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NGUYEN VU LE
(Material Science)
September 2021
Abstract
Three-way catalysts have played a pivotal role in minimizing the air
pollution from automobiles. However, a non-negligible amount of harmful emission
is still accounted for the cold-start engine. Furthermore, three-way catalysts require
nanoparticles of expensive and unabundant noble metals, especially rhodium, to
realize required performance. Hence, this work applied a series of high-throughput
experiments to construct a library of bimetallic three-way catalysts that allow
exploring information useful in finding more powerful and economic alternatives
for conventional three-way catalysts. In this library, 19 bimetallic combinations
were successfully synthesized, and 60 catalysts were prepared from them by high-
throughput synthetic setups. Later, the catalysts were subjected to in-house high-
throughput fixed bed reactors to evaluate their catalytic activities. With the aid of
statistical analysis, Rh’s alloys on any support materials, and Pd’s alloys when
loaded on CeO2-ZrO2 were found to be superior. Furthermore, Cu’s alloys on CeO2-
ZrO2 demonstrated high selectivity towards CO oxidation. This thesis elucidates the
relationship among constituent elements and supports in designing three-way
catalysts as well as suggests several less costly and/or non-rhodium alternatives.
Acknowledgements
I would like to extend my deepest gratefulness to my supervisor – Prof. Dr.
Toshiaki Taniike – for his enthusiastic instruction throughout this research.
1
Contents
List of Tables .............................................................................................................7
1.5 Objectives........................................................................................................18
2.1 Materials..........................................................................................................19
2
3.2.2 TiO2 based catalysts..............................................................................48
Appendix ..................................................................................................................63
References ................................................................................................................65
3
List of Figures
Figure 1: Schematic representations of basic mixing patterns: (a) core-shell, (b)
sub-cluster segregated and (c) alloy. Reproduced from Ref. 13. .......................................9
Figure 2: Advantages of the polyol process. Reproduced from Ref. 21. .................... 11
Figure 3: World gross demand by applications of rhodium between 2009 and 2013.
Reproduced from Ref. 49. ............................................................................................................ 14
Figure 4: World gross demand by applications of palladium between 2009 and
2013. Reproduced from Ref. 49. ............................................................................................... 14
Figure 5: World gross demand by application of platinum between 2009 and 2013.
Reproduced from Ref. 49. ........................................................................................................... 15
Figure 6: Parallel reactor setup for the synthesis of nanoparticles. .............................. 20
Figure 7: Synthetic scheme of bimetallic nanoparticles. .................................................. 20
Figure 8: (A) Design and (B) appearance of a XRD sample holder. ........................... 22
Figure 9: Concentration vs XRF intensity graphs for palladium, platinum, rhodium,
ruthenium, and iridium. ................................................................................................................. 24
Figure 10: Catalyst preparation scheme. ................................................................................ 25
Figure 11: Schematic representation of a high-throughput screening system.
Reproduced from Ref. 74. ............................................................................................................ 28
Figure 12: Copper product: (A) after synthesis, (B) after synthesis couple days. .. 30
Figure 13: TEM image library of bimetallic NPs. .............................................................. 33
Figure 14: Aqueous precursors solution of AuPt, AuPd, PdPt, PdRh, PtRh and
AuRh containing PVP. ................................................................................................................... 34
Figure 15: Library of particle size distribution. ................................................................... 35
Figure 16: TEM image of PdAg. .............................................................................................. 36
Figure 17: XRD library of bimetallic NPs. ........................................................................... 39
Figure 18: XRD pattern of PdAg with the powder diffraction file, Ag PDF 00-004-
0783. ..................................................................................................................................................... 40
Figure 19: XRD pattern of RuCu with the powder diffraction file, Cu PDF 00-004-
0836. ..................................................................................................................................................... 40
4
Figure 20: XRD pattern of RhCo with the powder diffraction file, Co PDF 00-015-
0806. ..................................................................................................................................................... 41
Figure 21: XRD pattern of RuCo with the powder diffraction file, Co PDF 01-071-
4239. ..................................................................................................................................................... 41
Figure 22: (A) Appearance of aqueous precursors solution containing PVP (B)
Appearance after the synthesis for RhRu, RhCu, RhCo, RuCu, RuCo and CuCo. .. 42
Figure 23: Appearance after the synthesis, appearance after adding NaOH and
appearance the synthesis with NaOH (pH = 9) for Fe, Cu and Co (left to right). .... 44
Figure 24: Temperature of 50 % C3H6 conversion for Al2O3-based (filled)
bimetallic catalysts and (stripe marked) monometallic catalysts.................................... 46
Figure 25: Temperature of 50 % NO conversion for Al2O3-based (filled) bimetallic
catalysts and (stripe marked) monometallic catalysts. ....................................................... 46
