Nan
Yi
,
Rui
Si
,
Howard
Saltsburg
and
Maria
Flytzani-Stephanopoulos
*
Department of Chemical and Biological Engineering, Tufts University, 4 Colby Street, Medford, MA 02155, USA. E-mail: maria.flytzani-stephanopoulos@tufts.edu; Fax: +1 617 627 3991; Tel: +1 617 627 3048
First published on 13th May 2010
We report that a small amount (<1 at%) of gold on ceria single crystals prepared as nanorods (10 ± 2.8 by 50–200 nm) of {110} and {100} crystal surfaces shows excellent catalytic activity in both the steam reforming of methanol (SRM) and the water gas shift (WGS) reactions at low temperatures (<250 °C). The ceria nanorods bind and stabilize gold as atoms and clusters (<1 nm, TEM invisible). On the other hand, gold nanoparticles (∼3 nm) are found on the {100} surfaces of ceria nanocubes. Very low rates of SRM and WGS were measured on the Au–ceria {100} cubes, while the rates on Au–ceria {110} rods were at least an order of magnitude higher. However, the apparent activation energies did not depend on the shape of ceria. Strong bonded Aun–O–Ce species are the active sites and these are present only in negligible concentrations on the {100} surfaces. Thus, both reactions are structure-insensitive on Au–ceria. SRM proceeds through the methyl formate route. The Au–ceria {110} catalyst shows both high SRM activity and high selectivity to CO2 at temperatures below 250 °C.
Broader contextNovel catalysts for the efficient conversion of fuels to hydrogen for fuel cell applications are under development. Among them a prominent place is held by new catalysts that are both active and stable for the low-temperature water-gas shift reaction to upgrade hydrogen. Another need is highly active and selective catalysts for the reforming of methanol, the easiest alcohol to reform at low temperatures. Achieving either of these two goals would be a breakthrough in the efforts to generate energy cleanly and with high efficiency. Here we demonstrate the feasibility of using trace amounts of gold on cerium oxide as an active and selective catalyst for both the steam reforming of methanol (SRM) and the water-gas shift (WGS) reactions at temperatures below 300 °C. Furthermore, we explore mechanistic issues of the SRM reaction activity and selectivity on this very promising catalyst system for fuel cell applications. |
Since the application of Au/Fe2O3 to water gas shift reaction was reported by Andreeva,3 Au catalysts have been widely investigated for this reaction. In a previous work in our group, we were first to identify Au/CeO2 as a promising low-temperature shift catalyst4 and further found that atomically dispersed gold in ceria, Aun–O–Ce, is responsible for the WGS activity.5,6 On the other hand, few reports currently exist on the catalytic applications of gold supported on oxides for methanol reactions. Bowker et al.7 found that Au/TiO2 photocatalyzes the reforming of methanol in an aqueous solution. Chang et al.8 reported that Au/TiO2 catalysts show relatively high activity for partial oxidation of methanol, and correlated the activity with the particle size of metallic gold. At the same time, the mechanism behind the methanol reforming reaction is still under debate, since the methanol decomposition/water gas shift route is sometimes proposed, while the methyl formate route is supported by experimental evidence under different sets of conditions.9,10
Because the SRM reaction may involve the WGS route in its mechanism, and our previous work has demonstrated that gold on nanoscale ceria is an excellent WGS catalyst,4–6,11,12 the exploration of the SRM properties of the same material was a reasonable extension of our investigation.13 An additional objective was to investigate potential shape effects of the ceria nanocrystals on the Au–ceria catalyst activity.
Transmission electron microscopy (TEM) and high-resolution TEM (HRTEM) were performed on a JEOL 200cx and JEOL 2010 at 200 kV, respectively. The TEM samples were prepared by drying an ethanol suspension containing dispersed catalyst powders on carbon film-coated copper grids.
