insufficient reduction. Conversely, an insufficient number of cores resulted in a thicker SiO2 shell, which hindered the penetration of the supplied H2 gas. Furthermore, the produced Fe@SiO2 particles exhibited soft-ferromagnetic characteristics with an excellent magnetic saturation value of 2.04 T, which is close to the standard theoretical value of 2.15 T. This work contributes new insights into the production of core-shell Fe@SiO2 particles, expanding their applicability to advanced soft-magnetic materials.
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Affiliation(s)
- Delyana Ratnasari
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University 1-4-1 Kagamiyama Higashi-Hiroshima Hiroshima 739-8527 Japan
| | - Eka Lutfi Septiani
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University 1-4-1 Kagamiyama Higashi-Hiroshima Hiroshima 739-8527 Japan
| | - Asep Bayu Dani Nandiyanto
- Program Studi Kimia, Fakultas Pendidikan Matematika dan Ilmu Pengetahuan Alam, Universitas Pendidikan Indonesia Jl. Setiabudhi No 229 Bandung West Java 40154 Indonesia
| | - Kiet Le Anh Cao
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University 1-4-1 Kagamiyama Higashi-Hiroshima Hiroshima 739-8527 Japan
| | - Nobuhiro Okuda
- Materials Research Center, Technology & Intellectual Property HQ, TDK Corporation 570-2 Matsugashita, Minami-Hadori Narita Chiba 286-8588 Japan
| | - Hiroyuki Matsumoto
- Materials Research Center, Technology & Intellectual Property HQ, TDK Corporation 570-2 Matsugashita, Minami-Hadori Narita Chiba 286-8588 Japan
| | - Tomoyuki Hirano
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University 1-4-1 Kagamiyama Higashi-Hiroshima Hiroshima 739-8527 Japan
| | - Takashi Ogi
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University 1-4-1 Kagamiyama Higashi-Hiroshima Hiroshima 739-8527 Japan
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8
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Sung YH, Senthil Raja D, Huang JH, Tsai DH. Microfluidic-Aerosol Hyphenated Synthesis of Metal-Organic Framework-Derived Hybrid Catalysts for CO 2 Utilization. SMALL METHODS 2024; 8:e2301435. [PMID: 38161255 DOI: 10.1002/smtd.202301435] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/18/2023] [Revised: 12/19/2023] [Indexed: 01/03/2024]
Abstract
A new and efficient technique is developed by combining the hyphenated microfluidic- and aerosol-based synthesis with the coupled differential mobility analysis for the effective and continuous synthesis and simultaneous analysis of metal-organic frameworks (MOFs)-derived hybrid nanostructured products. HKUST-1, a copper-based MOF, is chosen as the representative to fabricate Cu-based hybrid catalysts for reverse water-gas shift (RWGS) reaction, an effective route for CO2 utilization. The effect of precursor concentration and carrier selection on the properties of the resulting products, including mobility size distribution, crystallization degree, surface area, and metal dispersion are investigated, as well as the correlation between the material properties of the synthesized catalysts and their catalytic performance in RWGS reaction in terms of conversion ratio/rate, selectivity, and operational stability. The results indicate that the continuous microfluidic droplet system can successfully synthesize MOF colloids, followed by the continuous production of MOF-derived hybrid materials through the tandem aerosol spray-drying-reaction system. High catalytic activity and low initiate temperature toward RWGS (turnover frequency = 0.0074 s-1; 450 °C) are achievable. The work facilitates the production and the designed concept of relevant MOF-derived hybrid nanostructured catalysts in the continuous synthesis system and the enhancement of applications in CO2 capture and utilization.