Figure 26: Temperature of 50 % CO conversion for Al2O3-based (filled) bimetallic
catalysts and (stripe marked) monometallic catalysts. ....................................................... 47
Figure 27: Temperature of 50 % C3H6 conversion for TiO2-based (filled)
bimetallic catalysts and (stripe marked) monometallic catalysts.................................... 48
Figure 28: Temperature of 50 % NO conversion for TiO2-based (filled) bimetallic
catalysts and (stripe marked) monometallic catalysts. ....................................................... 49
Figure 29: Temperature of 50 % CO conversion for TiO 2-based (filled) bimetallic
catalysts and (stripe marked) monometallic catalysts. ....................................................... 49
Figure 30: Temperature of 50 % C3H6 conversion for CeO2-ZrO2-based (filled)
bimetallic catalysts and (stripe marked) monometallic catalysts.................................... 50
Figure 31: Temperature of 50 % NO conversion for CeO2-ZrO2-based (filled)
bimetallic catalysts and (stripe marked) monometallic catalysts.................................... 50
Figure 32: Temperature of 50 % CO conversion for CeO2-ZrO2-based (filled)
bimetallic catalysts and (stripe marked) monometallic catalysts.................................... 51
Figure 33: Catalytic activity comparison of bimetallic and monometallic
nanoparticles loaded on different supports in C3H6 oxidation by T50: CeO2-ZrO2
(orange), Al2O3 (gray) and TiO2 (purple). .............................................................................. 52
5
Figure 34: Catalytic activity comparison of bimetallic and monometallic
nanoparticles loaded on different supports in NO reduction by T 50: CeO2-ZrO2
(orange), Al2O3 (gray) and TiO2 (purple). .............................................................................. 53
Figure 35: Catalytic activity comparison of bimetallic and monometallic
nanoparticles loaded on different supports in CO oxidation by T50: CeO2-ZrO2
(orange), Al2O3 (gray) and TiO2 (purple). .............................................................................. 53
Figure 36: T50 comparison among C3H6 (red), NO (blue) and CO (green)
conversion for CeO2-ZrO2 based catalysts. Catalysts with selectivity toward CO
oxidation are caro marked. ........................................................................................................... 54
Figure 37: T50 comparison among C3H6 (red), NO (blue) and CO (green)
conversion for Al2O3-based catalysts. ...................................................................................... 55
Figure 38: T50 comparison among C3H6 (red), NO (blue) and CO (green)
conversion of TiO2-based catalysts. .......................................................................................... 55
Figure 39: Dendogram of agglomerative hierarchical clustering of 58 catalysts.
AuPt/Al2O3 and AuPt/CeO2-ZrO2 were omitted due to the lack of (a part of) T50
values. .................................................................................................................................................. 57
Figure 40: Symmetric plot in multiple correspondence analysis for 60 catalysts. .. 58
Figure A1: TEM images of CuRh, RhCo, RuCo and RuCu. .......................................... 63
Figure A2: Apperance after the synthesis for PdPt, PdRh, PtRh, AuRh, AuPt and
AuPd. ................................................................................................................................................... 64
Figure A3: Apperance after the synthesis for Au, Rh, Ru, Cu, Co and Fe. ............... 64
6
List of Tables
Table 1: Statistical parameters of XRF analysis of palladium, platinum, rhodium,
ruthenium, and iridium. ................................................................................................................. 24
Table 2: Feed gas composition for three-way catalyst evaluation. ............................... 26
Table 3: Target elements and their precursors ..................................................................... 29
Table 4 Summary of successfully synthesized nanoparticles and their
characteristics .................................................................................................................................... 32
Table 5: T50 values for all the catalysts ................................................................................... 47
7
Chapter 1
Introduction
Ancient human has already known how to enhance the physical properties of
metallic material by mixing two or more elements together. One of the very first
metallic combinations humans ever made is bronze, which is an alloy of copper and
tin. The mixed material shows better stiffness than that of copper alone and it was
widely used during the Bronze Age. Comprising metallic elements together not only
strengthens the physical properties of the constituents but also improves other
properties such as chemical properties. As an example, to prevent rusting of steel
due to iron oxidation, a small amount of chromium is blended, and the hybrid
material is nowadays well-known as stainless steel. Likewise, till these modern
days, this strategy is still being applied and extended to nano-sized metals in order
to enhance certain desired properties.
8
Subcluster segregated bimetallic NPs contain two sub-clusters of the two
constituents sharing an interface or only having a small number of bonding between
elements A and B (Figure 1-b).
A mixed bimetallic NP, commonly known as a bimetallic nanoalloy, is a
solid mixture of two metallic elements (Figure 1-c). The mixture can be randomly
organized or well ordered. A bimetallic nanoalloy can be synthesized by many
methods, for example, thermal decomposition,4–7 electrochemical synthesis,8,9 ion-
implantation,10 chemical co-reduction,11,12 and so on. In this research, this category
of bimetallic NP is mainly focused.
9
1.2 Bimetallic alloy synthesis – the polyol process
10
synthetic ways employ a low-boiling point solvent in order to dissolve or dilute a
reducing agent like citrate ion, NaBH4, and N2H4, leading to poorly crystallized
products. Hence, those methods require further thermal treatments, which are
energy consuming to collect well-crystallized particle. Unlike the examples
mentioned above, the polyol process has been proven as a simple and versatile
solution for the problems of the other methods, thus prevailing mixed bimetallic
nanoparticles synthesis on industrial scale.
