Z.-R.
Tang
a,
S. A.
Kondrat
a,
C.
Dickinson
b,
J. K.
Bartley
a,
A. F.
Carley
a,
S. H.
Taylor
a,
T. E.
Davies
a,
M.
Allix
b,
M. J.
Rosseinsky
b,
J. B.
Claridge
b,
Z.
Xu
b,
S.
Romani
b,
M. J.
Crudace
c and
G. J.
Hutchings
*a
aCardiff Catalysis Institute, School of Chemistry, Cardiff University, Main Building, Park Place, Cardiff, CF10 3AT, UK
bDepartment of Chemistry, University of Liverpool, Crown Street, Liverpool, L69 7ZD, UK
cMolecular Products Limited, Mill End, Thaxted, Essex, CM6 2LT, UK
First published on 24th May 2011
A series of high surface area nanocrystalline copper manganese oxide catalysts have been prepared by supercritical anti-solvent (SAS) precipitation using CO2 and tested for the ambient temperature oxidation of CO. The catalysts were prepared by precipitation from an ethanol/metal acetate solution and the addition of small quantities of water was found to result in a mixed acetate precursor with surface areas >200 m2 g−1, considerably higher than those prepared by conventional precipitation methods. The surface area of the final calcined mixed oxide was found to be dependent upon the initial water concentration. XRD and FT-IR analysis indicated that the addition of water promoted the formation of carbonate species in the amorphous acetate precursor, with high resolution TEM and STEM showing the material to consist of spherical agglomerations of fibrous strings of ca. 30 nm length. This is in contrast to the material prepared in the absence of water, using the same SAS methodology, which typically yields quasi-spherical particles of 100 nm size.
Recently we have shown how copper manganese oxide prepared by the SAS process can be highly active for the conversion of CO to CO2, highlighting how the intimate mixing afforded by the method resulted in a highly homogeneous mixed metal oxide.21 Comparison with a commercial copper manganese oxide catalyst showed that the material prepared using SAS precipitation was intrinsically more active, although the low surface area of the material limited its applicability.
Copper manganese oxide has been known to be active for the conversion of CO to CO2 for over a hundred years and although a number of more active materials have been discovered since, especially those based on precious metals,22,23 economic reasons have meant that hopcalite, amorphous CuMn2O4, is still the commercial catalyst of choice. The precise mechanism for the CO conversion has eluded researchers for years but there is a general consensus in the literature that activity is related to the redox couple at specific sites on the surface of the catalyst:24,25
Cu2+ + Mn3+ → Cu+ + Mn4+ |
A number of studies have looked into novel methods of hopcalite synthesis with varying degrees of success. Rangappa and co-workers have synthesised high surface area copper manganese oxide using supercritical water26 whereas Krämer et al. have shown that sol–gel preparation routes with ethylene glycol can result in high surface area materials with activity comparable to commercial hopcalite.27
The activity of hopcalite also depends on its morphology since many studies have shown that hopcalite is highly active in the amorphous state24,27,28 even at room temperature, and the activity is lost if the material is calcined at temperatures above ca. 500 °C when the crystalline spinel phase is formed. Studies of the synthesis methods indicated that the activity of hopcalite is known to depend on the structure of the catalyst precursor29 and in general this is controlled by the preparation method. We have previously investigated the effect of stoichiometry and the co-precipitation parameters on catalyst performance30,31 and demonstrated that the ageing time during which the co-precipitated composition ripens before it is separated and dried is of crucial importance. In the preparation of active hopcalite catalysts the most active catalysts were the stoichiometric CuMn2O4 prepared with a 12 h aging step. This modified approach has led to the preparation of hopcalite with significantly improved catalytic activity.
It is well known that active hopcalites are currently prepared by co-precipitation of a basic carbonate from a solution of the nitrates using sodium carbonate. Using supercritical fluids in catalyst preparation provides one possibility of a nitrate-free path to catalysts and catalyst precursors, thereby providing a new route for catalyst manufacture.
In the present study we have focused on the preparation of nanostructured CuMnOx using supercritical CO2 as an anti-solvent and acetates as starting precursors. Different solvents for metal acetates including pure solvents and co-solvents containing water have been investigated and catalysts with high activity for CO oxidation at room temperature have been obtained.