A Kratos AXIS Ultra Imaging X-ray Photoelectron Spectrometer (XPS) with a resolution of 0.1 eV was used to determine the atomic metal ratios of the surface region and the metal oxidation states of gold–ceria catalysts. Samples in powder form were pressed on a double-side adhesive copper tape for analysis. All measurements were carried out at room temperature without any sample pre-treatment. An Al Kα X-ray source was used in this work. All binding energies were calibrated with the C 1s peak at 285.0 eV.
In CH3OH-Temperature Programmed Desorption (TPD) and (CH3OH + H2O)-TPSR, typically 60 mg samples were used. The catalysts were diluted with quartz powder at a weight ratio of 1/3. Samples were first pre-reduced in 20% H2–He flowing at 70 mL min−1. In CH3OH-TPD, 16% CH3OH was obtained by flowing pure helium through the methanol bubbler. Following completion of the adsorption, the samples were purged with pure helium to clean the residual gases before each test. In CH3OH + H2O-TPSR, the mixture of methanol and water was also generated by flowing pure helium through a liquid bubbler filled with methanol and water.
All temperature programmed reactions were carried out with the heating rate of 5 °C min−1 from room temperature to the designed temperature. The outlet gas was analyzed online by a quadrupole residual gas analyzer (MKS model RS-1).
The WGS reaction tests were conducted at atmospheric pressure with a loading of ∼100 mg catalyst powders. The reaction gas mixture was 2% CO/10% H2O/He and a total gas flow rate of 70 mL min−1 was used. Measurements of reaction rates and activation energy were also carried out in product-free (2% CO/10% H2O/He) gases at low conversions to avoid mass transfer effects. CO2 and CO concentrations in the feed and product gas streams were analyzed by an HP-6890 gas chromatograph (GC) or an IR 703 non-dispersive infrared (NDIR).
| Sample | Aua (at%) | S BET/m2 gcat−1 | Au dispersionc (%) | Rated/µmol gcat−1 s−1 | |
|---|---|---|---|---|---|
| SRM | WGS | ||||
| a Determined by ICP-AES. b Determined by ICP-AES after NaCN leaching at room temperature. c The dispersion of gold was estimated from the TEM data. 100% dispersion assumed for the leached samples (in brackets). d Numbers in brackets are the temperatures at which reaction rates were measured for the parent and leached samples. e Number in bracket is the specific surface area of CeO2 {110} surfaces, based on the nanorod structure. | |||||
| Ceria (nanorods) | — | 105 (53)e | — | 4.3 (400) | NA |
| Ceria (nanocubes) | — | 27 | — | 1.2 (400) | NA |
| 1% Au–ceria (Rod) | 0.9 (0.5)b | 100 | 100 (100) | 12.3 (250) | 3.9 (175) |
| 1% Au–ceria (Cube) | 0.9 (0.03)b | 24 | 30 (100) | 0.2 (250) | 0.3 (175) |
Ceria nanoparticles maintained their original crystal shapes after gold deposition and air calcination. The CeO2 nanorods have a uniform width of 10.1 ± 2.8 nm with a length of 50–200 nm (Fig. 1a), while the CeO2 nanocubes have a side-size of 29.5 ± 10.6 nm (Fig. 2a). Based on the corresponding HRTEM images in Fig. 1b and 2b, we have determined the growth direction for ceria nanorods as {110}, and the exposed crystal planes as: {110} + {100} on the rods and {100} on the cubes. Fig. 2a and b show small gold nanoparticles with an average size of ∼3 nm on the {100} surfaces of the ceria cubes. However, for the rod samples, no such gold nanocrystals were found. This indicates that the CeO2 nanorod surfaces can disperse and stabilize gold atoms and sub-nm clusters (TEM invisible) which are not the case for the {100} surfaces of the nanocubes. By deduction, the {110} surfaces of the ceria nanorods are assumed to contain all the gold.