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Affiliation(s)
- Yi-Hsuan Sung
- Department of Chemical Engineering, National Tsing Hua University, No. 101, Sec. 2, Kuang-Fu Rd., Hsinchu City, Taiwan, 300044, Republic of China
| | - Duraisamy Senthil Raja
- Department of Chemical Engineering, National Tsing Hua University, No. 101, Sec. 2, Kuang-Fu Rd., Hsinchu City, Taiwan, 300044, Republic of China
| | - Jen-Huang Huang
- Department of Chemical Engineering, National Tsing Hua University, No. 101, Sec. 2, Kuang-Fu Rd., Hsinchu City, Taiwan, 300044, Republic of China
| | - De-Hao Tsai
- Department of Chemical Engineering, National Tsing Hua University, No. 101, Sec. 2, Kuang-Fu Rd., Hsinchu City, Taiwan, 300044, Republic of China
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9
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Kautsar DB, Le PH, Ando A, Cao KLA, Septiani EL, Hirano T, Ogi T. Controllable Synthesis of Porous and Hollow Nanostructured Catalyst Particles and Their Soot Oxidation. LANGMUIR : THE ACS JOURNAL OF SURFACES AND COLLOIDS 2024; 40:8260-8270. [PMID: 38574288 DOI: 10.1021/acs.langmuir.4c00490] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 04/06/2024]
Abstract
The introduction of macroporous structures into three-way catalysts (TWCs) through polymer template-assisted spray drying has attracted attention because of its enhanced gas diffusion and catalytic performance. However, the surface charge effect of polymeric template components has not been investigated to control the structure of the TWC particles during synthesis. Thus, this study investigated the effect of template surface charges on the self-assembly behavior of TWC nanoparticles (NPs) during drying. The self-assembly of TWC NPs and polymer particles with different charges produced a hollow structure, whereas using the same charges generated a porous one. Consequently, the mechanism of particle self-assembly during drying and final structure particle formation is proposed in this study. Here, porous TWC particles demonstrated a faster oxidation of soot particles than that of hollow-structured particles. This occurred as a result of the larger contact area between the catalyst surface and the solid reactant. Our findings propose a fundamental self-assembly mechanism for the formation of different TWC structures, thereby enhancing soot oxidation performance using macroporous structures.
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Affiliation(s)
- Duhaul Biqal Kautsar
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Phong Hoai Le
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Ai Ando
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Kiet Le Anh Cao
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Eka Lutfi Septiani
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Tomoyuki Hirano
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
| | - Takashi Ogi
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima 739-8527, Japan
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10
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Le PH, Kitamoto Y, Yamashita S, Cao KLA, Hirano T, Amen TWM, Tsunoji N, Ogi T. Macropore-Size Engineering toward Enhancing the Catalytic Performance of CO Oxidation over Three-Way Catalyst Particles. ACS APPLIED MATERIALS & INTERFACES 2023; 15:54073-54084. [PMID: 37944066 DOI: 10.1021/acsami.3c11489] [Citation(s) in RCA: 6] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/12/2023]
Abstract
In recent years, transportation-related air pollution has escalated into a global concern, necessitating the development of a three-way catalyst (TWC) technology to address harmful emissions. However, the efficiency of TWC's performance in mitigating these emissions has been hindered because of limited mass transfer efficiency within their structures. Thus, this study attempted to overcome the existing issue by synthesizing a series of macroporous TWC particles exhibiting various macropore sizes via a template-assisted spray process, aiming to achieve optimal mass transfer efficiency and catalytic performance. The synthesis incorporated various template particles (size of 67-381 nm) to obtain various macroporous structures. Thereafter, these macroporous particles were assessed for their carbon monoxide (CO) oxidation performance, revealing a substantial influence of the macropore size on the catalytic performance of TWC structures. Interestingly, among the investigated samples, those containing the smallest and largest macropores demonstrated the highest CO oxidation performances. Based on these results, a plausible reactant diffusion mechanism was proposed to explain the effect of the macropore size on the diffusion efficiency within the macroporous structures. This work may have significant implications in optimizing the macroporous structure to enhance catalytic performance in the gas purification process.
