Support stabilized PtCu single-atom alloys for propane dehydrogenation

Nitrogen-doped carbon nanotube encapsulated CoCu bimetallic alloy particles to promote efficient oxygen evolution reaction via electronic structure regulation

The rational design of efficient and cost-effective transition metal alloy electrocatalysts represents a huge challenge for the oxygen evolution reaction (OER). Herein, the bimetallic CoCu-MOF is employed as a template to significantly enhance the catalytic activity through in situ pyrolysis into melamine-assisted nitrogen-doped carbon nanotube (NCNT) encapsulated metal alloy electrocatalyst (Co1Cu1@NCNT/CC). The Co1Cu1@NCNT/CC demonstrates superior OER activity in 1 M KOH. The overpotential is 263 mV at 10 mA cm-2. Meanwhile, the catalyst exhibits superior long-term stability. The experimental results and density functional theory (DFT) calculations reveal the bimetallic synergies regulate the electronic structure and strong electronic metal-support interaction (EMSI) of the catalysts, increase the electron transport efficiency and optimize the adsorption capacity of oxygen-containing intermediates, leading to a significant improvement in both the OER activity and stability.

Structural engineering of core-shell PtCu alloy catalysts for propane dehydrogenation: a DFT study

Propane dehydrogenation (PDH) is an economically efficient and environmentally friendly industrial process for producing propylene. However, the understanding of the structure-performance relationship of PtCu bimetallic catalysts in PDH remains limited. In this work, we systematically investigated a series of PtCu bimetallic catalysts, including the Pt-skin PtxCuy core-shell structures and PtxCuy alloys, using first-principles calculations and ab initio molecular dynamics to assess their stability, activity, and selectivity. The results show that PtCu@Pt(111) and PtCu3@Pt(111) exhibit improved stability and performance compared to PtxCuy alloys, attributed to the electronic effect of Cu species and the compressive strain effect of the Pt-skin PtxCuy structures. Furthermore, we clarified the electron density at the Pt-C interface and its influence on the electronic interactions within the Pt-adsorbate complex, revealing the pattern of catalytic activity changes. Notably, PtCu@Pt(111) demonstrated stronger resistance to carbon deposition compared to Pt(111), thereby suppressing hydrogenolysis side reactions. This work provides critical insights for the rational design of efficient Pt-based catalysts for PDH via a doping strategy.

Ultrafine PtGa Clusters Confined in Porous ZrOx/SiO2 Nanofibers for Enhanced Propane Dehydrogenation

Ultrafine Pt clusters exhibit superior activity for propane dehydrogenation compared to larger Pt nanoparticles; however, they are prone to sintering at high operating temperatures, leading to a decline in both activity and selectivity. In this work, porous ZrOx/SiO2 nanofibers featuring highly dispersed ZrOx nanodomains within a SiO2 matrix were successfully fabricated via a high-throughput blow-spinning process. The abundant and thermal-stable 1.6 nm micropores significantly stabilize 1.5 nm PtGa clusters against sintering at temperatures over 800 °C, due to the pore confinement. Moreover, the electron transfer from Ga to Pt is significantly enhanced in close proximity to ZrOx, contributing to metallic Pt with exceptional activity toward C-H bond activation. Thereby, the sinter-resistant PtGa/ZrOx/SiO2 nanofibers maintained 98.8% propylene selectivity and 43.2% propane conversion rate over 100 h of reaction, with a deactivation rate constant down to 0.0045 h-1. This work explores a sinter-resistant catalytic system based on oxide nanofibers and elaborates a new logic for the design of high-performance propane dehydrogenation catalysts with long-term stability.

