Arindom
Saha‡
and
Darrell P.
Eyman
*
Department of Chemistry, University of Iowa, Iowa City, IA 52242-1294, USA. E-mail: darrell-eyman@uiowa.edu
First published on 19th April 2012
Steam reforming of hydrocarbons is one of the methods widely used to produce clean hydrogen for fuel cells. In previous studies in this group, a nickel-containing, V2Ox-ZrO2 co-grafted catalyst on γ-Al2O3, prepared from a solution of OV(OiPr)3 and Zr(OnBu)4 (precursor feed of 1 V nm−2
:
4 Zr nm−2) was found to generate significant turnover rates in the production of hydrogen from steam-reforming of alkanes and light alcohols. To investigate the influence of change in vanadium precursor ligand and other reaction conditions including time, temperature, concentration of co-grafting solution etc. on the surface optimization of these supported mixed oxides a compositional range of V2Ox-ZrO2 samples were synthesized using co-grafting solutions of OV(OEt)3 and Zr(OnBu)4. Temperature Programmed reduction (TPR) and X-ray Photoelectron Spectroscopy (XPS) studies furnished further insight into the red-ox behavior of the catalysts under steam-reforming conditions. It was observed that a V5+/V4+ red-ox couple was involved in this catalytic process. Zirconium was observed to be present only in the +4 oxidation state irrespective of temperature and other reduction conditions. Based on this premise it was concluded that the refractory nature of the Zr4+ species on the surface was responsible in preventing the vanadyl groups from sintering at temperatures above 600 °C, thereby stabilizing the red-ox active species during the steam-reforming process.
The technique of co-grafting refers to simultaneously grafting two or more metal derivatives on a surface. This is achieved by reacting, a solution containing two different metal oxide precursors with the surface functional groups of the support which are usually hydroxyls. Basset et al., were one of the foremost researchers in the area of co-grafted bimetallic catalysis.2–6 They used surface organometallic chemistry for the preparation of novel selective bimetallic catalysts by reacting tetra-n-butyl tin with silica supported Rh, Ru and Ni. These bimetallic catalysts were observed to be highly active and selective in hydrogenolysis reactions of various alkanes and esters. Bimetallic Sn-Pt complexes synthesized in the supercages of NaY zeolite using co-grafting techniques also showed excellent catalytic properties in selective hydrogenation of furfural to furfuryl alcohol.7 Silica-supported Pd-Ni bimetallic catalysts were also prepared using surface organometallic chemistry by reacting Ni(C5H5)2 with a reduced Pd/SiO2 support. A comparison between the X-ray methods and a careful analysis of the particle composition by energy–dispersive X-ray mapping in the scanning transmission electron microscope (EDX-STEM) showed that through this process nearly homogeneous alloys could be synthesized.8 Bimetallic Pt-Sn catalysts prepared through grafting processes also provided better activity and selectivity in dehydrogenation of isobutane to isobutene than when prepared through successive impregnation.9
To understand how change in vanadium ligand precursor and other controlled factors like time, concentration of grafting solution, temperature etc. affect the optimization of the support surface, a range of V2Ox-ZrO2 samples were synthesized on γ-Al2O3 using co-grafting solutions of OV(OEt)3 and Zr(OnBu)4 and studied. TPR and XPS studies furnished further insight into the red-ox behavior of the catalysts under steam-reforming conditions.
The γ-Al2O3 pellets used for the grafting studies were spherical in shape (∼1 mm diameter) and were generously donated by Saint-Gobain Norpro Corporation. The samples were dried at 110 °C for at least 24 h before use. A Micromeritics ASAP 2000 was used to measure surface area by adsorption and desorption of N2 at liquid nitrogen temperature. The surface area was determined from the acquired data using the BET (Brunaeur-Emmett-Teller) equation. Thermogravimetric Analysis (TGA) was used to determine the surface -OH density of the γ-Al2O3 pellets.
The physical properties of the γ-Al2O3 used for these studies were as follows: surface area ∼ 219 m2 g−1, pore volume ∼ 0.59 cm3 g−1 and average pore diameter of 6.7 nm. From TGA the surface -OH density was observed to be ∼ 13.02 ± 0.31 OH nm−2.
