Palladium Catalysts for Methane Oxidation: Old Materials, New Challenges.

ConspectusMethane complete oxidation is an important reaction that is part of the general scheme used for removing pollutants contained in emissions from internal combustion engines and, more generally, combustion processes. It has also recently attracted interest as an option for the removal of atmospheric methane in the context of negative emission technologies. Methane, a powerful greenhouse gas, can be converted to carbon dioxide and water via its complete oxidation. Despite burning methane being facile because the combustion sustains its complete oxidation after ignition, methane strong C-H bonds require a catalyst to perform the oxidation at low temperatures and in the absence of a flame so as to avoid the formation of nitrogen oxides, such as those produced in flares. This process allows methane removal to be obtained under conditions that usually lead to higher emissions, such as under cold start conditions in the case of internal combustion engines. Among several options that include homo- and heterogeneous catalysts, supported palladium-based catalysts are the most active heterogeneous systems for this reaction. Finely divided palladium can activate C-H bonds at temperatures as low as 150 °C, although complete conversion is usually not reached until 400-500 °C in practical applications. Major goals are to achieve catalytic methane oxidation at as low as possible temperature and to utilize this expensive metal more efficiently.Compared to any other transition metal, palladium and its oxides are orders of magnitude more reactive for methane oxidation in the absence of water. During the last few decades, much research has been devoted to unveiling the origin of the high activity of supported palladium catalysts, their active phase, the effect of support, promoters, and defects, and the effect of reaction conditions with the goal of further improving their reactivity. There is an overall agreement in trends, yet there are noticeable differences in some details of the catalytic performance of palladium, including the active phase under reaction conditions and the reasons for catalyst deactivation and poisoning. In this Account we summarize our work in this space using well-defined catalysts, especially model palladium surfaces and those prepared using colloidal nanocrystals as precursors, and spectroscopic tools to unveil important details about the chemistry of supported palladium catalysts. We describe advanced techniques aimed at elucidating the role of several parameters in the performance of palladium catalysts for methane oxidation as well as in engineering catalysts through advancing fundamental understanding and synthesis methods. We report the state of research on active phases and sites, then move to the role of supports and promoters, and finally discuss stability in catalytic performance and the role of water in the palladium active phase. Overall, we want to emphasize the importance of a fundamental understanding in designing and realizing active and stable palladium-based catalysts for methane oxidation as an example for a variety of energy and environmental applications of nanomaterials in catalysis.

Methane Oxidation over Cu2+ /[CuOH]+ Pairs and Site-Specific Kinetics in Copper Mordenite Revealed by Operando Electron Paramagnetic Resonance and UV/Visible Spectroscopy.

Cu-exchanged mordenite (MOR) is a promising material for partial CH4 oxidation. The structural diversity of Cu species within MOR makes it difficult to identify the active Cu sites and to determine their redox and kinetic properties. In this study, the Cu speciation in Cu-MOR materials with different Cu loadings has been determined using operando electron paramagnetic resonance (EPR) and operando ultraviolet-visible (UV/Vis) spectroscopy as well as in situ photoluminescence (PL) and Fourier-transform infrared (FTIR) spectroscopy. A novel pathway for CH4 oxidation involving paired [CuOH]+ and bare Cu2+ species has been identified. The reduction of bare Cu2+ ions facilitated by adjacent [CuOH]+ demonstrates that the frequently reported assumption of redox-inert Cu2+ centers does not generally apply. The measured site-specific reaction kinetics show that dimeric Cu species exhibit a faster reaction rate and a higher apparent activation energy than monomeric Cu2+ active sites highlighting their difference in the CH4 oxidation potential.

Direct Evidence on the Mechanism of Methane Conversion under Non-oxidative Conditions over Iron-modified Silica: The Role of Propargyl Radicals Unveiled.