Regulating the dispersion of CuO over SiO2 surface for selective oxidation of isobutane to tert-butanol

Controlling the highly selective oxidation of CH bonds in alkanes was still a challenge in the oxidation process, especially in oxygen atmospheres. Herein, three CuO/SiO2 catalysts were designed and prepared by regulating the introduction of copper species to achieve the selective oxidation of tertiary C-H of isobutane (i-C4H10) to tert-butanol (TBA). Under the condition of 130 °C and 1.5 h, CuO/SiO2-DP catalyst could achieve 92.7 % O2 conversion and 85.1 % TBA selectivity, and the cycle stability could be maintained. The improvement of catalytic performance could be attributed to the efficient utilization of Cu atoms, which was related to the regulating the formation of copper phyllosilicate and the full utilization of Si-OH on the surface of SiO2 during the catalyst synthesis process. Copper phyllosilicate formed a rich Si-O-Cu unit, enhanced the metal oxide-support interaction, inhibited the growth of copper species, improved the anchoring and dispersion of CuO, and ultimately improved the accessibility of substrate molecules on active CuO (111). In addition, the adsorption configuration of i-C4H10 and O2 on CuO (111) was determined by in-situ FT-IR and DFT, and the existence form of O2 after charge transfer was discussed. The reaction mechanism of i-C4H10 oxidation to TBA was revealed, which provided theoretical guidance for the selective preparation of TBA from i-C4H10 over metal oxides.

Substance migration in the synthesis of single-atom catalysts

Substance migration is universal and crucial in the synthesis of catalysts, which directly affects their existing form and the micro-structure of their active sites. Realizing migration during the synthesis of single-atom catalysts (SACs) is beneficial for not only increasing their metal loading capacity but also manipulating the electronic structures (coordination structure, long-range interactions, etc.) of their metal sites. This review summarizes the thermodynamics and kinetic processes involved in the synthesis of SACs to unveil the fundamental principles involved in their synthesis. For a better understanding of the effect of migration, the migration of both metal (including ions, atoms, and molecules) and nonmetal species is outlined. Moreover, we propose the research directions to guide the rational design of SACs in the future and deepen the fundamental understanding in the formation of catalysts.

Synthesis of defect-rich La2O2CO3 supports for enhanced CO2-to-methanol conversion efficiency

Converting CO2 to methanol is crucial for addressing fuel scarcity and mitigating the greenhouse effect. Cu-based catalysts, with their diverse surface states, offer the potential to control reaction pathways and generate reactive H* species. However, a major challenge lies in oxidizing active Cu0 species by water generated during the catalytic process. While nonreducible metal oxides are beneficial in stabilizing metallic states, their limited capability to generate surface oxygen vacancies (OV) hinders CO2 activation. Herein, we present a strategy by doping Nd into a La2O2CO3 (LOC) support, enhancing OV formation by disrupting its lattice dyadicity. This leads to higher Cu0 concentration and improved CO2 activation. The resulting Cu/LOC:Nd catalyst notably outperforms Cu/LOC and CuZnAl catalysts, achieving a methanol yield of 9.9 moles of methanol per hour per mole of Cu. Our approach opens up possibilities for enhancing Cu-based catalysts in CO2 conversion.

Design of Supported Metal Catalysts and Systems for Propane Dehydrogenation

Propane dehydrogenation (PDH) is currently an approach for the production of propylene with high industrial importance, especially in the context of the shale gas revolution and the growing global demands for propylene and downstream commodity chemicals. In this Perspective article, we comprehensively summarize the recent advances in the design of advanced catalysts for PDH and the new understanding of the structure-performance relationship in supported metal catalysts. Furthermore, we discuss the gaps between fundamental research and practical industrial applications in the catalyst developments for the PDH process. In particular, we overview some critical issues regarding catalyst regeneration and the compatibility of the catalyst and reactor design. Finally, we make perspectives on the future directions of PDH research, including the efforts toward achieving a unified understanding of the structure-performance relationship, innovation in reactor engineering, and translation of the knowledge accumulated on PDH studies to other important alkane dehydrogenation reactions.

