A spillover approach to oxidation catalysis over copper and manganese mixed oxides

The activity of a hopcalite-type catalyst for H₂ and CO oxidation is compared with that of single-phase oxides CuO, Mn₂O₃ and CuMn₂O₄ (spinel) and a mixture of 1:1 CuO and Mn₂O₃ in order to elucidate the effects that are responsible for the high catalytic activity of the former. The reaction rates over the hopcalite catalyst calcined at 550°C (a mixture of CuO, Mn₂O₃ and CuMn₂O₄) are very close to those of the physical mixture of CuO and Mn₂O₃, being much greater than the rates over the single-phase oxides. CuO, Mn₂O₃ and CuMn₂O₄ show a kinetic compensation behavior both in H₂ and CO oxidation. By taking into account the activation energies and the reducibility measured by TPR it was concluded that the oxidation reactions over CuO follow a redox mechanism using lattice oxygen, while over Mn₂O₃ the mechanism is associative involving adsorbed oxygen species. Based on the TPR and kinetic results, the synergy between copper and manganese oxides in hopcalite and in the CuO–Mn₂O₃ mixture is assigned to a spillover effect.     

Total oxidation catalysts based on manganese or copper oxides and platinum or palladium I: Characterisation

Temperature-programmed reduction (TPR), oxidation (TPO), Raman spectroscopy, X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD) were used to characterise catalysts based on manganese oxides, copper oxides or one of them mixed with platinum or palladium-supported on γ-alumina. The catalysts were characterised before and after they had been exposed either to high temperature in the presence of steam or to sulphur dioxide. Raman spectroscopy, XRD, XPS and TPR performed on the fresh samples of MnO_x, mixed MnO_x–Pt and MnO_x–Pd revealed the presence of a mixture of manganese oxides, particularly Mn₂O₃. In the fresh mixed MnO_x–Pd and CuO_x–Pd samples, Pd catalysed the reduction of both MnO_x and CuO_x, whereas Pt only catalysed the reduction of MnO_x. After hydrothermal treatment at 900°C of the MnO_x, mixed MnO_x–Pt and MnO_x–Pd samples, there was a formation of new manganese oxide phase, Mn₃O₄ detected by Raman spectroscopy. TPR revealed increasing interaction between the metal oxides and the noble metals in the hydrothermally treated mixed MnO_x–Pd and CuO_x–Pd samples, and also the appearance of interaction in the treated mixed CuO_x–Pt sample. The sulphur adsorbed in all the MnO_x samples formed sulphate, which was more difficult to reduce than the oxides. Also, the reduction temperature of sulphates was lowered when noble metals are present.     

Direct decomposition of nitric oxide over Ba catalysts supported on CeO2-based mixed oxides

The direct decomposition of nitric oxide (NO) over barium catalysts supported on various metal oxides was examined in the absence and presence of O₂. Among the Ba catalysts supported on single-component metal oxides, Ba/Co₃O₄ and Ba/CeO₂ showed high NO decomposition activities, while Ba/Al₂O₃, Ba/SiO₂, and Ba/TiO₂ exhibited quite low activities. The effect of an addition of second components to Co and Ce oxides was further examined, and it was found that the activities were significantly enhanced using Ce–Mn mixed oxides as support materials. XRD results indicated the formation of CeO₂–MnO_x solid solutions with the cubic fluorite structure. O₂-TPD of the CeO₂–MnO_x solid solutions showed a large desorption peak in a range of relatively low temperature. The BET surface areas of the CeO₂–MnO_x solid solutions were larger than those of pure CeO₂ and Mn₂O₃. These effects caused by the addition of Mn are responsible for the enhanced activities of the Ba catalysts supported on Ce–Mn mixed oxides.     