Samples for scanning transmission electron microscopy (STEM) and transmission electron microscopy (TEM) examination were prepared by dispersing the catalyst powder in high purity ethanol, then allowing a drop of the suspension to evaporate on a holey carbon microscope grid. Lattice imaging in both bright field (BF) and high angle annular dark field (HAADF) were carried out on a 3rd ordered spherical aberration corrected VG HB 501 with a Nion Mark II Quadropole-Octupole STEM (SuperSTEM) operating at 100 kV. The spatial resolution for the HAADF is ∼1 Å. Samples were also subjected to chemical microanalysis in a VG HB601 UX STEM operating at 100 kV. This microscope was fitted with an Oxford Instruments INCA TEM 300 system for energy dispersive X-ray (EDX) analysis. TEM images were taken on a JEOL 300 kV JEM3010 with LaB6 filament.
Water content (vol%) | Precursor (m2 g−1) | Calcined 300 °C 2 h (m2 g−1) |
---|---|---|
0 | 264 | 33 |
5 | 200 | 65 |
10 | 152 | 136 |
15 | 140 | 175 |
Analysis of the precursor material by XRD indicated that the addition of water promoted the formation of crystalline carbonate species (Fig. 1), with the main phases attributed to MnCO3. With no water present, the precursor is highly amorphous, but becomes increasingly crystalline as the concentration of water increases which is consistent with the decrease in surface area. The main phase present was identified as rhodochrosite (MnCO3 XRD reflections at 24.3, 31.5, 38.1, 41.8, 45.3, 51.9 degrees 2θ). No copper containing phases are observed in the diffractograms. The structure of the catalyst precursor is known to have a profound effect upon the activity of the final catalyst with Porta et al. highlighting the importance of the presence of hydroxycarbonates.32 It is proposed that in the process studied here, the addition of water promotes the formation of carbonic acid during the precipitation giving rise to carbonates as opposed to acetates.
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Fig. 1 XRD patterns of the precursors formed with different solvent mixtures: (a) 0 vol% H2O/EtOH (b) 5 vol% H2O/EtOH (c) 10 vol% H2O/EtOH (d) 15 vol% H2O/EtOH. |
Calcination of the precursor at 300 °C for 2 h (Fig. 2) resulted in the formation of Cu1.5Mn1.5O4 (XRD reflections at 30.6, 36.1, 38.8, 43.6, 57.8, 63.7 degrees 2θ), the crystallinity of which decreased with increasing water concentration. Interestingly, the more crystalline precursors gave a more amorphous catalyst as decomposition of the higher concentrations of carbonate became more difficult at 300 °C. Previously, Hutchings et al. demonstrated how amorphous materials comprising predominantly stoichiometric CuMn2O4 phases along with Mn2O3 and CuO are considerably more active than other materials.33TGA analysis of the precursor material prepared with pure ethanol is shown in Fig. 3a. The precursor displays a four stage weight loss with the first weight loss <100 °C attributed to residual solvent. The second weight loss at approximately 200 °C is indicative of copper hydroxide decomposition with the final weight losses at 236 and 297 °C attributed to the decomposition of copper acetate and manganese acetate respectively. With the increase in the water concentration the decomposition pattern changes as the carbonate species becomes dominant. Only three significant weight losses are apparent for the materials prepared with water present and these are attributed to the loss of physically adsorbed solvent (<100 °C), mixed copper acetate and carbonate (ca. 250 °C) and manganese acetate and carbonate (ca. 300 °C). Increasing the water concentration to 15 vol% resulted in the almost exclusive formation of carbonates, highlighted by the shift in the temperature of the weight losses from 245 to 269 °C and from 297 to 332 °C for the second and third decomposition steps respectively. This increase in the amount of carbonates present is confirmed by both the XRD and FT-IR analysis as shown in Fig. 4.
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Fig. 2 XRD patterns of the precursors formed with different solvent mixtures calcined at 300 °C: (a) 0 vol% H2O/EtOH (b) 5 vol% H2O/EtOH (c) 10 vol% H2O/EtOH (d) 15 vol% H2O/EtOH. |
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Fig. 3 TGA analysis of the precursors formed with different solvent mixtures: (a) 0 vol% H2O/EtOH (b) 5 vol% H2O/EtOH (c) 10 vol% H2O/EtOH (d) 15 vol%H2O/EtOH. |
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Fig. 4 FT-IR spectra of the precursors formed with different solvent mixtures: (a) 0 vol% H2O/EtOH (b) 5 vol% H2O/EtOH (c) 10 vol% H2O/EtOH (d) 15 vol% H2O/EtOH. |
FT-IR analysis of the sample prepared with pure ethanol confirmed the presence of metal acetate salts, demonstrated by the main bands at 1561 and 1481 cm−1. As the water content of the initial solvent mixture increases, the intensity of these bands decreases and the formation of the carbonate species is observed from the bands at 1485 and 862 cm−1.