Dynamic Behavior of Pt Multimetallic Alloys for Active and Stable Propane Dehydrogenation Catalysts

Improving the use of platinum in propane dehydrogenation catalysts is a crucial aspect to increasing the efficiency and sustainability of propylene production. A known and practiced strategy involves incorporating more abundant metals in supported platinum catalysts, increasing its activity and stability while decreasing the overall loading. Here, using colloidal techniques to control the size and composition of the active phase, we show that Pt/Cu alloy nanoparticles supported on alumina (Pt/Cu/Al2O3) displayed elevated rates for propane dehydrogenation at low temperature compared to a monometallic Pt/Al2O3 catalyst. We demonstrate that the enhanced catalytic activity is correlated with a higher surface Cu content and formation of a Pt-rich core and Cu-rich shell that isolates Pt sites and increases their intrinsic activity. However, rates declined on stream because of dynamic metal diffusion processes that led to a more uniform alloy structure. This transformation was only partially inhibited by adding excess hydrogen to the feed stream. Instead, cobalt was introduced to provide trimetallic Pt/Cu/Co catalysts with stabilized surface structure and stable activity and higher rates than the original Pt/Cu system. The structure-activity relationship insights in this work offer improved knowledge of propane dehydrogenation catalyst development featuring reduced Pt loadings and notable thermal stability for propylene production.

An Active and Regenerable Nanometric High-Entropy Catalyst for Efficient Propane Dehydrogenation

Propane dehydrogenation (PDH) is crucial for propylene production, but commercially employed Pt-based catalysts face susceptibility to deactivation due to the Pt sintering during reaction and regeneration steps. Here, we report a SiO2 supported nanometric (MnCoCuZnPt) high-entropy PDH catalyst with high activity and stability. The catalyst exhibited a super high propane conversion of 56.6 % with 94 % selectivity of propylene at 600 °C. The propylene productivity reached 68.5 molC3H6 ⋅ gPt -1 ⋅ h-1, nearly three times that of Pt/SiO2 (23.5 molC3H6 ⋅ gPt -1 ⋅ h-1) under a weight hourly space velocity of 60 h-1. In a high-entropy nanoparticle, Pt atoms were atomically dispersed through coordination with other metals and exhibited a positive charge, thereby showcasing remarkable catalytic activity. The high-entropy effect contributes to the catalyst a superior stability with a low deactivation constant of 0.0004 h-1 during 200 hours of reaction under the industrial gas composition at 550 °C. Such high-entropy PDH catalyst is easy regenerated through simple air combustion of deposited coke. After the fourth consecutive regeneration cycle, satisfactory catalytic stability was observed, and the element distribution of spent catalysts almost returned to their initial state, with no detectable Pt sintering. This work provides new insights into designing active, stable, and regenerable novel PDH catalysts.

Evolution of the Active Phase of Pt/Sn-Al2O3 Catalysts During Acidic Impregnation and Their Use in Propane Dehydrogenation

Alumina-supported PtSn is an industrialized catalyst for propane dehydrogenation. During the catalyst impregnation, the acidic impregnation solution with chloroplatinic acid as a precursor inevitably leads to the partial dissolution of the surface of amphoteric alumina support and finally varies catalytic performance. Herein, the structure evolution of the active phase, induced by an impregnated acidic solution, was studied with special care. According to the diffused double layer theory, we proposed a model of microgels during impregnation. The microgels formed in the solution with suitable acidity on the surface of the catalysts evolved into a structure of Al2O3-coated oxidized Pt by reprecipitation during drying and calcination. The covered Pt species could be exposed by Ar+ sputtering or migrate to the surface during reduction to serve as active sites for propane dehydrogenation. Noticeably, the surface Sn0 species was generated when the pH of the impregnated solution was around 0.56, which is solid proof for the unique active phase with the PtSn alloy present on SnOx species existing on the surface of the Sn-Al2O3 support. The synthesized catalyst exhibited high propylene selectivity (99.4%) and superior stability (kd = 0.002 h-1). This study provides new insight for the precise preparation of Pt/Sn-Al2O3 catalysts.

Discovery of highly efficient dual-atom catalysts for propane dehydrogenation assisted by machine learning

Propane dehydrogenation (PDH) is a highly efficient approach for industrial production of propylene, and the dual-atom catalysts (DACs) provide new pathways in advancing atomic catalysis for PDH with dual active sites. In this work, we have developed an efficient strategy to identify promising DACs for PDH reaction by combining high-throughput density functional theory (DFT) calculations and the machine-learning (ML) technique. By choosing the γ-Al2O3(100) surface as the substrate to anchor dual metal atoms, 435 kinds of DACs have been considered to evaluate their PDH catalytic activity. Four ML algorithms are employed to predict the PDH activity and determine the relationship between the intrinsic characteristics of DACs and the catalytic activity. The promising catalysts of CuFe, CuCo and CoZn DACs are finally screened out, which are further validated by the whole kinetic reaction calculations, and the highly efficient performance of DACs is attributed to the synergistic effects and interactions between the paired active sites.

