Carbon-based catalysts: Synthesis and applications

This paper summarizes the main results obtained by the Fuel Combustion Group in three applications: (1) carbon-based catalysts for the selective catalytic reduction (SCR) process of NO_x, (2) Pt and Pt–Ru catalysts for direct alcohol fuel cells, (3) carbon-supported catalysts for the electroreduction of CO₂. Concerning the first aspect, low-cost catalysts able to work at lower temperatures have been prepared and compared with commercial catalysts; for the second one, new catalysts for methanol and ethanol electrochemical oxidation exhibiting current densities that are double those of the commercial ones have been developed; as regards the third one, carbon-supported catalysts for the electroreduction of CO₂ based on Fe and Pd were synthesized and tested. Formic acid was obtained as the main product on all Fe/C electrodes.     

Low‐Coordinated Edge Sites on Ultrathin Palladium Nanosheets Boost Carbon Dioxide Electroreduction Performance

Electrochemical conversion of carbon dioxide (CO₂) to value‐added products is a possible way to decrease the problems resulting from CO₂ emission. Thanks to the eminent conductivity and proper adsorption to intermediates, Pd has become a promising candidate for CO₂ electroreduction (CO₂ER). However, Pd‐based nanocatalysts generally need a large overpotential. Herein we describe that ultrathin Pd nanosheets effectively reduce the onset potential for CO by exposing abundant atoms with comparatively low generalized coordination number. Hexagonal Pd nanosheets with 5 atomic thickness and 5.1 nm edge length reached CO faradaic efficiency of 94 % at ?0.5 V, without any decay after a stability test of 8 h. It appears to be the most efficient among all of Pd‐based catalysts toward CO₂ER. Uniform hexagonal morphology made it reasonable to build models and take DFT calculations. The enhanced activity originates from mainly edge sites on palladium nanosheets.     

High Electrocatalytic Activity of Pt–Pd Binary Spherocrystals Chemically Assembled in Vertically Aligned TiO2 Nanotubes

To obtain noble metal catalysts with high efficiency, long‐term stability, and poison resistance, Pt and Pd are assembled in highly ordered and vertically aligned TiO₂ nanotubes (NTs) by means of the pulsed‐current deposition (PCD) method with assistance of ultrasonication (UC). Here, Pd serves as a dispersant which prevents agglomeration of Pt. Thus Pt–Pd binary catalysts are embed into TiO₂ NTs array under UC in sunken patterns of composite spherocrystals (Sps). Owing to this synthesis method and restriction by the NTs, the these catalysts show improved dispersion, more catalytically active sites, and higher surface area. This nanotubular metallic support material with good physical and chemical stability prevents catalyst loss and poisoning. Compared with monometallic Pt and Pd, the sunken‐structured Pt–Pd spherocrystal catalyst exhibits better catalytic activity and poison resistance in electrocatalytic methanol oxidation because of its excellent dispersion. The catalytic current density is enhanced by about 15 and 310 times relative to monometallic Pt and Pd, respectively. The poison resistance of the Pt–Pd catalyst was 1.5 times higher than that of Pt and Pd, and they show high electrochemical stability with a stable current enduring for more than 2100 s. Thus, the TiO₂ NTs on a Ti substrate serve as an excellent support material for the loading and dispersion of noble metal catalysts.     

Metal‐Doped Nitrogenated Carbon as an Efficient Catalyst for Direct CO2 Electroreduction to CO and Hydrocarbons

This study explores the kinetics, mechanism, and active sites of the CO₂ electroreduction reaction (CO2RR) to syngas and hydrocarbons on a class of functionalized solid carbon‐based catalysts. Commercial carbon blacks were functionalized with nitrogen and Fe and/or Mn ions using pyrolysis and acid leaching. The resulting solid powder catalysts were found to be active and highly CO selective electrocatalysts in the electroreduction of CO₂ to CO/H₂ mixtures outperforming a low‐area polycrystalline gold benchmark. Unspecific with respect to the nature of the metal, CO production is believed to occur on nitrogen functionalities in competition with hydrogen evolution. Evidence is provided that sufficiently strong interaction between CO and the metal enables the protonation of CO and the formation of hydrocarbons. Our results highlight a promising new class of low‐cost, abundant electrocatalysts for synthetic fuel production from CO₂.     