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Affiliation(s)
- Phong Hoai Le
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima City, Hiroshima 739-8527, Japan
| | - Yasuhiko Kitamoto
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima City, Hiroshima 739-8527, Japan
| | - Shunki Yamashita
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima City, Hiroshima 739-8527, Japan
| | - Kiet Le Anh Cao
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima City, Hiroshima 739-8527, Japan
| | - Tomoyuki Hirano
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima City, Hiroshima 739-8527, Japan
| | - Tareq W M Amen
- Department of Applied Chemistry, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima City, Hiroshima 739-8527, Japan
| | - Nao Tsunoji
- Department of Applied Chemistry, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima City, Hiroshima 739-8527, Japan
| | - Takashi Ogi
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima City, Hiroshima 739-8527, Japan
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11
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Suteerapongpun T, Hanamura K. Numerical Design of Granular Support for Three-Way Catalyzed Solid- and Porous-Particles Membrane Filters. MEMBRANES 2023; 13:644. [PMID: 37505010 PMCID: PMC10383841 DOI: 10.3390/membranes13070644] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/25/2023] [Revised: 06/29/2023] [Accepted: 07/02/2023] [Indexed: 07/29/2023]
Abstract
A granular substrate used as a support for a three-way catalyzed (TWC) solid-particle membrane filter was investigated through numerical simulation. The proposed support could reduce the amount of required catalyst material by 39% and lower the pressure drop by 33%, compared to a conventional filter, while achieving almost 100% soot-filtration. Moreover, TWC porous particles, which are designed to introduce a fluid flow into their interconnected pore network, further decrease the pressure drop. However, a trade-off exists between the amount of the introduced fluid flow and the specific surface area.
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Affiliation(s)
- Teerapat Suteerapongpun
- Department of Mechanical Engineering, Tokyo Institute of Technology, 2-12-1 Ookayama, Meguro City, Tokyo 152-8550, Japan
| | - Katsunori Hanamura
- Department of Mechanical Engineering, Tokyo Institute of Technology, 2-12-1 Ookayama, Meguro City, Tokyo 152-8550, Japan
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12
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Raspberry Colloid Templated Catalysts Fabricated Using Spray Drying Method. Catalysts 2022. [DOI: 10.3390/catal13010060] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/29/2022] Open
Abstract
The majority of industrial chemical processes—from production of organic and inorganic compounds to air and water treatment—rely on heterogeneous catalysts. The performance of these catalysts has improved over the past several decades; in parallel, many innovations have been presented in publications, demonstrating increasingly higher efficiency and selectivity. One common challenge to adopting novel materials in real-world applications is the need to develop robust and cost-effective synthetic procedures for their formation at scale. Herein, we focus on the scalable production of a promising new class of materials—raspberry-colloid-templated (RCT) catalysts—that have demonstrated exceptional thermal stability and high catalytic activity. The unique synthetic approach used for the fabrication of RCT catalysts enables great compositional flexibility, making these materials relevant to a wide range of applications. Through a series of studies, we identified stable formulations of RCT materials that can be utilized in the common industrial technique of spray drying. Using this approach, we demonstrate the production of highly porous Pt/Al2O3 microparticles with high catalytic activity toward complete oxidation of toluene as a model reaction.
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13
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Septiani EL, Yamashita S, Cao KLA, Hirano T, Okuda N, Matsumoto H, Enokido Y, Ogi T. One-Step Aerosol Synthesis of SiO 2-Coated FeNi Particles by Using Swirler Connector-Assisted Spray Pyrolysis. Ind Eng Chem Res 2022. [DOI: 10.1021/acs.iecr.2c02837] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/03/2022]
Affiliation(s)
- Eka Lutfi Septiani
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima739-8527, Japan
- Chemical Engineering Department, Universitas Internasional Semen Indonesia, Kompleks PT. Semen Indonesia (Persero) Tbk, Jl. Veteran, Gresik, East Java61122, Indonesia
| | - Shunki Yamashita
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima739-8527, Japan
| | - Kiet Le Anh Cao
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima739-8527, Japan
| | - Tomoyuki Hirano
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima739-8527, Japan
| | - Nobuhiro Okuda
- Materials Research Center, Technology & Intellectual Property HQ, TDK Corporation, 570-2 Matsugashita, Minami-Hadori, Narita, Chiba286-8588, Japan
| | - Hiroyuki Matsumoto
- Materials Research Center, Technology & Intellectual Property HQ, TDK Corporation, 570-2 Matsugashita, Minami-Hadori, Narita, Chiba286-8588, Japan
| | - Yasushi Enokido
- Materials Research Center, Technology & Intellectual Property HQ, TDK Corporation, 570-2 Matsugashita, Minami-Hadori, Narita, Chiba286-8588, Japan
| | - Takashi Ogi
- Chemical Engineering Program, Department of Advanced Science and Engineering, Graduate School of Advanced Science and Engineering, Hiroshima University, 1-4-1 Kagamiyama, Higashi-Hiroshima, Hiroshima739-8527, Japan
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