Achieving Almost 100% Selectivity in Photocatalytic CO2 Reduction to Methane via In-Situ Atmosphere Regulation Strategy

Artificial photosynthesis, harnessing solar energy to convert CO2 into hydrocarbons, presents a promising solution for climate change and energy scarcity. However, photocatalytic CO2 reduction often terminates at the CO stage due to limited electron transfer capacity, hindering the formation of higher-energy hydrocarbons such as CH4. This study introduces, for the first time, an in-situ atmosphere regulation strategy, refined from molecular imprinting methodologies, using dynamically reacting molecules to precisely engineer photocatalytic surface sites for selective *CO adsorption and hydrogenation in CO2-to-CH4 conversion. Specifically, the single-atom Cu catalyst (Cu-SA-CO) is prepared by anchoring single-atom Cu onto defective TiO2 substrates (Cu-SA-CO) under a CO reduction atmosphere. Under illumination, the catalyst exhibited outstanding CH4 selectivity (almost 100%) and productivity (58.5 µmol g-1 h-1). Mechanistic investigations reveal that the coordination environment of the Cu single atoms is significantly affected by dynamically reacting molecules (CO and *CHxO) during synthesis, leading to a Ti-Cu-O structure. The structure, with the synergistic interaction between Cu single atoms and oxygen defects, significantly enhances *CO adsorption and hydrogenation, thereby promoting the formation of methane. This work pioneers the use of dynamically reactive molecules as imprinted templates to tune photocatalytic CO2 reduction selectivity, providing a novel avenue for designing efficient photocatalysts.

Effect of Bystander Hydrogen Atoms on Hydrogen Desorption on Single-Atom Alloy Surfaces: Insights from Simulated Temperature-Programmed Desorption Spectra

Single-atom alloy (SAA) catalysts exhibit unique and excellent catalytic properties in heterogeneous hydrogenation/dehydrogenation reactions. A thorough understanding of the microscopic surface processes is essential to improve the catalytic performance. Here, from a new perspective of the temperature-programmed desorption (TPD) spectra of hydrogen (H) on two common SAA surfaces, Pt@Cu(111) and Pd@Cu(111), we reveal and confirm the key influence of H atoms attached to Pt/Pd dopants, i.e., the H atom bystander, on the desorption process of surface H atoms. It is found that only after considering the effect of the H atom bystander can the simulated TPD spectra well reproduce the experimentally observed higher desorption temperature on Pt@Cu(111) than on Pd@Cu(111) and the leftward shift of the TPD peak with increasing H atom coverage; otherwise, the features are inconsistent with experiments. Our work provides direct evidence for the effect of bystander H atoms from a simulation perspective.

Stable anchoring of single rhodium atoms by indium in zeolite alkane dehydrogenation catalysts

Maintaining the stability of single-atom catalysts in high-temperature reactions remains extremely challenging because of the migration of metal atoms under these conditions. We present a strategy for designing stable single-atom catalysts by harnessing a second metal to anchor the noble metal atom inside zeolite channels. A single-atom rhodium-indium cluster catalyst is formed inside zeolite silicalite-1 through in situ migration of indium during alkane dehydrogenation. This catalyst demonstrates exceptional stability against coke formation for 5500 hours in continuous pure propane dehydrogenation with 99% propylene selectivity and propane conversions close to the thermodynamic equilibrium value at 550°C. Our catalyst also operated stably at 600°C, offering propane conversions of >60% and propylene selectivity of >95%.

