Improved Thermal Stability and Methane-Oxidation Activity of Pd/Al2O3 Catalysts by Atomic Layer Deposition of ZrO2

Periodic arrays of structurally complex oxide nanoshells and their use as substrate-confined nanoreactors

Sacrificial templates present an effective pathway for gaining high-level control over nanoscale reaction products. Atomic layer deposition (ALD) is ideally suited for such approaches due to its ability to replicate the surface topography of a template material through the deposition of an ultrathin conformal layer. Herein, metal nanostructures are demonstrated as sacrificial templates for the formation of architecturally complex and deterministically positioned oxide nanoshells, open-topped nanobowls, vertically standing half-shells, and nanorings. The three-step process sees metal nanocrystals formed in periodic arrays, coated with an ALD-deposited oxide, and hollowed out with a selective etch through nanopores formed in the oxide shell. The procedure is further augmented through the use of a directional ion beam that is used to sculpt the oxide shells into bowl- and ring-like configurations. The functionality of the so-formed materials is demonstrated through their use as substrate-confined nanoreactors able to promote the growth and confinement of nanomaterials. Taken together, the work expands the design space for substrate-based nanomaterials, creates a platform for advancing functional surfaces and devices and, from a broader perspective, advances the use of ALD in forming complex nanomaterials.

Review on supported metal catalysts with partial/porous overlayers for stabilization

Heterogeneous catalysts of supported metals are important for both liquid-phase and gas-phase chemical transformations which underpin the petrochemical sector and manufacture of bulk or fine chemicals and pharmaceuticals. Conventional supported metal catalysts (SMC) suffer from deactivation resulting from sintering, leaching, coking and so on. Besides the choice of active species (e.g. atoms, clusters, nanoparticles) to maximize catalytic performances, strategies to stabilize active species are imperative for rational design of catalysts, particularly for those catalysts that work under heated and corrosive reaction conditions. The complete encapsulation of metal active species within a matrix (e.g. zeolites, MOFs, carbon, etc.) or core-shell arrangements is popular. However, the use of partial/porous overlayers (PO) to preserve metals, which simultaneously ensures the accessibility of active sites through controlling the size/shape of diffusing reactants and products, has not been systematically reviewed. The present review identifies the key design principles for fabricating supported metal catalysts with partial/porous overlayers (SMCPO) and demonstrates their advantages versus conventional supported metals in catalytic reactions.

Preparation of SBA-15-Supported Metals by Vapor-Phase Infiltration

A simple method is presented for incorporating various catalytic metals into the pores of SBA-15 using vapor-phase infiltration. The precursors used in Atomic Layer Deposition (ALD) for Pt, Pd, Rh, Ru, and Ni were exposed to an evacuated SBA-15, resulting in monolayer films of the adsorbed precursors inside the mesopores. The metal particles that formed after removal of the precursor ligands remained in the pores and had particle sizes ranging from 3.8 nm for Pt to 5.2 nm for Ni, as determined by Transmission Electron Microscopy (TEM), XRD, and CO chemisorption. Metal loadings for saturation exposures ranged from 5.1-wt% for Ni to 9.1-wt% for Pt; however, uniform deposition was demonstrated for lower loadings of Pd by decreasing the amount of precursor. To determine the effect of the surface composition of the mesopores, Pd particles were also added to SBA-15 that was coated with a 0.2-nm film of ZrO2.

Site and Structural Requirements for the Dehydra-Decyclization of Cyclic Ethers on ZrO2

In this study, we examined the site and structural requirements for the dehydra-decyclization of cyclic ethers, tetrahydrofuran, and tetrahydropyran to produce conjugated dienes over ZrO2-based catalysts, a reaction that could be an important step in the use of biomass-derived sugars as a starting material to produce monomers for the plastics industry. To help identify the active sites for this reaction, studies were conducted in which ZrO2 surfaces were decorated with Na. These studies showed that Na was effective at poisoning the activity for the ring opening of cyclic ethers, but much less so for the dehydration of the resulting adsorbed alkoxides. The studies of the activity of different types of ZrO2 for the dehydra-decyclization reaction, including single crystals and ultra-thin films supported on MgAl2O4 and silica, also showed that the reaction was dependent on the local structure of the ZrO2 surface. The insights these results provide for identifying the active sites on the ZrO2 surface are discussed.