The term “polyol process” was firstly introduced in the late 80’s by Fietvet,
Lagier, and Figlazr. They discovered an ability of polyol compounds, which
distinctively possess multiple hydroxyl groups, in metal ion reduction to the
metallic state of noble metals, copper, and some other more electropositive
11
elements such as cobalt and nickel.22–27 Similar to any variants of the co-reduction
method, a particular polyol process consists of metal precursors, a capping agent
(commonly polyvinylpyrrolidone, hereafter abbreviated as PVP), and a polyol,
which works as both the solvent and reductant. These water-like solvents with their
unique characteristics offer numerous benefits as well summarized in Figure 2.
These are productions of well-crystallized nanoparticles due to high temperature
conditions facilitated by their boiling points, protection from oxidation by the
reducing medium, coalescence minimization due to the coordination of polyol
species with metal precursors and metal particles, and good morphological control
because of the diffusion-controlled regime created by their high viscosity.28 This
synthetic strategy was firstly deployed in large scale to generate Co and Ni NPs as
an ingredient of cemented carbides, in the early 90’s by Eurotungstene
Company.29,30 Thereafter, the use of the polyol process is widely expanded in the
industry. For example, due to the absence of contamination when using the polyol
process, Cu and Ag NPs are synthesized for polyurethane production by
Construction Research and Technology GmbH.31 In 2007, the process was also
exploited for the development of polymer-stabilized Ag NPs, which is introduced in
water-based silver ink contained in inkjet-printer products of SEMCO.32 Nowadays,
the polyol process is expanding to fabricate nano-metals in a vast spectrum of
compositions, structures, and application functions. The products from the polyol
process are surely promising candidates for tremendous applications such as in
sensing, fuel-cell, and catalysis.
12
1.3 Bimetallic alloy and their catalytic activity
13
12
Hundreds oz
10
8 Other
Glass
6
Electrical
Chemical
4
Autocatalyst
0
2009 2010 2011 2012 2013
Figure 3: World gross demand by applications of rhodium between 2009 and 2013.
Reproduced from Ref. 49.
11
Thousands oz
9
Other
7 Jewellery
Investment
5 Electrical
Dental
3 Chemical
Autocatalyst
1
14
9
Thousands oz
8
Other
7
Petroleum
6 Medical & Biomedical
5 Jewellery
4 Investment
Glass
3
Electrical
2
Chemical
1 Autocatalyst
0
2009 2010 2011 2012 2013
Figure 5: World gross demand by application of platinum between 2009 and 2013.
Reproduced from Ref. 49.
15
Reduction of NOx to N2:
𝐶 + 2𝑁𝑂 → 𝐶𝑂 + 2𝑁𝑂
2𝐻 + 2𝑁𝑂 → 2𝐻 𝑂 + 𝑁
𝐶 + 𝑂 → 𝐶𝑂
2𝐶𝑂 + 𝑂 → 2𝐶𝑂
2𝐶 𝐻 + 9𝑂 → 6𝐶𝑂 + 6𝐻 𝑂
Despite the best performance of these elements, the production cost of TWC
still remains high. Especially Rh which is the most essential component for NO x
reduction is one of the least abundant elements in the Earth’s crust. 52,53
Furthermore, low-temperature exhaust, or light-off exhaust contributes a notable
portion to the total emission of automobiles.54 To overcome these challenges, many
strategies have been proposed including modifying support materials,55,56 doping
rare earth57,58 and alkaline metals59,60 promoters, changing ratios of PGM
loading,61,62 and applying bimetallic alloy as catalytic particles.63 In this research,
substituting conventional PGM with bimetallic alloys in TWC is the main focus.
16
designed to serve the purpose. Depending on the nature of the parent elements and
the atomic ratios, the bimetallic alloys seem to exhibit better catalytic performances.
For instance, Pd60Rh40 has been reported to show better activity and higher stability
as compared to Pd and Rh standalone particles.70 Another example is the pseudo-Rh
nanoparticles, synthesized from two naturally immiscible elements Pd and Ru by
Kusada et al. and later by Sato et al.3,72 Their Pd50Ru50 alloy was demonstrated to
have a similar electronic state to that of Rh nanoparticles, which are commonly used
for NOx reduction.
17
1.5 Objectives
18
Chapter 2
Materials and Methods
2.1 Materials
All the samples were synthesized using an in-house parallel reactor setup,
which has the maximum capacity of carrying 6 parallel reactions (Figure 6). In a
particular synthesis (Figure 7), 88 mg of polyvinylpyrrolidone (PVP) as a capping
agent was dissolved in 20 ml of triethylene glycol (TEG) as a solvent in a 40 ml
glass vessel. In the cases of Cu-based bimetallic alloys, pH was controlled by
adding an adequate amount of a 30 % NaOH aqueous solution to adjust the pH of
the TEG-PVP solution to 9. The solution was vigorously stirred under N 2, followed
by heating to 190 oC. Subsequently, 2.0 ml of an aqueous solution dissolving metal
19
precursors (0.050 mmol per metal element) and 22 mg of PVP were swiftly injected
into the TEG-PVP mixture. After a dark color indicating the formation of NPs
appeared, the reaction mixture was kept for 30 min, and then naturally cooled to
room temperature. Synthesized nanoparticles were washed with an acetone/hexane
mixture (3/1 v/v), and recovered by centrifugation, which was repeated three times.