TPR and XRD studies of yttria-doped ceria/γ-alumina-supported copper oxide catalyst

Yttria-doped ceria (YDC) and pure ceria (CeO₂), respectively, were deposited on γ-alumina (γ-Al₂O₃) using the impregnation method; then, copper oxide was also supported on them by employing the impregnation method. For comparison, CuO/γ-Al₂O₃ catalysts were prepared in this work. The catalysts were characterized by temperature-programmed reduction (TPR) and X-ray diffraction (XRD). For CuO/γ-Al₂O₃ catalysts, two TPR peaks, namely β and γ, were observed. These have been attributed to the reduction of highly dispersed copper oxide species and bulk-like copper oxide, respectively. For CuO/CeO₂/γ-Al₂O₃ and CuO/YDC/γ-Al₂O₃ catalysts, four TPR peaks, namely ₁, ₂, β′ and γ′, could be observed. The peaks with lower peak temperatures as compared to those of β′ and γ′ peaks have been attributed to the reduction of interface-boundary copper oxide species that contact closely and interact strongly with the supported ceria or YDC. Crystal sizes calculated from XRD measurements confirmed that yttria (Y₂O₃) addition could lead to crystal growth of ceria and correspondingly enhance the dispersion of the supported copper oxide due to the partition of YDC crystallite. Hence, this work shows that supported YDC and ceria can act bi-functionally as a textural promoter as well as a structural promoter.     

Effect of copper species and the presence of reaction products on the activity of methane oxidation on supported CuO catalysts

The activity of the various CuO species found in supported copper catalysts and the effect of the presence of reaction products, CO₂ and H₂O, was studied during the complete oxidation of methane. Series of copper catalysts supported on ZrO₂, Al₂O₃ and SiO₂ with different metal concentrations were analyzed under identical experimental conditions of reactant concentration and temperature. The catalysts were characterized by TPR, UV–vis spectroscopy and XRD. The results show that the activity of supported CuO is closely related to the kind of Cu species formed on the different supports. It was found that the Cu species formed on ZrO₂ and Al₂O₃ are dependent on the metal loading/support's surface area ratio, and that the activity of highly dispersed Cu is substantially higher than that of bulk CuO. In the case of silica, only the formation of bulk CuO was detected, accounting for the low activity of CuO/SiO₂ catalysts. The activity of highly dispersed Cu species formed on ZrO₂ is higher than those formed over Al₂O₃, and it is not significantly affected by the formation of bulk CuO on the surface. On the contrary, the activity of copper species formed on alumina decreases continuously as the Cu loading is increased. Thus, for the range of copper loading studied in this work, the activity of the catalysts, per gram of loaded Cu, follows the sequence: CuO/ZrO₂ > CuO/Al₂O₃  CuO/SiO₂. It was also found that CO₂ does not inhibits the activity of the CuO/ZrO₂ catalysts, while water inhibits the combustion reaction of methane, with an estimated reaction order of about −0.2 for temperatures between 360 °C and 420 °C.     

Total oxidation of propene and propane over gold–copper oxide on alumina catalysts: Comparison with Pt/Al2O3

Oxidation of propene and propane to CO₂ and H₂O has been studied over Au/Al₂O₃ and two different Au/CuO/Al₂O₃ (4 wt.% Au and 7.4 wt.% Au) catalysts and compared with the catalytic behaviour of Au/Co₃O₄/Al₂O₃ (4.1 wt.% Au) and Pt/Al₂O₃ (4.8 wt.% Pt) catalysts. The various characterization techniques employed (XRD, HRTEM, TPR and DR-UV–vis) revealed the presence of metallic gold, along with a highly dispersed CuO (6 wt.% CuO), or more crystalline CuO phase (12 wt.% CuO).

A higher CuO loading does not significantly influence the catalytic performance of the catalyst in propene oxidation, the gold loading appears to be more important. Moreover, it was found that 7.4Au/CuO/Al₂O₃ is almost as active as Pt/Al₂O₃, whereas Au/Co₃O₄/Al₂O₃ performs less than any of the CuO-containing gold-based catalysts.

The light-off temperature for C₃H₈ oxidation is significantly higher than for C₃H₆. For this reaction the particle size effect appears to prevail over the effect of gold loading. The most active catalysts are 4Au/CuO/Al₂O₃ (gold particles less than 3 nm) and 4Au/Co₃O₄/Al₂O₃ (gold particles less than 5 nm).     