Electronically Engineering Water Resistance in Methane Combustion with an Atomically Dispersed Tungsten on PdO Catalyst

Improving the low-temperature water-resistance of methane combustion catalysts is of importance for industrial applications and it is challenging. A stepwise strategy is presented for the preparation of atomically dispersed tungsten species at the catalytically active site (Pd nanoparticles). After an activation process, a Pd-O-W₁ -like nanocompound is formed on the PdO surface with an atomic scale interface. The resulting supported catalyst has much better water resistance than the conventional catalysts for methane combustion. The integrated characterization results confirm that catalytic combustion of methane involves water, proceeding via a hydroperoxyl-promoted reaction mechanism on the catalyst surface. The results of density functional theory calculations indicate an upshift of the d-band center of palladium caused by electron transfer from atomically dispersed tungsten, which greatly facilitates the adsorption and activation of oxygen on the catalyst.

Designing Sites in Heterogeneous Catalysis: Are We Reaching Selectivities Competitive With Those of Homogeneous Catalysts?

A critical review of different prominent nanotechnologies adapted to catalysis is provided, with focus on how they contribute to the improvement of selectivity in heterogeneous catalysis. Ways to modify catalytic sites range from the use of the reversible or irreversible adsorption of molecular modifiers to the immobilization or tethering of homogeneous catalysts and the development of well-defined catalytic sites on solid surfaces. The latter covers methods for the dispersion of single-atom sites within solid supports as well as the use of complex nanostructures, and it includes the post-modification of materials via processes such as silylation and atomic layer deposition. All these methodologies exhibit both advantages and limitations, but all offer new avenues for the design of catalysts for specific applications. Because of the high cost of most nanotechnologies and the fact that the resulting materials may exhibit limited thermal or chemical stability, they may be best aimed at improving the selective synthesis of high value-added chemicals, to be incorporated in organic synthesis schemes, but other applications are being explored as well to address problems in energy production, for instance, and to design greener chemical processes. The details of each of these approaches are discussed, and representative examples are provided. We conclude with some general remarks on the future of this field.

Techniques of Preparation of Thin Films: Catalytic Combustion

Over the past several decades, an increasing amount of attention has been given to catalytic combustion as an environmentally friendly process. However, major impediments to large-scale application still arise on the materials side. Here, we review catalytic combustion on thin film catalysts in view of highlighting some interesting features. Catalytic films open the way for new designs of structured catalysts and the construction of catalysts for catalytic combustion. A special place is occupied by materials in the form of very thin films that reveal catalytic activity for various chemical reactions. In this review, we demonstrate the high catalytic activity of thin film catalysts in these oxidation reactions.

Modulating Interactions between Molten Polystyrene and Porous Solids Using Atomic Layer Deposition

Understanding and modulating the interactions between molten polymers and porous solids is important for numerous processes and phenomena including catalytic conversion of polymers and fabrication of nanocomposites and nanostructured materials. Although changing the surface composition of pores would enable modulation of interactions between polymers and nanoporous solids, it is challenging to achieve such a control without inducing significant changes to the size and structure of nanopores. In this work, we demonstrate that the interactions between molten polystyrene (PS) and disordered packings of SiO₂ nanoparticles (NPs) can be modulated by changing the surface composition of the NPs using atomic layer deposition (ALD). A disordered packing of silica NPs is modified with varying surface coverages of TiO₂, WO₃, and CaCO₃, with coverages estimated by the mass gain and the refractive index change of NP packings. Based on the time required to fully infiltrate these ALD-modified NP packings via capillarity, the contact angles for PS on different surfaces prepared via ALD are determined. The contact angle gradually changes from that of pure SiO₂ to that of the fully covered surfaces. The contact angles for PS on SiO₂, TiO₂, WO₃, and CaCO₃ are found to be 20, 62, 70, and 10°, respectively. Interestingly, the contact angles and interfacial energies between PS and the ALD-modified surfaces do not correlate strongly with the water contact angle of these surfaces; thus, caution must be exercised in predicting how a polymer would wet or interact with porous solids solely based on their hydrophilicity. The method presented in this work can be extended to study the interactions between a wide range of polymers and surfaces in porous media, which will have important implications for designing new catalytic materials for polymer upcycling reactions and novel NP-polymer composite films and membranes with enhanced mechanical and transport properties.