:
4 Zr nm−2 was used for sample synthesis. The co-grafted V2Ox-ZrO2 samples on γ-Al2O3 were synthesized by taking appropriate amounts of the metal precursors in THF in a two-necked round bottom flask and attaching it to a Schlenk-line under an inert nitrogen atmosphere. After the initial synthesis the samples were calcined at 500 °C for 24 h to get the final co-grafted V2Ox-ZrO2 catalysts (See ESI† for detailed synthetic procedures). Four series of co-grafted V2Ox-ZrO2 mixed oxides t-V2Ox-ZrO2/Al2O3, f-V2Ox(fixed)-ZrO2/Al2O3, f-V2Ox-ZrO2(fixed)/Al2O3 and c-T-V2Ox-ZrO2/Al2O3 were synthesized using OV(OEt)3 and Zr(OnBu)4 as the precursors. In these sample groups “t” stands for time of co-grafting, “f” for metal alkoxide feed in co-grafting solution, “c” stands for concentration of co-grafting solution and “T” for temperature of co-grafting. “x” is used to denote the number of oxygen groups in the final grafted vanadium species. An effort has been made to maintain a consistent nomenclature for these co-grafted samples. For example t(24h)-V2Ox-ZrO2/Al2O3, indicates a time sample synthesized by co-grafting for 24 h.
:
20 v/v) and transferred carefully to a 25 mL volumetric flask. The volume was made up with deionized water. Standard curves were generated each time with known concentrations of commercially available vanadium and zirconium ICP standards.
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| Fig. 1 Schematic diagram of the TPR apparatus used for reduction studies. | ||
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Fig. 2 Change in loading as a function of time for (a) vanadium, (b) zirconium, and (c) total metal using 1 V nm−2 : 4 Zr nm−2 precursor ratio in the co-grafting solution. | ||
An interesting aspect observed in this study was that the vanadium precursor grafted at a faster rate than the corresponding zirconium precursor. As mentioned earlier, a factor of four times greater precursor feed was used for zirconium compared to vanadium. Surprisingly, very low zirconium loading was observed on the catalyst surface and in most cases it was even lower than the corresponding vanadium loading. This observation is very important as it provides insight into the difference in the rate of grafting of the two metal oxide precursors.
With OV(OEt)3 precursor, vanadium loading remained consistent at ∼ 0.97 V nm−2 for all feeds. The corresponding zirconium loading kept increasing with increase in total metal feed until a loading of 0.45 ± 0.02 Zr nm−2 was observed using a feed of 5.0 M nm−2. With higher feeds of the co-grafting solution, it was observed that the zirconium loading remained constant at this value. The total metal loading with this precursor increased with increase in feed until a loading of 1.42 ± 0.05 M nm−2 was observed using a feed of 5.0 M nm−2 (Fig. 3). This loading was very similar in value to that obtained at 36 h from the time study with this precursor, 1.39 ± 0.01 M nm−2. As this loading at 36 h was considered to be the one at equilibrium, we can conclude that in this study equilibrium was reached using a feed of 5.0 M nm−2. In this study too, similar low loadings of zirconium were observed compared to those of vanadium even on using a molar feed ratio of 1 V nm−2
:
4 Zr nm−2. This again confirmed the observation from the time studies that the vanadium precursor grafted at a faster rate than the corresponding zirconium precursor.
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| Fig. 3 Change in surface loading as a function of precursor feed when vanadium feed is kept constant at 1.0 V nm−2 and zirconium feed is varied for (a) vanadium (b) zirconium and (c) total metal. | ||
In this study it was observed that the vanadium loading increased consistently with increase in precursor feed and reached a maximum loading of 3.16 ± 0.10 V nm−2 at a total metal feed of 6.0 M nm−2 (Fig. 4). In the same study, the zirconium loading remained more or less constant (0.48 ± 0.01 to 0.58 ± 0.01 Zr nm−2) with increase in total metal feed. The highest total metal loading (sum of individual V and Zr loading) of 3.50 ± 0.10 M nm−2 was observed at a total metal feed of 6.0 M nm−2.
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| Fig. 4 Change in loading as a function of precursor feed when zirconium feed is kept constant at 1.0 V nm−2 and vanadium feed is varied for (a) vanadium (b) zirconium and (c) total metal. | ||
This experiment again indicates that vanadium grafting occurs faster than zirconium and the high vanadium loadings were consistently observed to corroborate this.