Radical-mediated gas-phase reactions play an important role in the conversion of methane under non-oxidative conditions into olefins and aromatics over iron-modified silica catalysts. Herein, we use operando photoelectron photoion coincidence spectroscopy to disentangle the elusive C2+ radical intermediates participating in the complex gas-phase reaction network. Our experiments pinpoint different C2 -C5 radical species that allow for a stepwise growth of the hydrocarbon chains. Propargyl radicals (H2 C-C≡C-H) are identified as essential precursors for the formation of aromatics, which then contribute to the formation of heavier hydrocarbon products via hydrogen abstraction-acetylene addition routes (HACA mechanism). These results provide comprehensive mechanistic insights that are relevant for the development of methane valorization processes.

Hierarchical Structure of NiMo Hydrodesulfurization Catalysts Determined by Ptychographic X-Ray Computed Tomography.

Hydrodesulphurization, the removal of sulphur from crude oils, is an essential catalytic process in the petroleum industry safeguarding the production of clean hydrocarbons. Sulphur removal is critical for the functionality of downstream processes and vital to the elimination of environmental pollutants. The effectiveness of such an endeavour is among other factors determined by the structural arrangement of the heterogeneous catalyst. Namely, the accessibility of the catalytically active molybdenum disulphide (MoS2 ) slabs located on the surfaces of a porous alumina carrier. Here, we examined a series of pristine sulfided Mo and NiMo hydrodesulphurization catalysts of increasing metal loading prepared on commercial alumina carriers using ptychographic X-ray computed nanotomography. Structural analysis revealed a build consisting of two interwoven support matrix elements differing in nanoporosity. With increasing metal loading, approaching that of industrial catalysts, these matrix elements exhibit a progressively dissimilar MoS2 surface coverage as well as MoS2 cluster formation at the matrix element boundaries. This is suggestive of metal deposition limitations and/ or catalyst activation and following prohibitive of optimal catalytic utilization. These results will allow for diffusivity calculations, a better rationale of current generation catalyst performance as well as a better distribution of the active phase in next-generation hydrodesulphurization catalysts.

Continuous-Flow Microwave Synthesis of Metal-Organic Frameworks: A Highly Efficient Method for Large-Scale Production.

Metal-organic frameworks are having a tremendous impact on novel strategic applications, with prospective employment in industrially relevant processes. The development of such processes is strictly dependent on the ability to generate materials with high yield efficiency and production rate. We report a versatile and highly efficient method for synthesis of metal-organic frameworks in large quantities using continuous flow processing under microwave irradiation. Benchmark materials such as UiO-66, MIL-53(Al), and HKUST-1 were obtained with remarkable mass, space-time yields, and often using stoichiometric amounts of reactants. In the case of UiO-66 and MIL-53(Al), we attained unprecedented space-time yields far greater than those reported previously. All of the syntheses were successfully extended to multi-gram high quality products in a matter of minutes, proving the effectiveness of continuous flow microwave technology for the large scale production of metal-organic frameworks.

Structure and Reactivity of Active Oxygen Species on Silver Surfaces for Ethylene Epoxidation.

The epoxidation of ethylene stands as one of the most important industrial catalytic reactions, and silver-based catalysts show superior activity and selectivity. Oxygen is activated on the surface of silver during the reaction and exerts a substantial impact on product selectivity. Notably, the oxygen species residing in the topmost atomic layers profoundly influence the reactivity of a catalyst. However, their characterization under in situ reaction conditions remains a huge challenge, and specific structures have not been identified yet. In this study, we employ in situ X-ray photoelectron spectroscopy and density functional theory calculations to determine the oxygen species formed at the topmost atomic layers of a silver foil and to assign them a structure. Three different groups of oxygen species activated on silver are identified: (i) surface lattice oxygen and two oxygen species originating from associatively adsorbed dioxygen and (ii) top and (iii) subsurface oxygen. Transient in situ photoelectron spectroscopy experiments are carried out to reveal the dynamic evolution and thus reactivity of the different oxygen species under ethylene epoxidation reaction environments. The top oxygen atom from the adsorbed associated dioxygen is the most active. Meanwhile, a frequency-selective data analysis method, developed to process time-resolved data, provides insights into the evolving trends of peak intensities for different oxygen species. The versatility of this method suggests its potential application in future time-resolved characterization studies.