A Polymer Solution To Prevent Nanoclustering and Improve the Selectivity of Metal Nanoparticles for Electrocatalytic CO2 Reduction

The stability of metal nanocatalysts for electrocatalytic CO₂ reduction is of key importance for practical application. We report the use of two polymeric N‐heterocyclic carbenes (NHC) (polydentate and monodentate) to stabilize metal nanocatalysts (Au and Pd) for efficient CO₂ electroreduction. Compared with other conventional ligands including thiols and amines, metal–carbene bonds that are stable under reductive potentials prevent the nanoclustering of nanoparticles. Au nanocatalysts modified by polymeric NHC ligands show an activity retention of 86 % after CO₂ reduction at ?0.9 V for 11 h, while it is less than 10 % for unmodified Au. We demonstrate that the hydrophobicity of polymer ligands and the enriched surface electron density of metal NPs through σ‐donation of NHCs substantially improve the selectivity for CO₂ reduction over proton.     

Enhancing Activity and Reducing Cost for Electrochemical Reduction of CO2 by Supporting Palladium on Metal Carbides

Electrochemical CO₂ reduction reaction (CO₂RR) with renewable electricity is a potentially sustainable method to reduce CO₂ emissions. Palladium supported on cost‐effective transition‐metal carbides (TMCs) are studied to reduce the Pd usage and tune the activity and selectivity of the CO₂RR to produce synthesis gas, using a combined approach of studying thin films and practical powder catalysts, in situ characterization, and density functional theory (DFT) calculations. Notably, Pd/TaC exhibits higher CO₂RR activity, stability and CO Faradaic efficiency than those of commercial Pd/C while significantly reducing the Pd loading. In situ measurements confirm the transformation of Pd into hydride (PdH) under the CO₂RR environment. DFT calculations reveal that the TMC substrates modify the binding energies of key intermediates on supported PdH. This work suggests the prospect of using TMCs as low‐cost and stable substrates to support and modify Pd for enhanced CO₂RR activity.     

Stabilization of Palladium Nanoparticles on Nanodiamond–Graphene Core–Shell Supports for CO Oxidation

Nanodiamond–graphene core–shell materials have several unique properties compared with purely sp²‐bonded nanocarbons and perform remarkably well as metal‐free catalysts. In this work, we report that palladium nanoparticles supported on nanodiamond–graphene core–shell materials (Pd/ND@G) exhibit superior catalytic activity in CO oxidation compared to Pd NPs supported on an sp²‐bonded onion‐like carbon (Pd/OLC) material. Characterization revealed that the Pd NPs in Pd/ND@G have a special morphology with reduced crystallinity and are more stable towards sintering at high temperature than the Pd NPs in Pd/OLC. The electronic structure of Pd is changed in Pd/ND@G, resulting in weak CO chemisorption on the Pd NPs. Our work indicates that strong metal–support interactions can be achieved on a non‐reducible support, as exemplified for nanocarbon, by carefully tuning the surface structure of the support, thus providing a good example for designing a high‐performance nanostructured catalyst.     

High‐Curvature Transition‐Metal Chalcogenide Nanostructures with a Pronounced Proximity Effect Enable Fast and Selective CO2 Electroreduction

A considerable challenge in the conversion of carbon dioxide into useful fuels comes from the activation of CO₂ to CO₂^.? or other intermediates, which often requires precious‐metal catalysts, high overpotentials, and/or electrolyte additives (e.g., ionic liquids). We report a microwave heating strategy for synthesizing a transition‐metal chalcogenide nanostructure that efficiently catalyzes CO₂ electroreduction to carbon monoxide (CO). We found that the cadmium sulfide (CdS) nanoneedle arrays exhibit an unprecedented current density of 212 mA cm^?2 with 95.5±4.0 % CO Faraday efficiency at ?1.2 V versus a reversible hydrogen electrode (RHE; without iR correction). Experimental and computational studies show that the high‐curvature CdS nanostructured catalyst has a pronounced proximity effect which gives rise to large electric field enhancement, which can concentrate alkali‐metal cations resulting in the enhanced CO₂ electroreduction efficiency.     

