Академический Документы
Профессиональный Документы
Культура Документы
net/publication/320972332
CITATIONS READS
4 770
5 authors, including:
Some of the authors of this publication are also working on these related projects:
All content following this page was uploaded by Sonia Eskandari on 01 August 2018.
This chapter was originally published in the book Advances in Catalysis, Vol. 61 published by Elsevier,
and the attached copy is provided by Elsevier for the author's benefit and for the benefit of the author's
institution, for non-commercial research and educational use including without limitation use in instruction
at your institution, sending it to specific colleagues who know you, and providing a copy to your
institution’s administrator.
All other uses, reproduction and distribution, including without limitation commercial reprints, selling or
licensing copies or access, or posting on open internet sites, your personal or institution’s website or
repository, are prohibited. For exceptions, permission may be sought for such use through Elsevier's
permissions site at:
http://www.elsevier.com/locate/permissionusematerial
From Bahareh A.T. Mehrabadi, Sonia Eskandari, Umema Khan, Rembert D. White and John R.
Regalbuto, A Review of Preparation Methods for Supported Metal Catalysts. In: Chunshan Song, editor,
Advances in Catalysis, Vol. 61, Burlington: Academic Press, 2017, pp. 1-35.
ISBN: 978-0-12-812078-1
© Copyright 2017 Elsevier Inc.
Academic Press
Author's personal copy
CHAPTER ONE
Contents
1. Introduction 2
1.1 Impregnation Methods 3
1.2 Deposition Precipitation 4
1.3 Reductive Deposition 5
1.4 Colloidal 6
2. Literature Study of Synthesis Efficacy 7
2.1 Method Surveys 8
2.2 Particle Size Ranges 10
3. Newer Methods: SEA and CEDI 12
3.1 Strong Electrostatic Adsorption 12
3.2 Charge-Enhanced Dry Impregnation 26
4. Summary 29
References 32
About the Authors 34
Abstract
To gauge the efficacy of the various methods to synthesize supported metal catalysts,
over 1500 literature articles from the past 3 years have been surveyed. Platinum catalysts
over silica (SiO2), alumina (Al2O3), titania (TiO2), and carbon (C) supports have been
selected as examples. We include our work on the methods of strong electrostatic
adsorption (SEA) and a newer version of it, charge-enhanced dry impregnation
(CEDI). These methods are compared and contrasted to those most prevalent in the
literature. SEA and CEDI yield ultra-small nanoparticles, usually less than 1.5 nm average
particle size, and are simple and scalable, especially CEDI, which is a simple adaptation of
common incipient wetness impregnation. These methods can be extended to the syn-
thesis of supported bimetallic nanoparticles with equally efficacious results.
1. INTRODUCTION
Catalysts play a vital role in chemical reactions in the chemical
industry. The active component of many catalysts is a supported metal such
as nickel, platinum, or chromium, and since only the surface of the metal is
available to catalyze the reaction, it is normally advantageous to maximize the
metal surface area for a given weight of metal. Thus, it is usually desired to
synthesize small metal crystallites, typically less than about 1–10 nm, anchored
to a thermally stable, high-surface-area support such as alumina (Al2O3),
silica (SiO2), titania (TiO2), or carbon (C). The synthesis of nanoparticles
with controllable nanoscale sizes and shapes and the prevention of the int-
rinsic propensity of nanoscale aggregation are the most important challenges
for catalyst preparation. In addition, the preparation method of supported
catalysts significantly affects their activity, selectivity, and lifetime (1).
A number of books on supported catalyst synthesis (2–5) have appeared
in the last decade or so, as well as a book chapter (6) and several review arti-
cles (7,8). Schwarz (8) described two main routes to synthesize supported
metal nanoparticles: in solution with “three-dimensional chemistry,” after
which they can be deposited onto catalyst supports, or by “two-dimensional
chemistry” involving deposition of metal precursors at the liquid–support
interface, after which the precursors can be thermochemically converted
to metal particles. This review mostly covers the latter set of methodologies,
as these serve as the most direct comparison of our own SEA and CEDI
methods. For a thorough review of the former, the reader is referred to
the classic Schwarz review (8) or a recent book chapter (6).