Synthesis and reactivity of Zn-biphenyl metal-organic frameworks, introducing a diphenylphosphino functional group.

Structural features, synthesis, and reactivity of Zn-biphenyl metal-organic frameworks with MOF-5 topology are presented to show the chemical flexibility of such materials and to demonstrate the challenges that can be encountered and solved to avoid interpenetration. We introduce the synthesis of a Zn-biphenyl MOF with diphenylphosphino functionalization and illustrate its structural and chemical properties.

Catalysis by metal-organic frameworks: fundamentals and opportunities.

Crystalline porous materials are extremely important for developing catalytic systems with high scientific and industrial impact. Metal-organic frameworks (MOFs) show unique potential that still has to be fully exploited. This perspective summarizes the properties of MOFs with the aim to understand what are possible approaches to catalysis with these materials. We categorize three classes of MOF catalysts: (1) those with active site on the framework, (2) those with encapsulated active species, and (3) those with active sites attached through post-synthetic modification. We identify the tunable porosity, the ability to fine tune the structure of the active site and its environment, the presence of multiple active sites, and the opportunity to synthesize structures in which key-lock bonding of substrates occurs as the characteristics that distinguish MOFs from other materials. We experience a unique opportunity to imagine and design heterogeneous catalysts, which might catalyze reactions previously thought impossible.

Sparse ab initio x-ray transmission spectrotomography for nanoscopic compositional analysis of functional materials.

The performance of functional materials is either driven or limited by nanoscopic heterogeneities distributed throughout the material's volume. To better our understanding of these materials, we need characterization tools that allow us to determine the nature and distribution of these heterogeneities in their native geometry in 3D. Here, we introduce a method based on x-ray near-edge spectroscopy, ptychographic x-ray computed nanotomography, and sparsity techniques. The method allows the acquisition of quantitative multimodal tomograms of representative sample volumes at sub-30 nm half-period spatial resolution within practical acquisition times, which enables local structure refinements in complex geometries. To demonstrate the method's capabilities, we investigated the transformation of vanadium phosphorus oxide catalysts with industrial use. We observe changes from the micrometer to the atomic level and the formation of a location-specific defect so far only theorized. These results led to a reevaluation of these catalysts used in the production of plastics.

Aging of the reaction mixture as a tool to modulate the crystallite size of UiO-66 into the low nanometer range.

Nanosized UiO-66 with an unprecedented crystallite size of 10 nm was synthesized by exploiting controlled aging of stock solutions of Zr(4+) in N,N-dimethylformamide in the presence of variable amounts of water and acetic acid prior to the addition of the ligand. The yield of the synthesis is not affected, affording high conversion of the starting reagents into the product.

Ammonium formate decomposition over Au/TiO2: a unique case of preferential selectivity against NH3 oxidation.

The unique selectivity of Au/TiO2 for converting ammonium formate to CO2 in the presence of excess O2 and H2O without oxidising NH3 up to 300 °C is reported. The catalyst is highly stable and selective even after severe hydrothermal aging.

An in situ and operando X-ray absorption spectroscopy setup for measuring sub-monolayer model and powder catalysts.

A new spectroscopic cell has been designed for studying model catalysts using in situ or operando X-ray absorption spectroscopy. The setup allows gas treatment and can be used between 100 and 870 K. Pressures from 10(-3) Pa up to 300 kPa can be applied. Measurements on model systems in this particular pressure range are a valuable extension of the commonly used UHV characterization techniques. Using this setup, we were able to analyze the Au L3 EXAFS of a silica wafer covered with sub-monolayer concentrations of gold (0.05 ML). By modifying the sample holder, powder catalysts can also be analyzed under plug-flow conditions. As an example, the reduction of a Au/SiO2 powder catalyst prepared from HAuCl4 was followed.