Finally, the product was re-dispersed and stored in methanol before use.
20
2.3 TEM analysis
21
A B
1.2 cm
1.7 cm
4.4 cm
1.6 cm
1.3 cm
3.0 cm
2 mm
1.75
mm
22
2.6 Non-destructive quantitative analysis with XRF
23
Table 1: Statistical parameters of XRF analysis of palladium, platinum, rhodium,
ruthenium, and iridium.
LoD* LoQ**
Element Analytical Equation R2
(mg/kg) (mg/kg)
450
400
350
300
Intensity (cps)
Pd
250
Pt
200
Rh
150
Ru
100
Ir
50
0
0 20 40 60 80 100 120
Concentration (mg/kg)
24
2.7 Catalyst preparation
25
2.8 HTP catalytic evaluation
CO 26000
C3H6 4000
NO 6000
O2 28000
He (83.6%) 836000
26
increment, the temperature is kept for half an hour in order to evaluate catalytic
activity at that particular temperature before it continues to rise.
After the reaction, the effluent gas continues to enter the autosampler that is
connected to the QMS. Auto sampling is performed by a programmed action
sequence of pneumatically actuated diaphragm valves (MEGA ONE, Fujikin). In a
typical sampling, a sampling time is 1.2 seconds followed by vacuum evacuation
for 10 seconds. For one lap of measurement, the time is 224 seconds in total. Any
leftover effluent gas is evacuated to the exhaust system. During the measurement,
the sampled gas is continuously transferred from the autosampler to the QMS, and
signals of pre-designated mass fractions are recorded.
In a typical test, before performing the three-ways reaction, loaded catalysts
were pre-activated by calcination at 550 oC for one hour in the hollow furnace. After
that, the model exhaust gas is prepared by blending all components with the gas
mixer, following the gas composition listed in Table 2, and then the TWC reaction
was started. The light-off performance of catalysts was evaluated as the temperature
of 50 % conversion (T50) for C3H6, CO, and NO, respectively.
27
Figure 11: Schematic representation of a high-throughput screening system.
Reproduced from Ref. 74.
28
Chapter 3
Results and Discussion
25 26 27 28
Fe Co Ni Cu
(FeCl3) (CoCl2) (NiCl2) (CuCl2)
44 45 46 47
Ru Rh Pd Ag
(RuCl3) (RhCl3) (K2PdCl4) (AgNO3)
77 78 79
Ir Pt Au
(IrCl3) (H2PtCl6) (HAuCl3)
29
3.1.1 TEM images
Figure 12: Copper product: (A) after synthesis, (B) after synthesis couple days.
30
For bimetallic synthesizes, AuRh, AuPd, and AuPt had average particle sizes
of 8.5 ± 2.5 nm, 9.6 ± 1.7, and 11.6 ± 2.1 respectively, which were 3 to 10 times
higher than those of the other bimetallic nanoparticles in the library (Table 4). The
results indicate that weak coordination between Au precursor and PVP pays the
major cause for the large size distribution. Furthermore, good dispersions were
found in nearly all cases except for AuPt. Unlike the synthesis of the other
bimetallic alloys, the addition of a small amount (22 mg) of PVP into the precursor
solution was omitted for AuPt and Au to prevent clogging during hot-injection (the
presence of PVP in Au precursors caused precipitation which can be seen in Figure
14). Severe precipitation of PVP was also observed in the synthesis of Au
nanoparticles. The precipitation of PVP suggests weak coordination between the
capping agent and Au precursor causing the lack of growth control as well as the
poor dispersion. Later in the catalyst evaluation section, this poor dispersion
appeared to influence greatly to the catalytic activity of AuPt regardless of the
support on which it was loaded.
Large deviations in particle size distribution were also found in Cu’s alloys
(Figure 15) in which Cu is the lowest reduction potential element among the used
elements. Non-uniform growth behavior of these alloys can be explained by a large
difference in the reduction rate caused by the reduction potential gaps between two
elements. Indeed, the Pt, Pd, Rh, Ru, and Ir precursors possess similar reduction
potentials76 and in this library, the bimetallic combinations among them led to
nicely uniform particle size distributions (Figure 15). Unlike any other bimetallic
NPs, PdAg grew into rod-like shape particles (Figure 16), plausibly due to the
formation of a stable AgCl precipitate during the synthesis. AgCl traps and slowly
releases Ag+ into the TEG medium, causing the slow reduction of silver. Another
explanation could be that AgCl suppresses the reduction of Ag+ to Ag by
modulating its reduction potential.76 In any case, the inhibition of Ag+ reduction can
be clearly seen later in the SEM-EDS results.