Structural insight into an atomic layer deposition (ALD) grown Al2O3 layer on Ni/SiO2: impact on catalytic activity and stability in dry reforming of methane

The development of stable Ni-based dry reforming of methane (DRM) catalysts is a key challenge owing to the high operating temperatures of the process and the propensity of Ni for promoting carbon deposition. In this work, Al2O3-coated Ni/SiO2 catalysts have been developed by employing atomic layer deposition (ALD). The structure of the catalyst at each individual preparation step was characterized in detail through a combination of in situ XAS-XRD, ex situ 27Al NMR and Raman spectroscopy. Specifically, in the calcination step, the ALD-grown Al2O3 layer reacts with the SiO2 support and Ni, forming aluminosilicate and NiAl2O4. The Al2O3-coated Ni/SiO2 catalyst exhibits an improved stability for DRM when compared to the benchmark Ni/SiO2 and Ni/Al2O3 catalysts. In situ XAS-XRD during DRM together with ex situ Raman spectroscopy and TEM of the spent catalysts confirm that the ALD-grown Al2O3 layer suppresses the sintering of Ni, in turn reducing also coke formation significantly. In addition, the formation of an amorphous aluminosilicate phase by the reaction of the ALD-grown Al2O3 layer with the SiO2 support inhibited catalysts deactivation via NiAl2O4 formation, in contrast to the reference Ni/Al2O3 system. The in-depth structural characterization of the catalysts provided an insight into the structural dynamics of the ALD-grown Al2O3 layer, which reacts both with the support and the active metal, allowing to rationalize the high stability of the catalyst under the harsh DRM conditions.

Two-Dimensional Perovskite Crystals Formed by Atomic Layer Deposition of CaTiO3 on γ-Al2O3

CaTiO₃ films with an average thickness of 0.5 nm were deposited onto γ-Al₂O₃ by Atomic Layer Deposition (ALD) and then characterized by a range of techniques, including X-ray Diffraction (XRD) and High-Resolution, Transmission Electron Microscopy (HRTEM). The results demonstrate that the films form two-dimensional crystallites over the entire surface. Lattice fringes from HRTEM indicate that the crystallites range in size from 5 to 20 nm and are oriented in various directions. Films of the same thickness on SiO₂ remained amorphous, indicating that the support played a role in forming the crystallites.

Exceptionally stable sol-immobilization derived Pd/SBA-15 catalysts for methane combustion

Pd/SBA-15-SI catalysts are more efficient for methane combustion than Pd/SBA-15-IWI catalysts due to anti-sintering property of the catalysts.

A Thermodynamic Investigation of Ni on Thin-Film Titanates (ATiO3)

Thin, ~1-nm films of CaTiO3, SrTiO3, and BaTiO3 were deposited onto MgAl2O4 by Atomic Layer Deposition (ALD) and then studied as catalyst supports for ~5 wt % of Ni that was added to the perovskite thin films by Atomic Layer Deposition. Scanning Transmission Electron Microscopy demonstrated that both the Ni and the perovskites uniformly covered the surface of the support following oxidation at 1073 K, even after redox cycling, but large Ni particles formed following a reduction at 1073 K. When compared to Ni/MgAl2O4, the perovskite-containing catalysts required significantly higher temperatures for Ni reduction. Equilibrium constants for Ni oxidation, as determined from Coulometric Titration, indicated that the oxidation of Ni shifted to lower PO2 on the perovskite-containing materials. Based on Ni equilibrium constants, Ni interactions are strongest with CaTiO3, followed by SrTiO3 and BaTiO3. The shift in the equilibrium constant was shown to cause reversible deactivation of the Ni/CaTiO3/MgAl2O4 catalyst for CO2 reforming of CH4 at high CO2 pressures, due to the oxidation of the Ni.