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| Fig. 1 TEM images of 1% Au–ceria (Rod): (a) fresh; (b) fresh, high-resolution; (c) after use in SRM (2% CH3OH + 2.6% H2O/He, 15 h on-stream, T = 300 °C); (d) after use in WGS (2% CO + 10% H2O/He, 15 h on-stream; T = 350 °C). | ||
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| Fig. 2 TEM images of 1% Au–ceria (Cube): (a) fresh; (b) fresh, high-resolution; (c) after use in SRM (2% CH3OH + 2.6% H2O/He, 15 h on-stream, T = 300 °C); (d) after use in WGS (2% CO + 10% H2O/He, 15 h on-stream, T = 350 °C). | ||
The morphologies of the used Au–ceria nanorods and nanocubes after the SRM and WGS reactions were also investigated by TEM. Fig. 2c and d show that the cube shape of ceria was maintained after reaction in CH3OH/H2O or CO/H2O atmospheres. The sizes of both CeO2 nanocubes and Au nanoparticles did not change. For the rod samples, it can be seen from Fig. 1c and d that the reaction conditions had an effect on the morphologies of the CeO2 crystals. Some short nanorods, together with some polycrystals, were formed after either the SRM or the WGS reaction. However, gold particles were still absent as checked by TEM/HRTEM; gold atoms and clusters (<1 nm) were thus stable on the {110} surfaces even after 15 h on stream.
From the XPS (Axis Ultra, Al-Kα) data listed in Table 2, it can be seen that the surface Au concentrations (0.8–1.3 at%) are in good agreement with the bulk (0.9 at%), indicating that the gold species are present on the surface or the sub-surface layers of the ceria after the 400 °C calcination step. Specific elemental XPS spectra in Fig. 3a show a distinct binding-energy shift of the Au 4f peaks between the rod and the cube samples. After peak-deconvolution, we found that ionic gold (Au+ and Au3+) is the main species in the rod sample, while metallic gold (Au0) is dominant on the ceria nanocubes. We also investigated the used catalysts after 15 h on-stream in the SRM and WGS reactions. A mixture of mainly metallic gold and some ionic gold was found (Fig. 3b and c). Pre-reduction of the Au–ceria samples at 300 °C with 20% H2/He was employed before the SRM tests, while the catalysts were used in the as calcined state in WGS. Detailed XPS peak analysis is shown in Table 2. Furthermore, according to the TEM/HRTEM results (Fig. 1 and 2), the zero valent gold was still well dispersed on the WGS- and SRM-used rod samples, since no gold particles bigger than 1 nm were identified.
| Sample | Conditiona | XPS Au 4f peakb | |||
|---|---|---|---|---|---|
| Auc (at%) | Au0 (%) | Au+ (%) | Au3+ (%) | ||
| a Fresh, WGS, and SRM refer to sample as-prepared after air calcination at 400 °C, 15 hon-stream in WGS, and 15 h on-stream in SRM. b The binding energy was calibrated to the C 1s peak at 285.0 eV. c Determined from Au 4f and Ce 3d cores in XPS spectra. | |||||
| 1% Au–ceria (Rod) | Fresh | 0.9 | — | 86 | 14 |
| WGS | 0.8 | 87 | 10 | 3 | |
| SRM | 1.1 | 85 | 11 | 4 | |
| 1% Au–ceria (Cube) | Fresh | 1.1 | 77 | 17 | 6 |
| WGS | 1.3 | 85 | 9 | 6 | |
| SRM | 1.3 | 86 | 10 | 4 | |
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| Fig. 3 XPS spectra of Au4f over Au–ceria: (a) fresh, (b) after use in SRM (2% CH3OH–2.6% H2O/He, 15 h on-stream, T = 300 °C); (c) after use in WGS (2% CO + 10% H2O/He, 15 h on-stream, T = 350 °C). | ||
The interaction of the ceria rods and Au–ceria (Rod) surfaces with methanol using CH3OH-TPD was evaluated here, as shown in Fig. 4a and b, respectively. Hydrogen and carbon monoxide elute simultaneously on the ceria nanorods, apparently due to the decomposition of the methoxy group, which was found to form upon adsorption of methanol on ceria surfaces.14 On the other hand, weak hydrogen desorption took place from the {100} ceria cube faces.13 This suggests a different interaction of the {110} and {100} surfaces with methanol.