Total oxidation catalysts based on manganese or copper oxides and platinum or palladium II: Activity, hydrothermal stability and sulphur resistance

Deactivation of catalysts based on either manganese oxides, copper oxides, platinum, palladium or combinations of these metal oxides and noble metals supported on γ-alumina was studied. The activity of the catalysts for the oxidation of carbon monoxide, naphthalene and methane, in a mixture resembling the flue gases from wood combustion, was measured before and after exposure of the catalysts either to a temperature of 900°C in the presence of steam or to sulphur dioxide. Most of the mixed catalysts were more resistant to hydrothermal and sulphur treatments than the catalysts with a single active component. After the hydrothermal treatment the activity of the MnO_x catalyst was enhanced. When Pt is combined with MnO_x or CuO_x, the loss of activity of Pt was decreased during the hydrothermal treatment. Also, the hydrotreated mixed MnO_x–Pd and CuO_x–Pd catalysts were more active than the treated Pd catalyst for the oxidation of methane. After sulphur treatment, the activities of the mixed MnO_x–Pt (Pt: 0.05 mol%), MnO_x–Pd and CuO_x–Pd catalysts were improved for the oxidation of carbon monoxide and naphthalene. Among the catalysts studied, the MnO_x–Pt, CuO_x–Pt and CuO_x–Pd catalysts, with a metal oxide and a noble metal loading of 10 and 0.1 mol%/γ-alumina, respectively, had the best combination of activity, thermal stability and resistance to sulphur treatment.     

Catalytic performance of Co3O4/CeO2 and Co3O4/CeO2–ZrO2 composite oxides for methane combustion: Influence of catalyst pretreatment temperature and oxygen concentration in the reaction mixture

The influence of catalyst pre-treatment temperature (650 and 750 °C) and oxygen concentration (λ = 8 and 1) on the light-off temperature of methane combustion has been investigated over two composite oxides, Co₃O₄/CeO₂ and Co₃O₄/CeO₂–ZrO₂ containing 30 wt.% of Co₃O₄. The catalytic materials prepared by the co-precipitation method were calcined at 650 °C for 5 h (fresh samples); a portion of them was further treated at 750 °C for 7 h, in a furnace in static air (aged samples).

Tests of methane combustion were carried out on fresh and aged catalysts at two different WHSV values (12 000 and 60 000 mL g⁻¹ h⁻¹). The catalytic performance of Co₃O₄/CeO₂ and Co₃O₄/CeO₂–ZrO₂ were compared with those of two pure Co₃O₄ oxides, a sample obtained by the precipitation method and a commercial reference. Characterization studies by X-ray diffraction (XRD), BET and temperature-programmed reduction (TPR) show that the catalytic activity is related to the dispersion of crystalline phases, Co₃O₄/CeO₂ and Co₃O₄/CeO₂–ZrO₂ as well as to their reducibility. Particular attention was paid to the thermal stability of the Co₃O₄ phase in the temperature range of 750–800 °C, in both static (in a furnace) and dynamic conditions (continuous flow). The results indicate that the thermal stability of the phase Co₃O₄ heated up to 800 °C depends on the size of the cobalt oxide crystallites (fresh or aged samples) and on the oxygen content (excess λ = 8, stoichiometric λ = 1) in the reaction mixture. A stabilizing effect due to the presence of ceria or ceria–zirconia against Co₃O₄ decomposition into CoO was observed.

Moreover, the role of ceria and ceria–zirconia is to maintain a good combustion activity of the cobalt composite oxides by dispersing the active phase Co₃O₄ and by promoting the reduction at low temperature.     

Role of CeO2 in Ni/CeO2–Al2O3 catalysts for carbon dioxide reforming of methane

Ni catalysts supported on γ-Al₂O₃, CeO₂ and CeO₂–Al₂O₃ systems were tested for catalytic CO₂ reforming of methane into synthesis gas. Ni/CeO₂–Al₂O₃ catalysts showed much better catalytic performance than either CeO₂- or γ-Al₂O₃-supported Ni catalysts. CeO₂ as a support for Ni catalysts produced a strong metal–support interaction (SMSI), which reduced the catalytic activity and carbon deposition. However, CeO₂ had positive effect on catalytic activity, stability, and carbon suppression when used as a promoter in Ni/γ-Al₂O₃ catalysts for this reaction. A weight loading of 1–5 wt% CeO₂ was found to be the optimum. Ni catalysts with CeO₂ promoters reduced the chemical interaction between nickel and support, resulting in an increase in reducibility and stronger dispersion of nickel. The stability and less coking on CeO₂-promoted catalysts are attributed to the oxidative properties of CeO₂.     