Recent advances in single-atom alloys: preparation methods and applications in heterogeneous catalysis

Single-atom alloys (SAAs) are a different type of alloy where a guest metal, usually a noble metal (e.g., Pt, Pd, and Ru), is atomically dispersed on a relatively more inert (e.g., Ag and Cu) host metal. As a type of atomic-scale catalyst, single-atom alloy catalysts have broad application prospects in the field of heterogeneous catalysis for hydrogenation, dehydrogenation, oxidation, and other reactions. Numerous experimental and characterization results and theoretical calculations have confirmed that the resultant electronic structure caused by charge transfer between the host metal and guest metal and the special geometric structure of the guest metal are responsible for the high selectivity and catalytic activity of SAA catalysts. In this review, the common methods for the preparation of single-atom alloys in recent years are introduced, including initial wet impregnation, physical vapor deposition, and laser ablation in liquid technique. Afterwards, the applications of single-atom alloy catalysts in selective hydrogenation, dehydrogenation, oxidation reactions, and hydrogenolysis reactions are emphatically reviewed. Finally, several challenges for the future development of SAA catalysts are proposed.

Amorphous CeOx Islands on Dealuminated Zeolite Beta to Stabilize Pt Nanoparticles as Efficient and Antisintering Catalysts for Propane Dehydrogenation

Pt-based catalysts have been widely used in propane dehydrogenation due to their superior activation of C-H bonds and weak scission of C-C bonds. However, in the process of repeated calcination to remove deposited coke, the active Pt species tend to sinter, resulting in a significant decline in catalytic activity. In this study, amorphous CeOx islands loaded on dealuminated Beta zeolite were prepared via simple wetness impregnation. Then, partially embedded Pt nanoparticles in CeOx islands were obtained after reduction owing to the affinity of CeOx for Pt. In the propane dehydrogenation reaction, Pt/Ce5-SiBeta with a Ce loading of 4.55 wt % and Pt loading of 0.72 wt % exhibited the highest activity and the lowest inactivation constant at 550 °C. More importantly, due to the anchoring effect of CeOx on Pt, the catalytic activity of Pt could be recovered after a simple calcination-reduction regeneration process, avoiding the chlorination treatment for the redispersion of Pt species used in industry. In addition, to improve the selectivity of the Pt/Ce5-SiBeta catalyst, a PtSn/Ce5-SiBeta catalyst with excellent activity, selectivity, and recycling stability has been prepared by introducing Sn into Pt/Ce5-SiBeta. The use of amorphous CeOx islands to improve the sintering resistance of Pt opens up new prospects for the design of stable industrial dehydrogenation catalysts.

Galvanic Replacement Reaction: Enabling the Creation of Active Catalytic Structures

The galvanic replacement reaction (GRR) is recognized as a redox process where one metal undergoes oxidation by the ions of another metal possessing a higher reduction potential. This reaction takes place at the interface between a substrate and a solution containing metal ions. Utilizing metal or metal oxide as sacrificial templates enables the synthesis of metallic nanoparticles, oxide-metal composites, and mixed oxides through GRR. Growing evidence showed that GRR has a direct impact on surface structures and properties. This has generated significant interest in catalysis and opened up new horizons for the application of GRR in energy and chemical transformations. This review provides a comprehensive overview of the synthetic strategies utilizing GRR for the creation of catalytically active structures. It discusses the formation of alloys, intermetallic compounds, single atom alloys, metal-oxide composites, and mixed metal oxides with diverse nanostructures. Additionally, GRR serves as a postsynthesis method to modulate metal-oxide interfaces through the replacement of oxide domains. The review also outlines potential future directions in this field.

Ti-Doping in Silica-Supported PtZn Propane Dehydrogenation Catalysts: From Improved Stability to the Nature of the Pt-Ti Interaction