31
Table 4 Summary of successfully synthesized nanoparticles and their
characteristics.
Average Average
Crystal
Name (AB) Element A Element B element ratio particle size
structure
(A : B, at%) (nm)
Au Au - - Fcc ≥100
Pt Pt - - Fcc 3.6 ± 0.6
Pd Pd - - Fcc 3.2 ± 0.9
Rh Rh - - Fcc 2.5 ± 0.4
Ru Ru - - Hcp 0.8 ± 0.1
Ir Ir - - Fcc ≤ 0.7
AuRh Au Rh 46 : 54 Fcc 8.5 ± 2.5
AuPd Au Pd 46 : 54 Fcc 9.6 ± 1.7
AuPt Au Pt 50 : 50 Fcc 11.6 ± 2.1
PtRh Pt Rh 47 : 53 Fcc 2.8 ± 0.4
PdPt Pd Pt 55 : 45 Fcc 3.2 ± 0.4
PdRh Pd Rh 51 : 49 Fcc 2.7 ± 0.6
RhRu Rh Ru 51 : 49 Fcc 1.7 ± 0.3
PdRu Pd Ru 57 : 43 Fcc 2.6 ± 1.5
PtRu Pt Ru 47 : 53 Fcc 2.5 ± 0.6
RhIr Rh Ir 51 : 49 Fcc 1.7 ± 0.2
PdIr Pd Ir 57 : 43 Fcc 2.5 ± 0.5
PtIr Pt Ir 47 : 53 Fcc 2.1 ± 0.4
RhCu* Rh Cu 73 : 27 Fcc 1.7 ± 0.7
PdCu* Pd Cu 46 : 54 Fcc 2.6 ± 1.3
PtCu* Pt Cu 57 : 43 Fcc 2.0 ± 0.5
CuRh Cu Rh 6 : 94 Fcc ~ 5.0
RhCo Rh Co 78 : 22 Fcc 1.4 ± 0.2
RuCo Ru Co 80 : 20 Hcp 0.7 ± 0.2
RuCu Ru Cu 85 : 15 Fcc 0.9 ± 0.2
PdAg Pd Ag 70 : 30 Fcc n.d.
*pH-controlled reduction with NaOH, in which pH = 9
32
Figure 13: TEM image library of bimetallic NPs.
33
Figure 14: Aqueous precursors solution of AuPt, AuPd, PdPt, PdRh, PtRh and
AuRh containing PVP.
34
Figure 15: Library of particle size distribution.
35
Figure 16: TEM image of PdAg.
36
3.1.2 XRD results
𝑎 ( )
= 𝑥𝑎 + (1 − 𝑥)𝑎
and 𝐵 with the molar fraction 𝑥 of 𝐴, respectively. His empirical finding dictates
that the XRD peak position of a solid solution lies between the positions of its two
components. In the case of bimetallic alloy, the XRD peak of the nano-alloy is
located in between the XRD peaks of the two monometallic counterparts.
Successful alloy formation was confirmed for all of the combinations among
Au, Pt, Pd, Rh, Ir, and Cu, (Figure 17) as well as for PdAg, RuCu, RhCo, and RuCo
(Figure 19-21 respectively). From the XRD patterns, the face-centered cubic (fcc) is
the dominant crystal structure in most of the cases except Ru monometallic and
RuCo NPs that exhibited the hexagonal close-packed (hcp) crystal lattice. In the
cases of bimetallic alloys made of either Pt, Pd, and Ir, more careful consideration
was required to judge their alloying since the references of those elements have
very similar XRD peak positions and so do their alloys. The successful alloying was
judged from the fact that the products were composed of a single crystalline phase
and that the chemical composition was uniform in SEM-EDS. These would not be
observed when a core-shell structure or a segregated structure was formed.
37
Indeed, in SEM-EDS that will be discussed in the later section, RhCu did not
achieve the desired average element ratio of 50:50 even with the use of pH control.
Nonetheless, RhCu possessed a board XRD peak, which was suspected to arise
from a mixture of nanoparticles with different chemical compositions, probably
including 50:50 ones.
The successful alloy formations were also confirmed for RhCo, RuCo and
RuCu. These bimetallic combinations possessed very small average particle sizes as
can be seen in TEM images (Figure A1). Hence, the XRD signals of these
combinations were less intense. However, their alloying could be justified with
SEM-EDS results (discussed later).