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| Fig. 4 CH3OH-TPD over (a) ceria (Rod) and (b) 1% Au–ceria (Rod) (16% CH3OH/He for TPD adsorption, flow rate: 70 mL min−1, heating rate: 5 °C min−1). | ||
On the Au–ceria samples, no CO peak was observed; only CO2 and H2 were produced. If the intermediate was the methoxy species, same as on ceria, we should observe the simultaneous desorption of CO and H2, instead of CO2 and H2. Thus, methanol decomposition on ceria and gold–ceria may follow different pathways.15,16 Indeed, we found methyl formate intermediate on the Au–ceria, but not on ceria during CH3OH-TPSR.13
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| Fig. 5 Steady-state reaction rates for (a) WGS reaction and (b) SRM reaction measured in 2% CO–10% H2O–He for WGS and 2% CH3OH–2.6% H2O–He for SRM. | ||
The difference in the (per gram catalyst) rates is due to the very different amounts of active gold stabilized on the different ceria nanoshapes. Thus, the observed shape effect is “indirect”, and can be understood in terms of the active phase being the fully dispersed gold on ceria.
Let us now consider the activity of the Au–ceria catalyst for the SRM reaction. Reduction of the samples with 20% H2/He at 300 °C preceded the activity tests because the oxidized (as calcined) samples showed lower activity. Steady-state data were collected after 1.5 h testing at each temperature. Both temperature ramping up and down were followed. Addition of gold was found to improve the activity of ceria dramatically. The 1% Au–ceria (Rod) catalyst shows full methanol conversion at ∼300 °C.13 Reaction rates were much lower on the 1% Au–ceria (Cube) than on the 1% Au–ceria (Rod), although the apparent activation energies were the same, ∼110 kJ mol−1, as shown in Fig. 5b. Similar arguments to those made above for the structure insensitivity of the WGS reaction can be made also for the SRM reaction on Au–ceria, because the same turnover frequencies (e.g. TOF = ∼0.42 s−1 at 250 °C) were calculated for both ceria nanoshapes.
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| Fig. 6 (a) CO + H2O-TPSR over 1% Au–ceria (Rod) (1% CO + 3% H2O/He, heating rate = 5 °C min−1); (b) CH3OH + H2O-TPSR over 1% Au–ceria (Rod); (c) CH3OH + H2O-TPSR over 1% Au–ceria (Cube) (gas composition: 16% CH3OH + 3% H2O/He, heating rate = 5 °C min−1). | ||
TPSR was carried out also with a mixture of methanol and water over the Au–ceria samples. As shown in Fig. 6b, during the temperature ramp over the 1% Au–ceria (Rod), hydrogen and carbon dioxide were formed beginning at ∼175 °C (temp. I). This agrees with our activity test results that showed that hydrogen and carbon dioxide were produced in the low-temperature region.13 Carbon monoxide was observed starting at ∼275 °C (temp. II, Fig. 6b). In the temperature range from 275 °C to 335 °C (temp. III), the formation of CO took place. There are two possible sources of carbon monoxide: one is the decomposition of methoxy adsorbed on ceria and the other is the reverse water gas shift reaction. Either possibility can account for the reduced CO2 selectivity above 275 °C. In the temperature range between 335 °C and 395 °C (temp. IV), CO and water decrease sharply but CO2 and H2 increase. Since methanol conversion is complete at 325 °C, this manifests a sharp increase in the WGS reaction. Evidently, the presence of methanol inhibits the water gas shift reaction. At even higher temperatures (>395 °C, Fig. 6b) the reverse water gas shift reaction dominates.