Non-steady activity during methane combustion over Pd/Al2O3 and the influences of Pt and CeO2 additives

Methane combustion over Pd/Al₂O₃ catalysts with and without added Pt and CeO₂ in both oxygen-rich and methane-rich mixtures at temperatures in the range 250–520°C has been investigated using a temperature-programmed reaction procedure with on-line gas analysis (FTIR). During the temperature loop under oxygen-rich conditions, there was an appreciable hysteresis in the activity of unmodified Pd/Al₂O₃, which was greatly enhanced over Pd–Pt/Al₂O₃. Over both catalysts the hysteresis was reversed under slightly methane-rich atmospheres, and as temperature was reduced, a sudden collapse or fluctuations in activity were shown respectively over Pd–Pt/Al₂O₃ and Pd/Al₂O₃. Such non-steady behaviour was almost eliminated over Pd/Al₂O₃–CeO₂. Under a very narrow range of conditions and over a Pd/Al₂O₃ packed bed, oscillation of methane combustion was observed.     

Oxidative degradation properties of Co-based catalysts in the presence of ozone

Four series of cobalt-based catalysts, such as bare Co₃O₄ and CoO, CoO_x–CeO₂ mixed oxides, CoO_x supported over alumina and alumina–baria and CoMgAl and CoNiAl hydrotalcites have been synthesized and investigated for the oxidative degradation of phenol in the presence of ozone. Characterizations were obtained by several techniques in order to investigate the nature of cobalt species and their morphological properties, depending on the system. Analyses by XRD, BET, TPR, UV–visible diffuse reflectance spectroscopy and TG/DT were performed.

The CoNiAl hydrotalcite exhibits, after 4 h of reaction, the highest phenol ozonation activity followed by Co(3 wt%)/Al₂O₃–BaO and CoMgAl. The samples Co(1 wt%)/Al₂O₃–BaO and Co(1 and 3 wt%)/Al₂O₃ show a comparable medium activity, while the oxidation properties of bare oxides Co₃O₄, CoO and CoO_x–CeO₂ are really low. Leaching of cobalt ions in the water solution was detected during the reaction, the amount varied depending on the nature of catalysts. A massive release was observed for the CoMgAl and CoNiAl hydrotalcites, while cobalt catalysts over alumina and alumina–baria look much more stable. The recycle of CoO_x/Al₂O₃ and CoO_x/Al₂O₃–BaO was studied by performing three consecutive cycles in the phenol oxidation. Because of the potential interest of the cobalt-supported catalysts in the ozonation process, the oxidative degradation of naphtol blue black was also investigated.

On the basis of TPR and UV–visible results it appears that highly dispersed Co²⁺ ions especially present over Co(3 wt%)/Al₂O₃–BaO are the main active sites for phenol and naphtol blue black oxidative degradation by ozone.     

Catalytic activity of dispersed CuO phases towards nitrogen oxides (N2O, NO, and NO2)

A systematic reactivity study of N₂O, NO, and NO₂ on highly dispersed CuO phases over modified silica supports (SiO₂–Al₂O₃, SiO₂–TiO₂, and SiO₂–ZrO₂) has been performed. Different reaction paths for the nitrogen oxide species abatement were studied: from direct decomposition (N₂O) to selective reductions by hydrocarbons (N₂O, NO, and NO₂) and oxidation (NO to NO₂). The oxygen concentration, temperature, and contact time, were varied within suitable ranges in order to investigate the activity and in particular the selectivity in the different reactions studied. The support deeply influenced the catalytic properties of the active copper phase. The most acidic supports, SiO₂–Al₂O₃ and SiO₂–ZrO₂, led to a better activity and selectivity of CuO for the reactions of N₂O, NO, and NO₂ reductions and N₂O decomposition than SiO₂–TiO₂. The catalytic results are discussed in terms of actual turnover frequencies starting from the knowledge of the copper dispersion values.     