CO oxidation activity for the calcined catalyst has been determined and is presented in Fig. 5. From the results, a number of important conclusions may be drawn. Firstly it is apparent that the catalytic activity is enhanced when using water as a co-solvent. Secondly, the most active catalyst is that prepared using 10 vol% H2O/ethanol with activity decreasing dramatically with a modest increase in the water concentration to 15 vol%. It is evident that the presence of water has a profound effect on the chemistry, with minor concentration variations giving rise to major differences in the catalytic activity. The pattern of activity with time-on-line is interesting as it shows a high initial activity which drops off rapidly after ca. 20 min. A similar pattern is observed with precious metal catalysts prepared using standard co-precipitation.18
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Fig. 5 Conversion of CO at 25 °C with time-on-line (5000 ppm CO, GHSV 12![]() |
Scanning electron micrographs (Fig. 6) highlight the differences between precursors and final catalysts after calcination, as well as the differences between materials made with and without water as co-solvent. It was observed that the material formed without water present (Fig. 6a) had particles of a quasi-spherical morphology, with sizes ranging from 50 to 150 nm that tended to aggregate into clusters. In the presence of water (Fig. 6b), larger spherical particles ranging from 350 nm to >1 μm were observed. Upon higher magnification, these larger spherical particles were found to comprise aggregates of smaller (∼20–30 nm) sized particles.
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Fig. 6 SEM images of: (a) 0 vol% H2O/EtOH precursor, (b) 10 vol% H2O/EtOH precursor and (c) 10 vol% H2O/EtOH calcined catalyst. |
The observable change in morphology with the addition of water indicates a change in the precipitation mechanism. The small quasi-spherical morphology formed in the pure ethanol system is consistent with materials produced in a surface tension free environment. The lack of surface tension has been reported in SAS precipitations in which the system is above the mixed critical point, with the solvent and the CO2 anti-solvent being completely miscible.34 The addition of water to the system reduces the miscibility of solvent and anti-solvent which results in the presence of surface tension between the solution droplet and the CO2. Consequently, a conventional diffusion based mechanism would predominate, with CO2 diffusing into the droplet and resulting in the formation of the observed agglomerates. The morphology of the precursors did not significantly alter on calcination with the only change observed being a partial breakdown of the spherical agglomerates. Fig. 7 shows TEM images of calcined catalysts precipitated using 10 vol% H2O in ethanol, along with that of a sample formed using 100% ethanol. As observed previously, particles formed without water as co-solvent are quasi-spherical and are approximately 100 nm in size. Particles formed with the addition of water are small fibres with dimensions of 30 by <5 nm, and these aggregate to form the larger spherical particles seen in the SEM images.
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Fig. 7 TEM images of calcined catalysts prepared with (a) 0 vol% H2O/ethanol (b–d) 10 vol% H2O/ethanol. |
High resolution TEM of the catalyst samples (Fig. 8), indicate that the calcined material from the 10 vol% H2O in ethanol precipitation were predominantly amorphous with small areas of crystalline material. STEM analysis indicated that the samples formed with 10 vol% H2O in ethanol comprise predominantly homogeneous and intimately mixed copper/manganese phases. A small degree of phase separation was observed (Fig. 9), with greater degrees of separation being observed in the less active catalysts. This indicates that a diffusion based mechanism proceeds with the addition of water, which results in a more phase separated catalyst precursor and subsequent catalyst. Greater volumes of water in the system led to further reductions in CO2-solvent miscibility and therefore, greater phase separation. Therefore, the addition of water co-solvent in the SAS precipitation resulted in an alteration of the composition of both the precursor and the final catalyst. The addition of water resulted in the retention of particle surface area upon calcination due to the formation of carbonate precursors as opposed to the acetate materials obtained with pure ethanol.
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Fig. 8 HRTEM images of the calcined catalysts prepared with 10 vol% H2O/EtOH showing (a) amorphous and (b) small crystallites in amorphous material. |
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Fig. 9 STEM X-ray energy-dispersive spectrometry (EDS) high resolution mapping of (a) 10 vol% H2O/EtOH CuMnOx precursor and (b) 10 vol% H2O/EtOH CuMnOx calcined catalyst showing phase separation. |
This journal is © The Royal Society of Chemistry 2011 |