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| Fig. 5 Change in loadings of vanadium, zirconium and total metal as a function of concentration of the co-grafting solution at: (a) 25 °C, (b) 40 °C, (c) 60 °C, and (d) 80 °C. | ||
Comparing zirconium loadings at four different temperatures, it was observed that the highest loading achieved decreased with increase in temperature. For instance, at 25 °C the highest loading of zirconium obtained was 1.90 ± 0.11 Zr nm−2 whereas at 80 °C it was 1.00 ± 0.12 Zr nm−2. At 25 °C and at 40 °C, high vanadium loadings of 0.95 ± 0.02 V nm−2 and 0.96 ± 0.02 V nm−2 were observed, respectively, even at low concentrations of 0.1 M of the co-grafting solution. Further increase of concentrations up to 0.4 M did not result in significant changes in the loadings. At 60 °C and 80 °C the loadings showed gradual increase with increase in concentration of the co-grafting solution and highest loading values of 0.90 ± 0.03 V nm−2 and 0.59 ± 0.04 V nm−2, were observed, respectively. The highest total metal loadings (sum of individual V and Zr loadings) observed with these precursors at 25 °C and 80 °C were 2.90 ± 0.12 M nm−2 and 1.89 ± 0.12 M nm−2, respectively.
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| Fig. 6 Powder XRD spectra of bare γ-Al2O3 sample and a grafted time sample, t(12h)-V2Ox-ZrO2/Al2O3. | ||
All the prepared V2Ox-ZrO2 catalysts appeared yellowish white following calcination. The intensity of color is a very helpful optical indicator of the loading and agrees qualitatively with the data obtained through elemental analysis.
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| Fig. 7 XPS Spectra of the three calcined samples (a) V2p spectra of the time sample, (b) V2p spectra of the precursor feed sample, (c) V2p spectra of conc. sample, (d) Zr 3d spectra of the time sample, (e) Zr 3d spectra of the precursor feed sample, and (f) Zr-3d spectra of the concentration sample. | ||
In the studies performed at different temperatures it was observed that the total metal loadings decreased with increase in temperature. It is possible that this decrease was an effect of some degrafting process taking place on the surface. This decrease of loading with increase in temperature indicates that the co-grafting process has a negative ΔH value and thus is exothermic in nature. These results are consistent with previous studies of zirconium grafting, in which it was reported that zirconium loading decreased with increasing temperature indicating the exothermic nature of the grafting process.11
XRD studies showed that even after co-grafting, the support surface appeared to be amorphous in nature, thereby confirming the success of the co-grafting process. Combined TPR and XPS studies helped to identify the vanadium and zirconium oxidation state(s) in different samples. It was observed that in the calcined co-grafted samples, V5+ was the only observed vanadium species. This observation was anticipated as the calcination was carried out under aerobic conditions. On performing reduction studies, using 10% H2/He mixtures on the same samples at various temperatures, a mixture of V5+ and V4+ species were observed for vanadium. It was also observed that with increase in reduction temperature the percentage composition of the reduced species (V4+) increased while that of V5+ decreased. Irrespective of the fact that the sample was calcined or reduced, only one oxidation species of zirconium, Zr4+, was observed. The observations in this research suggest that zirconium oxides are essential for the successful functioning of these catalysts. Vanadium oxide “single sites” are known to decompose above temperatures of 600 °C and the supported zirconium oxides in all probability play a very significant role in holding the vanadium “single-sites” intact at the typically higher temperatures of catalytic operation resulting in the longevity of the catalyst.
| Co-grafting | A catalyst loading technique, which typically utilizes a direct chemical reaction between two or more metal precursors and the surface hydroxyl groups of the support material. |
| Feed | The theoretical maximum loading possible with the available quantity of grafting precursor. |
| Loading | The actual amount of metal precursor deposited on the support surface. |
Footnotes |
| † Electronic supplementary information (ESI) available: Additional discussion sections, surface density plots and XPS spectra of TPR studies. See DOI: 10.1039/c2cy20039b |
| ‡ Present address: 6E Fenske Laboratories, Department of Chemical Engineering, Pennsylvania State University, State College, PA 16801, USA. |
| This journal is © The Royal Society of Chemistry 2012 |