Tuning interactions between zeolite and supported metal by physical-sputtering to achieve higher catalytic performances.

To substitute for petroleum, Fischer-Tropsch synthesis (FTS) is an environmentally benign process to produce synthetic diesel (n-paraffin) from syngas. Industrially, the synthetic gasoline (iso-paraffin) can be produced with a FTS process followed by isomerization and hydrocracking processes over solid-acid catalysts. Herein, we demonstrate a cobalt nano-catalyst synthesized by physical-sputtering method that the metallic cobalt nano-particles homogeneously disperse on the H-ZSM5 zeolite support with weak Metal-Support Interactions (MSI). This catalyst performed the high gasoline-range iso-paraffin productivity through the combined FTS, isomerization and hydrocracking reactions. The weak MSI results in the easy reducibility of the cobalt nano-particles; the high cobalt dispersion accelerates n-paraffin diffusion to the neighboring acidic sites on the H-ZSM5 support for isomerization and hydrocracking. Both factors guarantee its high CO conversion and iso-paraffin selectivity. This physical-sputtering technique to synthesize the supported metallic nano-catalyst is a promising way to solve the critical problems caused by strong MSI for various processes.