38
Rh Pd Pt
Rh Au
Pd
AuRh AuPt
AuPd Au
Au
Au
Intensity (a.u)
Intensity (a.u)
Intensity (a.u)
Au
20 40 60 80 20 40 60 80
20 40 60 80
2θ (degree) 2θ (degree)
2θ (degree)
Rh
PtRh Pt
Pt PdPt
Pd
Intensity (a.u)
Intensity (a.u)
Pt
20 40 60 80 20 40 60 80
2θ (degree) 2θ (degree)
Rh
PdRh
Pd
Intensity (a.u)
Pd
20 40 60 80
2θ (degree)
Rh Pd Pt
RhRu PdRu PtRu
Ru Ru Ru
Ru
Intensity (a.u)
Intensity (a.u)
Intensity (a.u)
20 40 60 80 20 40 60 80 20 40 60 80
2θ (degree) 2θ (degree) 2θ (degree)
Rh Pd Pt
RhIr PdIr PtIr
Ir Ir Ir
Ir
Intensity (a.u)
Intensity (a.u)
Intensity (a.u)
20 40 60 80 20 40 60 80 20 40 60 80
Rh Pd Pt
RhCu PdCu PtCu
Cu (PDF 00-004-0836) Cu (PDF 00-004-0836) Cu (PDF 00-004-0836)
Intensity (a.u)
Intensity (a.u)
Intensity (a.u)
Cu*
20 40 60 80 20 40 60 80
20 40 60 80
2θ (degree) 2θ (degree)
2θ (degree)
39
Pd
PdAg
Ag (PDF 00-004-0783)
Intensity (a.u)
20 40 60 80
2θ (degree)
Figure 18: XRD pattern of PdAg with the powder diffraction file, Ag PDF 00-004-
0783.
Ru
RuCu
Cu (PDF 00-004-0836)
Intensity (a.u)
20 40 60 80
2θ (degree)
Figure 19: XRD pattern of RuCu with the powder diffraction file, Cu PDF 00-004-
0836.
40
Rh
RhCo
Co (PDF 00-015-0806)
Intensity (a.u)
20 40 60 80
2θ (degree)
Figure 20: XRD pattern of RhCo with the powder diffraction file, Co PDF 00-015-
0806.
Ru
RuCo
Co (PDF 01-071-4239)
Intensity (a.u)
20 40 60 80
2θ (degree)
Figure 21: XRD pattern of RuCo with the powder diffraction file, Co PDF 01-071-
4239.
41
3.1.3 SEM-EDS results
Figure 22: (A) Appearance of aqueous precursors solution containing PVP (B)
Appearance after the synthesis for RhRu, RhCu, RhCo, RuCu, RuCo and CuCo.
Besides checking the desired average atomic ratio of 50:50 for each
constituent, the homogeneity of EDS results over the measured nine positions of the
nanoparticles droplet was also exploited as supplemental information to confirm the
formation of alloys. The homogeneity of EDS signals was found for all the
bimetallic combinations, which supports the XRD results indicating the successful
formation of bimetallic alloys. Desired average element ratios were achieved in
most of the cases except PdAg, RhCu, RhCo, RuCo, and RuCu (Table 4). Recall
from Section 3.1.1, TEM images, due to the formation of AgCl, the reduction of
Ag+ reduction was inhibited causing the rod-like shape particles as well as the
unwanted molar element ratio of 70 % for Pd and 30 % for Ag. In the cases of Cu,
obtaining the 50:50 atomic ratio tended to be difficult. As also mentioned in Section
42
3.1.1, in order to successfully reduce a low reduction potential element such as Cu,
Co, and Fe, pH control was required. Nearly desired elemental ratios were
confirmed for Pd46Cu54 and Pt57Cu43, while it was not achieved for RhCu. Without
pH control, this combination stood at 6 % of Cu and 94 % of Rh, whereas with the
TEG solution at pH = 9, the content of Cu in the new product was increased to 30
%. Nevertheless, as mentioned in the previous section, from the XRD pattern, it was
considered that RhCu produced under the pH control partly contained nanoparticles
with an elemental ratio close to 50:50.
In the case of RhCo, RuCo and RuCu, due to the reduction potential gap or
in other word, the difficulty in the reduction of Cu and Co, none of these bimetallic
combinations successfully led to the 50:50 ratio. However, the EDS results
demonstrated that reduction of low reduction potential elements such as Cu and Co
was more viable in presence of noble metals than the reduction of these elements
alone. In fact, Cu and Co were partly reduced in presence of Rh and Ru while it was
failed to do so without the noble metals. In addition, homogeneity in the EDS signal
of these species somewhat indicated them as bimetallic alloys.
43
Figure 23: Appearance after the synthesis, appearance after adding NaOH and
appearance the synthesis with NaOH (pH = 9) for Fe, Cu and Co (left to right).
44
3.2 Library of bimetallic three-way catalysts
As shown in Figure 24-26, and Table 5, PtRh led to the best light-off
performance on Al2O3 with 50% conversion (T50) at 263 oC, 251 oC, and 238 oC for
C3H6, NO, and CO respectively. In addition, the majority of bimetallic alloys
exhibited lower T50 values than their monometallic counterparts and this is
absolutely in contrast with many previous statements.47,54,77 Performat combinations
mostly contained Rh, which indicates that the three-way reactions favor Rh as an
essential element. Bimetallic alloys such as AuRh, RhCu, and RhRu, PdRh and
PtRh had very competitive performance to Rh monometallic NPs, hence it is indeed
feasible to reduce the production cost of conventional TWC with more economical
element than Rh while enhancing its activity by alloying with Rh. Besides, some
non-rhodium-containing alloys like PdCu and PdRu could also be considered as less
expensive and more abundant alternatives since the abundance of Rh on Earth’s
surface is the rarest in PGM.52,53 The result of PdRu from this library is likely
consistent with that of PdRu synthesized by Kusada et al. and later by Sato et al.