Reduced SnO2 Porous Nanowires with a High Density of Grain Boundaries as Catalysts for Efficient Electrochemical CO2‐into‐HCOOH Conversion

Electrochemical conversion of CO₂ into energy‐dense liquids, such as formic acid, is desirable as a hydrogen carrier and a chemical feedstock. SnO_x is one of the few catalysts that reduce CO₂ into formic acid with high selectivity but at high overpotential and low current density. We show that an electrochemically reduced SnO₂ porous nanowire catalyst (Sn‐pNWs) with a high density of grain boundaries (GBs) exhibits an energy conversion efficiency of CO₂‐into‐HCOOH higher than analogous catalysts. HCOOH formation begins at lower overpotential (350 mV) and reaches a steady Faradaic efficiency of ca. 80 % at only −0.8 V vs. RHE. A comparison with commercial SnO₂ nanoparticles confirms that the improved CO₂ reduction performance of Sn‐pNWs is due to the density of GBs within the porous structure, which introduce new catalytically active sites. Produced with a scalable plasma synthesis technology, the catalysts have potential for application in the CO₂ conversion industry.     

Regulation of Coordination Number over Single Co Sites: Triggering the Efficient Electroreduction of CO2

The design of active, selective, and stable CO₂ reduction electrocatalysts is still challenging. A series of atomically dispersed Co catalysts with different nitrogen coordination numbers were prepared and their CO₂ electroreduction catalytic performance was explored. The best catalyst, atomically dispersed Co with two‐coordinate nitrogen atoms, achieves both high selectivity and superior activity with 94 % CO formation Faradaic efficiency and a current density of 18.1 mA cm^?2 at an overpotential of 520 mV. The CO formation turnover frequency reaches a record value of 18 200 h^?1, surpassing most reported metal‐based catalysts under comparable conditions. Our experimental and theoretical results demonstrate that lower a coordination number facilitates activation of CO₂ to the CO₂^.? intermediate and hence enhances CO₂ electroreduction activity.     

MoP Nanoparticles Supported on Indium‐Doped Porous Carbon: Outstanding Catalysts for Highly Efficient CO2 Electroreduction

Electrochemical reduction of CO₂ into value‐added product is an interesting area. MoP nanoparticles supported on porous carbon were synthesized using metal–organic frameworks as the carbon precursor, and initial work on CO₂ electroreduction using the MoP‐based catalyst were carried out. It was discovered that MoP nanoparticles supported on In‐doped porous carbon had outstanding performance for CO₂ reduction to formic acid. The Faradaic efficiency and current density could reach 96.5 % and 43.8 mA cm^?2, respectively, when using ionic liquid 1‐butyl‐3‐methylimidazolium hexafluorophosphate as the supporting electrolyte. The current density is higher than those reported up to date with very high Faradaic efficiency. The MoP nanoparticles and the doped In₂O₃ cooperated very well in catalyzing the CO₂ electroreduction.     

Boosting Electrochemical CO2 Reduction on Metal–Organic Frameworks via Ligand Doping

Electrochemical CO₂ reduction relies on the availability of highly efficient and selective catalysts. Herein, we report a general strategy to boost the activity of metal–organic frameworks (MOFs) towards CO₂ reduction via ligand doping. A strong electron‐donating molecule of 1,10‐phenanthroline was doped into Zn‐based MOFs of zeolitic imidazolate framework‐8 (ZIF‐8) as CO₂ reduction electrocatalyst. Experimental and theoretical evidences reveal that the electron‐donating nature of phenanthroline enables a charge transfer, which induces adjacent active sites at the sp² C atoms in the imidazole ligand possessing more electrons, and facilitates the generation of *COOH, hence leading to improved activity and Faradaic efficiency towards CO production.     