Influence of metal oxides on the catalytic behavior of Au/Al2O3 for the selective reduction of NOx by hydrocarbons

The reduction of NO by propene in the presence of excess oxygen over mechanical mixtures of Au/Al₂O₃ with a bulk oxide has been investigated. The oxides studied were: Co₃O₄, Mn₂O₃, Cr₂O₃, CuO, Fe₂O₃, NiO, CeO₂, SnO₂, ZnO and V₂O₅. Under lean C₃H₆-SCR conditions, these oxides (with the exception of SnO₂) convert selectively NO to NO₂. When mechanically mixed with Au/Al₂O₃, the Mn₂O₃ and Co₃O₄ oxides and, to a much greater extent, CeO₂ act synergistically with this catalyst greatly enhancing its SCR performance. It was found that their synergistic action is not straightforwardly related to their activity for NO oxidation to NO₂. The exhibited catalytic synergy may be due to the operation of either remote control or a bifunctional mechanism. In the later case, the key intermediate must be a short-lived compound and not the NO₂ molecule in gas-phase.     

Selective catalytic reduction of NO by C3H8 over CoOx/Al2O3: An investigation of structure–activity relationships

A series of CoO_x/Al₂O₃ catalysts was prepared, characterized, and applied for the selective catalytic reduction (SCR) of NO by C₃H₈. The results of XRD, UV–vis, IR, Far-IR and ESR characterizations of the catalysts suggest that the predominant oxidation state of cobalt species is +2 for the catalysts with low cobalt loading (≤2 mol%) and for the catalysts with 4 mol% cobalt loading prepared by sol–gel and co-precipitation. Co₃O₄ crystallites or agglomerates are the predominant species in the catalysts with high cobalt loading prepared by incipient wetness impregnation and solid dispersion. An optimized CoO_x/Al₂O₃ catalyst shows high activity in SCR of NO by C₃H₈ (100% conversion of NO at 723 K, GHSV: 10,000 h⁻¹). The activity of the selective catalytic reduction of NO by C₃H₈ increases with the increase of cobalt–alumina interactions in the catalysts. The influences of cobalt loading and catalyst preparation method on the catalytic performance suggest that tiny CoAl₂O₄ crystallites highly dispersed on alumina are responsible for the efficient catalytic reduction of NO, whereas Co₃O₄ crystallites catalyze the combustion of C₃H₈ only.     

Catalytic combustion of hydrocarbons with Mn and Cu-doped ceria–zirconia solid solutions

The catalytic activity of a series of CeO₂–ZrO₂ mixed oxides in the total oxidation of methane and light hydrocarbons has been investigated. The influence of dopants like Mn and Cu has also been studied. It is shown that both MnO_x and CuO at low loading dissolve within the ceria–zirconia lattice. This strongly influences the redox behaviour of the catalysts by promoting low-temperature reduction of Ce⁴⁺. In addition, the ternary oxides show better stability to repeated redox cycles, which is attributed to the presence of ZrO₂. The catalytic activity of pure CeO₂ is also enhanced in the presence of ZrO₂, reaching a maximum with Ce_0.92Zr_0.08O₂; a further promotion of activity is observed with the introduction of MnO_x and CuO dissolved into CeO₂–ZrO₂ lattice.     

Ultrahigh temperature water gas shift catalysts to increase hydrogen yield from biomass gasification

Noble metal (Rh, Pt, Pd, Ir, Ru, and Ag) and Ni catalysts supported on CeO₂–Al₂O₃ were investigated for water gas shift reaction at ultrahigh temperatures. Pt/CeO₂–Al₂O₃ and Ru/CeO₂–Al₂O₃ demonstrated as the best catalysts in terms of activity, hydrogen yield and hydrogen selectivity. At 700 °C and steam to CO ratio of 5.2:1, Pt/CeO₂–Al₂O₃ converted 76.3% of CO with 94.7% of hydrogen selectivity. At the same conditions, the activity and hydrogen selectivity for Ru/CeO₂–Al₂O₃ were 63.9% and 85.6%, respectively. Both catalysts showed a good stability over 9 h of continuous operation. However, both catalysts showed slight deactivation during the test period. The study revealed that Pt/CeO₂–Al₂O₃ and Ru/CeO₂–Al₂O₃ were excellent ultrahigh temperature water gas shift catalysts, which can be coupled with biomass gasification in a downstream reactor.     