The reason behind PdRu competitive catalytic activity to Rh is the formation of
pseudo – Rh particles that mimic the electronic state of Rh NPs by alloying two
immiscible elements, Pd and Ru.3,72 On the other hand, the remarkable catalytic
activity of PdCu nano-alloy is likely explained due to the stabilization of Pd
45
metallic state, where is the adsorption site for hydrocarbon and CO, made by Cu
when the alloy of Pd-Cu formed.47,66,78,79 In contrast, AuPt was the only species that
did not show any activity between the temperatures of 100 oC and 400 oC. As
mentioned in Section 3.1.1, the disability in three-way catalysis seemed to be
contributed by the poor dispersion of AuPt.
400
350
300
T50 (oC)
250
200
150
400
350
300
T50 (oC)
250
200
150
46
400
350
300
T50 (oC)
250
200
150
47
3.2.2 TiO2 based catalysts
400
350
300
T50 (oC)
250
200
150
48
400
350
300
T50 (oC)
250
200
150
350
300
T50 (oC)
250
200
150
Once again, similar to the trending in the Al2O3- and TiO2-based catalysts,
the preference of Rh-containing particles in TWC reactions was demonstrated in
Figure 30-32. The general catalytic mechanism in supported noble metal is the
reversible redox process between the metal state, M0, and an oxidized state
MOx.47,77,80–82 The reason for Rh superior activity in three-way reactions perhaps is
that each Rh atom can exchange 3 electrons while in other elements, such as Pd, Pt,
and Cu, only 2 electrons are exchanged.77,83
49
bimetallic alloy. The proposed mechanism of the synergy was that the Rh metal
state is stabilized by H2 spillover from neighboring Pt particles. However, in this
study, the employed feed gas did not contain H2 and only use CO as the main
reductant. The outstanding performance of PtRh in this research surely did not
come from the same mechanism proposed by Hu et al, but from alloy formation.
The alloy synergism in PtRh could be because of the Rh3+-Rh0 light-off redox
process facilitated by Pt2+. 77,86
400
350
300
T50 (oC)
250
200
150
400
350
300
T50 (oC)
250
200
150
50
400
350
300
T50 (oC)
250
200
150
𝛿
𝐶𝑒𝑂 + 𝑂 → 𝐶𝑒𝑂
2
51
involving the lability of lattice oxygen was proposed by Yentekakis et al. In their
model, labile lattice oxygen from CeO2 spillovers and covers metal particles like Ir
and Rh to create a negatively charged layer on the surface of the particles. This
negatively charged surface makes particles repel each other and prevent
agglomeration among them during high-temperature operation. 89,92,93 Similar
mechanism that also involving the migration of lattice oxygen was also reported in
the interaction of Pd and Pt with CeO2.94–96 In the cases of metal support bonding, it
was reported that strong bonding of Pt with CeO2, i.e. Pt-O-Ce, inhibits the
sintering of these nanoparticles during high-temperature performance.47,90 Similarly,
the unique effect of metal bonding with CeO2 was also discovered in Ru
nanoparticles, where the formation of stable bonding, Ru-O-Ce, led to very high
dispersion of Ru on CeO2.81,97 It was also reported that loading metal nanoparticles
facilitate the reducibility of Ce4+ by weakening Ce-O bonds.95,98
400
350
T50 of C3H6 conversion (oC)
300
250
200
150
52
400
350
250
200
150
400
350
T50 of CO conversion (oC)
300
250
200
150
53
more specific it is the special metal-support interaction between Pd and CeO2. Thus,
it is certainly another type of synergistic effect of alloy formation.
Recall that AuPt exhibited an extremely poor catalytic ability toward all
three redox processes of pollutants removal on both Al2O3 and TiO2 and that this
poor performance was plausibly attributed to the poor dispersion of as-synthesized
nanoparticles themselves. With no exception, even by loading on CeO2-ZrO2 with
good oxygen storage capacity (OSC), AuPt ineffectively converted CO to CO 2.
Furthermore, there was no significant conversion of C3H6 and NO detected with
AuPt/CeO2-ZrO2.
3.2.4 CO oxidation
400
350
300
T50 (oC)
250
200
150
Figure 36: T50 comparison among C3H6 (red), NO (blue) and CO (green)
conversion for CeO2-ZrO2 based catalysts. Catalysts with selectivity toward CO
oxidation are caro marked.
54
400
350
300
T50 (oC)
250
200
150
Figure 37: T50 comparison among C3H6 (red), NO (blue) and CO (green)
conversion for Al2O3-based catalysts.