While in CH3OH-TPSR methyl formate species were found,13 when H2O was used along with methanol as shown in Fig. 6b, no methyl formate was identified in the products. There was also no methane present. Trace amounts of formic acid were found, however. This suggests that methyl formate hydrolysis took place:9,13
| HCOOCH3 + H2O → HCOOH + CH3OH |
The formic acid is then decomposed to produce CO2 and H2.
As shown in Fig. 6c, similar product distribution was observed on the 1% Au–ceria (Cube) except that the corresponding elution temperatures shifted to higher values.
From the similarities of Fig. 6b and c, and the rate measurements of Fig. 5, we can argue that the SRM reaction on Au–ceria is structure-insensitive. The rates on the Au–ceria (Cube) are much lower due to the lack of active sites (Aun–O–Ce) but the few sites that remain after leaching (0.03 at% Au on the {100} surfaces) have the same intrinsic activity as the gold clusters on the {110} surfaces of the ceria nanorods.
Methanol is known to adsorb weakly and molecularly on a clean gold surface15,17 However, on oxygen-activated gold (111) surfaces, reconstruction and formation of small gold islands take place and on these, stronger adsorption of methanol has been reported.15,17,18 In the present work, ceria can serve as the source of active oxygen to the small gold clusters stabilized on its surface. Based on previous studies on gold single crystals,15,19 formaldehyde is stable on gold surfaces and can easily continue to react with methoxy or other sources of oxygen to form methyl formate groups. From CH3OH-TPSR tests,13 we have found that methyl formate and hydrogen appear together, and H2 and CO2 are the dominant products.13,20
On the basis of the above, we suggest a cooperative mechanism for Au–ceria in steam reforming of methanol: reduced ceria adsorbs methanol as methoxy which combines with the formaldehyde adsorbed on gold.13 The methyl formate pathway is then followed, as depicted in the graphical abstract. At the same time, gold facilitates the reduction of ceria, which in turn can adsorb water, as has been reported for the Rh/ceria(111) system.21 Adsorbed water helps to hydrolyze methyl formate to formic acid, which is then decomposed to CO2 and H2. In summary, the following steps are proposed for steam reforming of methanol over Au–ceria:
| 2CH3OH → HCOOCH3 + 2H2 |
| HCOOCH3 + H2O → HCOOH + CH3OH |
| HCOOH → CO2 + H2 |
The other major finding of this work is that different surfaces of ceria bind and stabilize gold clusters and atoms differently. Thus, very different amounts of atomically dispersed gold are present on the {110} and {100} surfaces of the ceria nanoshapes. This in turn controls the reaction rates for both the SRM and WGS reactions. It is documented that ceria planes have different bonding characteristics, namely the very stable and neutral {111} surface, the less stable, slightly puckered {110} surface, and the higher energy {100} surface.22 According to the model proposed by Wang and Feng,23 the surface density of atoms in the corresponding planes follows {111} > {100} > {110}. The energy of formation of oxygen vacancies follows the same order on these surfaces. Thus, the {110} surfaces have a higher number density of oxygen vacancies. For CeO2 {100} polar plane, which is composed of positively charged Ce layers and negatively charged O layers, this structure is not stable upon heating and will relax to a low-energy surface.24
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Fig. 7 Stability of 1% Au–ceria (Rod) in cyclic start up/shutdown SRM tests (gas composition: 2% CH3OH/2.6% H2O/bal. He, GHSV: 42 000 h−1). | ||
Overall, the Au–ceria catalyst shows good activity and stability for both the WGS and SRM reactions. Because of its high CO2 selectivity in SRM below 250 °C, this catalyst merits further evaluation for practical applications to future fuel processing and fuel cell systems.
Footnote |
| † This article was submitted as part of a Themed Issue on fuels of the future. Other papers on this topic can be found in issue 3 of vol. 3 (2010). This issue can be found from the Energy & Environmental Science, homepage http://www.rsc.org/publishing/journals/ee/. |
| This journal is © The Royal Society of Chemistry 2010 |