A molecular dynamics study on the thermal properties of carbon-based gold nanoparticles

Due to unique features in surface activity, thermal stability, electrical and thermal conductivity, and compatibility with biomolecules such as DNA and proteins, carbon-based nanoparticles are raised potential as a candidate for various applications such as catalytic processes, drug delivery, light, and electrical engineering. Based on this premise, thermodynamic features of pure, graphene, and carbon nanotube (CNT)-based gold nanoparticles (AuNPs) are investigated using molecular dynamics approach. Melting, heat capacity, thermal conductivity, contact angle of molten AuNPs, and phase transition are calculated as indicators of thermodynamic properties of pure and carbon-based AuNPs. Simulation results indicate that the presence of a carbon platform and its contact surface area has a significant role in the thermodynamic properties of AuNPs and leads the phononic heat capacity and thermal conductivity to decrease for AuNPs. The platform also causes the melting point temperature of AuNPs to increase. The melting of gold on the carbon base is of the first-order type. In addition, contact angle for molten AuNPs on the Graphene is significantly higher than the one on the CNT due to more contact area on the Graphene substrate.Graphical abstract .

Designing Nanoparticles and Nanoalloys for Gas-Phase Catalysis with Controlled Surface Reactivity Using Colloidal Synthesis and Atomic Layer Deposition

Supported nanoparticles are commonly applied in heterogeneous catalysis. The catalytic performance of these solid catalysts is, for a given support, dependent on the nanoparticle size, shape, and composition, thus necessitating synthesis techniques that allow for preparing these materials with fine control over those properties. Such control can be exploited to deconvolute their effects on the catalyst's performance, which is the basis for knowledge-driven catalyst design. In this regard, bottom-up synthesis procedures based on colloidal chemistry or atomic layer deposition (ALD) have proven successful in achieving the desired level of control for a variety of fundamental studies. This review aims to give an account of recent progress made in the two aforementioned synthesis techniques for the application of controlled catalytic materials in gas-phase catalysis. For each technique, the focus goes to mono- and bimetallic materials, as well as to recent efforts in enhancing their performance by embedding colloidal templates in porous oxide phases or by the deposition of oxide overlayers via ALD. As a recent extension to the latter, the concept of area-selective ALD for advanced atomic-scale catalyst design is discussed.

Surface functionalization on nanoparticles via atomic layer deposition

As an ultrathin film preparation method, atomic layer deposition (ALD) has recently found versatile applications in fields beyond semiconductors, such as energy, environment, catalysis and so on. The design, preparation and characterization of thin film applied in the emerging fields have attracted great interests. The development of ALD technique on particles opens up a broad horizon in the advanced nanofabrication. Pioneering applications are exploring conformal coating, porous coating and selective surface modification of nanoparticles. Conformal encapsulation of particles is a major application to protect materials with ultrathin films from being eroded by the external environment while keeping the original properties of the primary particles. Porous coating has been developed to simultaneously expose the particles' surface and provide nanopores, which is another important method that demonstrates its advantages in modification of electrode materials, catalysis and energy applications, etc. Selective ALD takes the method forward in order to precisely control the directionality of decoration sites on the particles and selectively passivate undesired facets, sites, or defects. Such methods provide practical strategies for atomic scale and precise surface functionalization on particles and greatly expand its potential applications.

Synergetic effect on catalytic activity and charge transfer in Pt-Pd bimetallic model catalysts prepared by atomic layer deposition

Pt-Pd bimetallic nanoparticles were synthesized on TiO₂ support on the planar substrate as well as on high surface area SiO₂ gel by atomic layer deposition to identify the catalytic performance improvement after the formation of Pt-Pd bimetallic nanoparticles by surface analysis techniques. From X-ray absorption near edge spectra of Pt-Pd bimetallic nanoparticles, d-orbital hybridization between Pt 5d and Pd 4d was observed, which is responsible for charge transfer from Pt to Pd. Moreover, it was found from the in situ grazing incidence X-ray absorption spectroscopy study that Pt-Pd nanoparticles have a Pd shell/Pt core structure with CO adsorption. Resonant photoemission spectroscopy on Pt-Pd bimetallic nanoparticles showed that Pd resonant intensity is enhanced compared to that of Pd monometallic nanoparticles because of d-orbital hybridization and electronic states broadening of Pt and Pd compared monometallic catalysts, which results in catalytic performance improvement.