Transition Metal Nitrides as Promising Catalyst Supports for Tuning CO/H2 Syngas Production from Electrochemical CO2 Reduction

The electrochemical carbon dioxide reduction reaction (CO₂RR) to produce synthesis gas (syngas) with tunable CO/H₂ ratios has been studied by supporting Pd catalysts on transition metal nitride (TMN) substrates. Combining experimental measurements and density functional theory (DFT) calculations, Pd‐modified niobium nitride (Pd/NbN) is found to generate much higher CO and H₂ partial current densities and greater CO Faradaic efficiency than Pd‐modified vanadium nitride (Pd/VN) and commercial Pd/C catalysts. In‐situ X‐ray diffraction identifies the formation of PdH in Pd/NbN and Pd/C under CO₂RR conditions, whereas the Pd in Pd/VN is not fully transformed into the active PdH phase. DFT calculations show that the stabilized *HOCO and weakened *CO intermediates on PdH/NbN are critical to achieving higher CO₂RR activity. This work suggests that NbN is a promising substrate to modify Pd, resulting in an enhanced electrochemical conversion of CO₂ to syngas with a potential reduction in precious metal loading.     

Copper‐Bismuth Bimetallic Microspheres for Selective Electrocatalytic Reduction of CO2 to Formate

Electrocatalytic carbon dioxide reduction holds great promise for reducing the atmospheric CO₂ level and alleviating the energy crisis. High‐performance electrocatalysts are often required in order to lower the high overpotential and expedite the sluggish reaction kinetics of CO₂ electroreduction. Copper is a promising candidate metal. However, it usually suffers from the issues of poor stability and low product selectivity. In this work, bimetallic Cu‐Bi is obtained by reducing the microspherical copper bismuthate (CuBi₂O₄) for selectively catalyzing the CO₂ reduction to formate (HCOO^–). The bimetallic Cu‐Bi electrocatalyst exhibits high activity and selectivity with the Faradic efficiency over 90% in a wide potential window. A maximum Faradaic efficiency of ~95% is obtained at –0.93 V versus reversible hydrogen electrode. Furthermore, the catalyst shows high stability over 6 h with Faradaic efficiency of ~95%. This study provides an important clue in designing new functional materials for CO₂ electroreduction with high activity and selectivity.     

Mild Synthesis of Pt/SnO2/Graphene Nanocomposites with Remarkably Enhanced Ethanol Electro‐oxidation Activity and Durability

We have designed a new Pt/SnO₂/graphene nanomaterial by using L ‐arginine as a linker; this material shows the unique Pt‐around‐SnO₂ structure. The Sn²⁺ cations reduce graphene oxide (GO), leading to the in situ formation of SnO₂/graphene hybrids. L ‐Arginine is used as a linker and protector to induce the in situ growth of Pt nanoparticles (NPs) connected with SnO₂ NPs and impede the agglomeration of Pt NPs. The obtained Pt/SnO₂/graphene composites exhibit superior electrocatalytic activity and stability for the ethanol oxidation reaction as compared with the commercial Pt/C catalyst owing to the close‐connected structure between the Pt NPs and SnO₂ NPs. This work should have a great impact on the rational design of future metal–metal oxide nanostructures with high catalytic activity and stability for fuel cell systems.     

Delivery of Highly Active Noble‐Metal Nanoparticles into Microspherical Supports by an Aerosol‐Spray Method

Noble metal nanoparticles (NPs) with 1–5 nm diameter obtained from NaHB₄ reduction possess high catalytic activity. However, they are rarely used directly. This work presents a facile, versatile, and efficient aerosol‐spray approach to deliver noble‐metal NPs into metal oxide supports, while maintaining the size of the NPs and the ability to easily adjust the loading amount. In comparison with the conventional spray approach, the size of the loaded noble‐metal nanoparticles can be significantly decreased. An investigation of the 4‐nitrophenol hydrogenation reaction catalyzed by these materials suggests that the NPs/oxides catalysts have high activity and good endurance. For 1 % Au/CeO₂ and Pd/Al₂O₃ catalysts, the rate constants reach 2.03 and 1.46 min^?1, which is much higher than many other reports with the same noble‐metal loading scale. Besides, the thermal stability of catalysts can be significantly enhanced by modifying the supports. Therefore, this work contributes an efficient method as well as some guidance on how to produce highly active and stable supported noble‐metal catalysts.     