400
350
300
T50 (oC)
250
200
150
Figure 38: T50 comparison among C3H6 (red), NO (blue) and CO (green)
conversion of TiO2-based catalysts.
The selective behavior was found when some nanoparticles were loaded on
CeO2-ZrO2. In Figure 36, catalysts with Ru or Cu containing nanoparticles have
much lower T50 values in CO conversion than those of NO and C3H6 conversions.
In particular, Ru/CeO2-ZrO2 and PtRu/CeO2-ZrO2 exhibited much higher catalytic
55
activity in CO conversion than their siblings of Al2O3 and TiO2 (Figure 35).
Previously, Ru had been reported to be favored in CO oxidation.82 The fundamental
of CO removal with Ru involves the formation of RuOx as active species.
Moreover, CeO2 was found to anchor and stabilize this oxide species.95,100 Recalling
the lattice oxygen migration mechanism mentioned above,88,89,92,93 it was believed
that the same mechanism occurred to Ru and its alloy. Once the labile oxygen from
CeO2-ZrO2 covers the Ru constituent particles, more of RuOx active site is
generated on the catalyst surface, hence the CO conversion is enhanced.
56
3.2.5 Cluster analysis
PdIr/Al2O3
Pd/Al2O3
PtCu/TiO2
Ru/TiO2
PdIr/TiO2
PdPt/TiO2
PdCu/TiO2
Pd/TiO2
PdRu/TiO2
Pt/CeO2.ZrO2
PtRu/TiO2
PdRh/TiO2
AuPd/CeO2.ZrO2
PdCu/Al2O3
Ru/CeO2.ZrO2
PtRu/CeO2.ZrO2
PtIr/CeO2.ZrO2
PtCu/CeO2.ZrO2
Ir/CeO2.ZrO2
Ir/Al2O3
Ir/TiO2
PtIr/TiO2
AuPt/TiO2
PtIr/Al2O3
AuPd/Al2O3
PtRu/Al2O3
Pt/Al2O3
Poor
Ru/Al2O3
AuPd/TiO2
PtCu/Al2O3
Pt/TiO2
PdPt/Al2O3
PtRh/CeO2.ZrO2
PdRh/CeO2.ZrO2
PdRu/CeO2.ZrO2
PtRh/TiO2
Good
PtRh/Al2O3
Pd/CeO2.ZrO2
PdRh/Al2O3
RhIr/CeO2.ZrO2
Rh/CeO2.ZrO2
AuRh/CeO2.ZrO2
RhCu/CeO2.ZrO2
PdCu/CeO2.ZrO2
RhIr/TiO2
Rh/TiO2
RhCu/Al2O3
Rh/Al2O3
RhRu/CeO2.ZrO2
AuRh/TiO2
RhRu/Al2O3
AuRh/Al2O3
RhIr/Al2O3
PdRu/Al2O3
PdPt/CeO2.ZrO2
PdIr/CeO2.ZrO2
RhRu/TiO2
RhCu/TiO2
0 1 2 3 4 5 6
Dissimilarity
57
Figure 40: Symmetric plot in multiple correspondence analysis for 60 catalysts.
The AHC iteratively classifies catalysts based on the dissimilarity among the
58 catalysts, which was calculated from the reduced Euclidean distance of the three
T50 values for C3H6 oxidation, NO reduction, and CO oxidation. The algorithm
omitted AuPt/Al2O3 and AuPt/CeO2-ZrO2 due to the missing T50 values.
Homogenous groups were created by the complete linkage method. In Figure 39, it
was found that there are two major groups presented in the dendrogram, good
catalysts (green color), whose T50 values are mostly below 300 oC, and poor
catalysts (red color), whose values are much above 300 oC. As being discussed in
58
the previous sections, Rh-containing catalysts were demonstrated to be dominant in
three-way reactions. Furthermore, CeO2-ZrO2 based catalysts, especially with Pd-
containing particles, exhibited remarkably better catalytic activity than those on the
other two supports. The same trending can also be seen in the dendrogram in which
most of the catalysts are either Rh alloys on different supports or Pd alloys loaded
on CeO2-ZrO2.
59
oxidation. Of course, Ru constituted particles on CeO2-ZrO2 have weaker power
than Cu ones, which is once again indicated by the distance of the Ru dot from the
good CO oxidation dot is further than that of the Cu dot. In addition, Al2O3-based
catalysts equipped with Rh-containing particles are drastically better than those
without Rh.
60
Chapter 4
Conclusion
61
conversion. Surely, this extended version of the library brings a comprehensive
picture in catalyst design, and it is believed that with the application of statistical
analysis such as clustering, the scope of this library can be extended furthermore.
62
Appendix
I. TEM of other combinations
CuRh RhCo
RuCo RuCu
63
II. Pictures of the synthesizes
Figure 42: Apperance after the synthesis for PdPt, PdRh, PtRh, AuRh, AuPt and
AuPd.
Figure 43: Apperance after the synthesis for Au, Rh, Ru, Cu, Co and Fe.
64
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