Al2O3-Coated Ni/CeO2 nanoparticles as coke-resistant catalyst for dry reforming of methane

To mitigate catalyst deactivation during the dry reforming of methane, Ni/CeO₂ catalysts composed of monodisperse Ni nanoparticles supported on CeO₂ nanorods are designed and coated with Al₂O₃ layers by atomic layer deposition.

Janus coordination polymer derived PdO/ZnO nanoribbons for efficient 4-nitrophenol reduction

Bimetallic coordination polymers–Zn(MAA)₂/Pd(ii) nanoribbons are prepared by employing two terminal units with distinct hard–soft properties of the smallest semi-rigid methacrylate anion to combine with two different metal ions.

Atomic-scale engineering of metal–oxide interfaces for advanced catalysis using atomic layer deposition

Two main routes to optimization of metal–oxide interfaces: reducing metal particle size and oxide overcoating.

An effective partial charge model for bulk and surface properties of cubic ZrO2, Y2O3 and yttrium-stabilised zirconia

In this work a newly parametrised Coulomb plus Buckingham potential formulation for cubic ZrO₂, Y₂O₃ and yttrium-stabilised zirconia (YSZ) is presented. The density and pair distributions obtained for neat ZrO₂ and Y₂O₃ under ambient conditions are in excellent agreement with experimental data, while the vibrational power spectra are highly similar compared to those obtained via ab initio molecular dynamics simulations at the PBEsol level. In addition, it is shown that the use of effective partial charges has several advantages compared to interaction potentials employing the oxidation states in the evaluation of the coulombic interactions: (i) the diffusion coefficient and the associated activation energy of oxygen ions evaluated for YSZn (n = 4 to 12) display the best agreement with experimental data; (ii) no unphysical reorganisation of the interface and the bulk are observed in simulations of the (110) and (111) surfaces of cubic ZrO₂ and Y₂O₃, while due to the strong coulombic contributions in the case of the tested full-charge models a pronounced restructuring of the interface and the bulk is observed in the ZrO₂ case, and (iii) the use of effective partial charges ensures compatibility with existing solvent models and force-fields for the treatment of molecular compounds.

Pentacoordinated Al3+ -Stabilized Active Pd Structures on Al2 O3 -Coated Palladium Catalysts for Methane Combustion

Supported Pd catalysts are active in catalyzing the highly exothermic methane combustion reaction but tend to be deactivated owing to local hyperthermal environments. Herein we report an effective approach to stabilize Pd/SiO₂ catalysts with porous Al₂ O₃ overlayers coated by atomic layer deposition (ALD). ²⁷ Al magic angle spinning NMR analysis showed that Al₂ O₃ overlayers on Pd particles coated by the ALD method are rich in pentacoordinated Al³⁺ sites capable of strongly interacting with adjacent surface PdO_x phases on supported Pd particles. Consequently, Al₂ O₃ -decorated Pd/SiO₂ catalysts exhibit active and stable PdO_x and Pd-PdO_x structures to efficiently catalyze methane combustion between 200 and 850 °C. These results reveal the unique structural characteristics of Al₂ O₃ overlayers on metal surfaces coated by the ALD method and provide a practical strategy to explore stable and efficient supported Pd catalysts for methane combustion.