Ce1−xCuxO2−x/Al2O3/FeCrAl catalysts for catalytic combustion of methane

A series of the Ce_1−xCu_xO_2−x/Al₂O₃/FeCrAl catalysts (x = 0–1) were prepared. The structure of the catalysts was characterized using XRD, SEM and H₂-TPR. The catalytic activity of the catalysts for the combustion of methane was evaluated. The results indicated that in the Ce_1−xCu_xO_2−x/Al₂O₃/FeCrAl catalysts the surface phase structure were the Ce_1−xCu_xO_2−x solid solution, -Al₂O₃ and γ-Al₂O₃. The surface particle shape and size were different with the variety of the molar ratio of Ce to Cu in the Ce_1−xCu_xO_2−x solid solution. The Cu component of the Ce_1−xCu_xO_2−x/Al₂O₃/FeCrAl catalysts played an important role to the catalytic activity for the methane combustion. There were the stronger interaction among the Ce_1−xCu_xO_2−x solid solution and the Al₂O₃ washcoats and the FeCrAl support.     

Development of new catalysts for N2O-decomposition from adipic acid plant

Direct decomposition of N₂O was investigated using simulated and real industrial gas stream coming from an adipic acid plant. Two different kinds of catalysts were studied: (i) LaB_1−xB′_xO₃ and CaB_1−xCu_xO₃ (B = Mn, Fe and B′ = Cu, Ni) perovskites (PVKs) and (ii) supported PVKs (10 or 20 wt.%) on γ-Al₂O₃ and CeO₂–ZrO₂. The structural modifications induced by the composition of PVK samples affect the catalytic performances: mixed oxide formation in CaMn_0.7Cu_0.3O₃ samples allows to reach the highest values of N₂O conversion while the effect of PVK phases is more controversial. The importance of copper on catalytic activities is confirmed by the investigation on CaMn_1−xCu_xO₃ samples. The best results were obtained with a CaMn_0.6Cu_0.4O₃ catalyst calcined at 700 °C for 5 h, in which the presence of copper maximises the Ca₃CuMnO₆ phase formation. The increase in Cu-content produces a large segregation of CuO despite PVK formation. The best catalyst was tested using industrial gas stream, showing good stability also in the presence of H₂O and O₂ (8% v/v ) after 1400 h on-stream. To increase surface area, Cu-containing PVKs were deposed on γ-Al₂O₃ and CeO₂–ZrO₂, and this latter has been recognised as the best support. Indeed, the activity of the PVKs supported on ceria–zirconia is comparable to and even better than that of the bulk catalysts. A possible explanation regards the support contribution in terms of activity and/or promotion of O₂ mobility which enhances the overall activity of the catalyst.     

K-, CeO2-, and Mn-promoted Ni/Al2O3 catalysts for stable CO2 reforming of methane

Reforming of methane with carbon dioxide into syngas over Ni/γ-Al₂O₃ catalysts modified by potassium, MnO and CeO₂ was studied. The catalysts were prepared by impregnation technique and were characterized by N₂ adsorption/desorption isotherm, BET surface area, pore volume, and BJH pore size distribution measurements, and by X-ray diffraction and scanning electron microscopy. The performance of these catalysts was evaluated by conducting the reforming reaction in a fixed bed reactor. The coke content of the catalysts was determined by oxidation conducted in a thermo-gravimetric analyzer. Incorporation of potassium and CeO₂ (or MnO) onto the catalyst significantly reduced the coke formation without significantly affecting the methane conversion and hydrogen yield. The stability and the lower amount of coking on promoted catalysts were attributed to partial coverage of the surface of nickel by patches of promoters and to their increased CO₂ adsorption, forming a surface reactive carbonate species. Addition of CeO₂ or MnO reduced the particle size of nickel, thus increasing Ni dispersion. For Ni–K/CeO₂–Al₂O₃ catalysts, the improved stability was further attributed to the oxidative properties of CeO₂. Results of the investigation suggest that stable Ni/Al₂O₃ catalysts for the carbon dioxide reforming of methane can be prepared by addition of both potassium and CeO₂ (or MnO) as promoters.