Propane dehydrogenation is an important industrial reaction to access propene, the world's second most used polymer precursor. Catalysts for this transformation are required to be long living at high temperature and robust toward harsh oxidative regeneration conditions. In this work, combining surface organometallic chemistry and thermolytic molecular precursor approach, we prepared well-defined silica-supported Pt and alloyed PtZn materials to investigate the effect of Ti-doping on catalytic performances. Chemisorption experiments and density functional calculations reveal a significant change in the electronic structure of the nanoparticles (NPs) due to the Ti-doping. Evaluation of the resulting materials PtZn/SiO₂ and PtZnTi/SiO₂ during long deactivation phases reveal a stabilizing effect of Ti in PtZnTi/SiO₂ with a k_d of 0.015 h^-1 compared to PtZn/SiO₂ with a k_d of 0.022 h^-1 over 108 h on stream. Such a stabilizing effect is also present during a second deactivation phase after applying a regeneration protocol to the materials under O₂ and H₂ at high temperatures. A combined scanning transmission electron microscopy, in situ X-ray absorption spectroscopy, electron paramagnetic resonance, and density functional theory study reveals that this effect is related to a sintering prevention of the alloyed PtZn NPs in PtZnTi/SiO₂ due to a strong interaction of the NPs with Ti sites. However, in contrast to classical strong metal-support interaction, we show that the coverage of the Pt NPs with TiO_x species is not needed to explain the changes in adsorption and reactivity properties. Indeed, the interaction of the Pt NPs with Ti^III sites is enough to decrease CO adsorption and to induce a red-shift of the CO band because of electron transfer from the Ti^III sites to Pt⁰.

Reactivity of Single-Atom Alloy Nanoparticles: Modeling the Dehydrogenation of Propane

Physical catalysts often have multiple sites where reactions can take place. One prominent example is single-atom alloys, where the reactive dopant atoms can preferentially locate in the bulk or at different sites on the surface of the nanoparticle. However, ab initio modeling of catalysts usually only considers one site of the catalyst, neglecting the effects of multiple sites. Here, nanoparticles of copper doped with single-atom rhodium or palladium are modeled for the dehydrogenation of propane. Single-atom alloy nanoparticles are simulated at 400-600 K, using machine learning potentials trained on density functional theory calculations, and then the occupation of different single-atom active sites is identified using a similarity kernel. Further, the turnover frequency for all possible sites is calculated for propane dehydrogenation to propene through microkinetic modeling using density functional theory calculations. The total turnover frequencies of the whole nanoparticle are then described from both the population and the individual turnover frequency of each site. Under operating conditions, rhodium as a dopant is found to almost exclusively occupy (111) surface sites while palladium as a dopant occupies a greater variety of facets. Undercoordinated dopant surface sites are found to tend to be more reactive for propane dehydrogenation compared to the (111) surface. It is found that considering the dynamics of the single-atom alloy nanoparticle has a profound effect on the calculated catalytic activity of single-atom alloys by several orders of magnitude.

Promotion Effect of Well-Defined Deposited Water Layer on Carbon Monoxide Oxidation Catalyzed by Single-Atom Alloys

Single-atom alloys (SAAs) exhibit excellent catalytic performance and unique electronic structures, emerging as promising catalysts for potential industrial reactions. While most of them have been widely employed under reducing conditions, few are applied in oxidation reactions. Herein, using density functional theory calculations and microkinetic simulations, we demonstrate that a well-defined one water layer can improve CO oxidation on model SAAs, with reaction rates increased by orders of magnitude. It is found that the formation of hydrogen bonds and the transfer of charges effectively enhance the adsorption and activation of oxygen molecules at the H₂O/SAA interfaces, which not only increases the surface coverage of O₂ species but also reduces the energy barrier of CO oxidation. The proposed strategy in this work would extend the application range of SAA catalysts to oxidation reactions.

Oxide-Metal Interaction Probed by Scanning Tunneling Microscope Manipulation of Cr2O7 Clusters on Au(111)

Interfacial interaction plays a crucial rule in catalysis over supported catalysts, and the catalyst-support interaction needs to be explored at microscopic scale. Here, we use the scanning tunneling microscope (STM) tip to manipulate Cr₂O₇ dinuclear clusters on Au(111) and find that the Cr₂O₇-Au interaction can be weakened by an electric field in the STM junction, facilitating rotation and translation of the individual clusters at the imaging temperature (78 K). Surface alloying with Cu makes the manipulation of the Cr₂O₇ clusters hard due to the enhanced Cr₂O₇-substrate interaction. Density functional theory calculations reveal that barrier for translation of a Cr₂O₇ cluster on the surface can be increased by surface alloying, influencing the tip manipulation. Our study demonstrates that the oxide-metal interfacial interaction can be probed by STM tip manipulation of supported oxide clusters, which provides a new method to investigate the interfacial interaction.