Comparative Study of the Characteristics and Activities of Pd/γ-Al2O3 Catalysts Prepared by Vortex and Incipient Wetness Methods

5 wt% Pd/γ-Al2O3 catalysts were prepared by a modified Vortex Method (5-Pd-VM) and Incipient Wetness Method (5-Pd-IWM), and characterized by various techniques (Inductively coupled plasma atomic emission spectroscopy (ICP-AES), N2-physisorption, pulse CO chemisorption, temperature programmed reduction (TPR), X-ray photoelectron spectroscopy (XPS), scanning transmission electron microscopy (STEM), and X-ray diffraction (XRD)) under identical conditions. Both catalysts had similar particle sizes and dispersions; the 5-Pd-VM catalyst had 0.5 wt% more Pd loading (4.6 wt%). The surfaces of both catalysts contained PdO and PdOx with about 7% more PdOx in 5-Pd-VM. High-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM) and scanning electron microscope (SEM) images indicated presence of PdO/PdOx nanocrystals (8–10 nm) on the surface of the support. Size distribution by STEM showed presence of smaller nanoparticles (2–5 nm) in 5-Pd-VM. This catalyst was more active in the lower temperature range of 275–325 °C and converted 90% methane at 325 °C. The 5-Pd-VM catalyst was also very stable after 72-hour stability test at 350 °C showing 100% methane conversion, and was relatively resistant to steam deactivation. Hydrogen TPR of 5-Pd-VM gave a reduction peak at 325 °C indicating weaker interactions of the oxidized Pd species with the support. It is hypothesized that smaller particle sizes, uniform particle distribution, and weaker PdO/PdOx interactions with the support may contribute to the higher activity in 5-Pd-VM.

Biofilter with mixture of pine bark and expanded clay as packing material for methane treatment in lab-scale experiment and field-scale implementation

Low methane (CH₄) emission reduction efficiency (< 25%) has been prevalent due to inefficient biological exhaust gas treatment facilities in mechanic biological waste treatment plants (MBTs) in Germany. This study aimed to quantify the improved capacity of biofilters composed of a mixture of organic (pine bark) and inorganic (expanded clay) packing materials in reducing CH₄ emissions in both a lab-scale experiment and field-scale implementation. CH₄ removal performance was evaluated using lab-scale biofilter columns under varied inflow CH₄ concentrations (70, 130, and 200 g m^-3) and corresponding loading rates of 8.2, 4.76, and 3.81 g m^-3 h^-1, respectively. The laboratory CH₄ removal rates (1.2-2.2 g m^-3 h^-1) showed positive correlation with the inflow CH₄ loading rates (4-8.2 g m^-3 h^-1), indicating high potential for field-scale implementation. Three field-scale biofilter systems with the proposed mixture packing materials were constructed in an MBT in Neumünster, northern Germany. A relatively stable CH₄ removal efficiency of 38-50% was observed under varied inflow CH₄ concentrations of 28-39 g m^-3 (loading rates of 1120-2340 g m^-3 h^-1) over a 24-h period. The CH₄ removal rate was approximately 500-700 g m^-3 h^-1, which was significantly higher than relevant previously reported field-scale biofilter systems (16-50 g m^-3 h^-1). The present study provides a promising configuration of biofilter systems composed of a mixture of organic (pine bark) and inorganic (expanded clay) packing materials to achieve high CH₄ emission reduction. Graphic abstract ᅟ.

Mesoporous Silica-Supported Nanostructured PdO/CeO2 Catalysts for Low-Temperature Methane Oxidation

Nanostructured PdO/CeO₂ supported on mesoporous SBA-15 silica was synthesized using a combination of incipient wetness impregnation and surface-assisted reduction. After calcination, the materials showed good activity as catalysts for the low-temperature oxidation of methane, with a sample having 5 wt % Pd loading showing 50% conversion to CO₂ at ∼290 °C and complete conversion below 360 °C. The stability of catalysts in the presence of water was studied. The formation of Pd(0) during the methane oxidation reaction increases the oxygen vacancies on the surface of catalysts, improving the catalytic activity.

Improved durability of Co3O4 particles supported on SmMn2O5 for methane combustion

To eliminate the aggregation of Co₃O₄ in the methane combustion process at high temperature, a thermally stable mullite structure, SmMn₂O₅ (SMO), was utilized as a support to improve the catalytic durability of Co₃O₄ particles.