Gated Channels and Selectivity Tuning of CO2 over N2 Sorption by Post‐Synthetic Modification of a UiO‐66‐Type Metal–Organic Framework

The highly porous and stable metal–organic framework (MOF) UiO‐66 was altered using post‐synthetic modifications (PSMs). Prefunctionalization allowed the introduction of carbon double bonds into the framework through a four‐step synthesis from 2‐bromo‐1,4‐benzenedicarboxylic acid; the organic linker 2‐allyl‐1,4‐benzenedicarboxylic acid was obtained. The corresponding functionalized MOF (UiO‐66‐allyl) served as a platform for further PSMs. From UiO‐66‐allyl, epoxy, dibromide, thioether, diamine, and amino alcohol functionalities were synthesized. The abilities of these compounds to adsorb CO₂ and N₂ were compared, which revealed the structure–selectivity correlations. All synthesized MOFs showed profound thermal stability together with an increased ability for selective CO₂ uptake and molecular gate functionalities at low temperatures.     

The Stabilization Effect of CO2 in Lithium–Oxygen/CO2 Batteries

The lithium (Li)–air battery has an ultrahigh theoretical specific energy, however, even in pure oxygen (O₂), the vulnerability of conventional organic electrolytes and carbon cathodes towards reaction intermediates, especially O₂^?, and corrosive oxidation and crack/pulverization of Li metal anode lead to poor cycling stability of the Li‐air battery. Even worse, the water and/or CO₂ in air bring parasitic reactions and safety issues. Therefore, applying such systems in open‐air environment is challenging. Herein, contrary to previous assertions, we have found that CO₂ can improve the stability of both anode and electrolyte, and a high‐performance rechargeable Li–O₂/CO₂ battery is developed. The CO₂ not only facilitates the in situ formation of a passivated protective Li₂CO₃ film on the Li anode, but also restrains side reactions involving electrolyte and cathode by capturing O₂^?. Moreover, the Pd/CNT catalyst in the cathode can extend the battery lifespan by effectively tuning the product morphology and catalyzing the decomposition of Li₂CO₃. The Li–O₂/CO₂ battery achieves a full discharge capacity of 6628 mAh g^?1 and a long life of 715 cycles, which is even better than those of pure Li–O₂ batteries.     

Ultrathin Coating of Confined Pt Nanocatalysts by Atomic Layer Deposition for Enhanced Catalytic Performance in Hydrogenation Reactions

Metal‐support interfaces play a prominent role in heterogeneous catalysis. However, tailoring the metal‐support interfaces to realize full utilization remains a major challenge. In this work, we propose a graceful strategy to maximize the metal‐oxide interfaces by coating confined nanoparticles with an ultrathin oxide layer. This is achieved by sequential deposition of ultrathin Al₂O₃ coats, Pt, and a thick Al₂O₃ layer on carbon nanocoils templates by atomic layer deposition (ALD), followed by removal of the templates. Compared with the Pt catalysts confined in Al₂O₃ nanotubes without the ultrathin coats, the ultrathin coated samples have larger Pt–Al₂O₃ interfaces. The maximized interfaces significantly improve the activity and the protecting Al₂O₃ nanotubes retain the stability for hydrogenation reactions of 4‐nitrophenol. We believe that applying ALD ultrathin coats on confined catalysts is a promising way to achieve enhanced performance for other catalysts.     

Synthesis of Supported Bimetal Catalysts using Galvanic Deposition Method

Supported bimetallic catalysts have been studied because of their enhanced catalytic properties due to metal‐metal interactions compared with monometallic catalysts. We focused on galvanic deposition (GD) as a bimetallization method, which achieves well‐defined metal‐metal interfaces by exchanging heterogeneous metals with different ionisation tendencies. We have developed Ni@Ag/SiO₂ catalysts for CO oxidation, Co@Ru/Al₂O₃ catalysts for automotive three‐way reactions and Pd−Co/Al₂O₃ catalysts for methane combustion by using the GD method. In all cases, the catalysts prepared by the GD method showed higher catalytic activity than the corresponding monometallic and bimetallic catalysts prepared by the conventional co‐impregnation method. The GD method provides contact between noble and base metals to improve the electronic state, surface structure and reducibility of noble metals.