The common criteria for a high-performance catalyst are narrow size dis-
tribution and high dispersion on support. According to these criteria, several
innovative and cost-effective preparation methods have been developed
beyond the oldest, most common method of impregnation and show prom-
ise for reaching performance optimization by controlling synthetic proce-
dures and conditions. Among them there are deposition precipitation
(DP), reductive deposition, and colloidal syntheses. In addition to those
methods, strong electrostatic adsorption (SEA) and charge-enhanced dry
impregnation (CEDI) methods are discussed in depth in later sections. These
methods have been recently introduced as simple techniques to maximize
the interaction between a support and a catalytic metal precursor and can give
more control over particle size and size distributions. The advantages and dis-
advantages of each method will be summarized at the end of the review.
Author's personal copy
Preparation of Supported Metal Catalysts 3
Supported Pt
Fig. 2 (A) A schematic of the procedure for the preparation of the Pt–Au/CeO2 catalyst
by deposition precipitation. (B) TEM images and EDX spectra of the Pt–Au/CeO2 catalyst
(15). Modified from Hong, X.; et al. Catal. Sci. Technol. 2016, 6, 3606–3615. Copyright 2015
Royal Society of Chemistry.
precursors are highly desired for the improvement in productivity and sus-
tainability of synthetic processes of metal-based nanomaterials (17). Another
problem with this method is that the type of reducing agent employed has
been found to greatly affect the resulting particles. Fig. 3 depicts the sche-
matic representation of size-controlled silver nanoparticles synthesized
employing the coreduction approach.
1.4 Colloidal
Colloidal syntheses are “three-dimensional” methods involving several steps:
(1) preparation of catalyst precursors in a solvent using a protective agent, such
as a surfactant (e.g., cetyltrimethylammonium bromide), (2) deposition of the
Fig. 4 (A) A schematic illustration of the synthesis of the polyol method (12). (B) TEM
micrograph for a sample of ternary Pt32V13Fe55 nanoparticles prepared by colloidal
method (20). Reprinted with permission from Chan, K. Y.; et al. J. Mater. Chem. 2004,
14(4), 505–516. Copyright 2004 Royal Society of Chemistry and from Luo, J.; et al. Chem.
Mater. 2005, 17(21), 5282–5290. Copyright 2005 American Chemical Society.
colloids into the support, and (3) reduction of the mixture using chemicals
(19). Colloidal metals can be prepared in an aqueous or organic medium,
depending on the stabilizing agent used. The colloidal route can provide very
small particle sizes, but the use of surfactant and protective agents required
that the catalyst will be washed in an appropriate solvent several times;
or use high temperatures in an inert environment to decompose or remove
these foreign compounds. Before performing this step, the catalyst needs to
be adsorbed into the support to prevent the agglomeration of metal nano-
particles. Therefore, it is desirable to use an alternative route for create small
nanoparticles without the use of protecting agents, thus decreasing the
level of difficulty and avoiding contamination. Fig. 4 shows the schematic
illustration of the synthesis of the polyol method.
relatively high metal loadings. Also of note is that alumina employs the
highest fraction of impregnation preparations. This is likely because of
the effectiveness of DI with alumina. Alumina is often impregnated with
chloroplatinic acid (CPA, H2PtCl6). When dissolved in solution, CPA
gives anionic Pt hexachloride, [PtCl6]2, and two protons, which can
Fig. 5 The methods of preparation for Pt catalysts reported in the literature from 2014
to 2017 for (A) silica, (B) alumina, (C) titania, and (D) carbon.
Author's personal copy
10 Bahareh A.T. Mehrabadi et al.
Fig. 5—Cont’d
charge the alumina surface and, in doing so, create electrostatic attraction
between the anionic metal precursor and the protonated, positively
charged alumina surface (21).
to the total number of metal atoms. Dispersion has a reciprocal relation with
particle size: in 1 nm particles, virtually 100% of the metal atoms are
exposed, at 2 nm, about 50% are exposed, at 3 nm, dispersion is about
33%, and at 5 nm, dispersion is about 20% (22). It is of interest to
compare the particle size and size distributions which were obtained by
different catalyst preparation methods to see which methods can obtain
the smallest particle size and narrowest size distribution. To this purpose,
we have summarized the average Pt particle sizes, averaged over all papers
for a given year and support, which obtained by each method over the
last 4 years. Fig. 6A–D shows the average Pt particle sizes and size ranges
for Pt/SiO2, Pt/Al2O3, Pt/TiO2, and Pt/C catalysts. The Pt particle size
standard deviations obtained by different methods, again averaged for all
papers for a given year and support, are also shown in Fig. 6A–D as error
bars. The standard deviations for most years and most supports are larger
than the particle sizes for most methods, with the exception of SEA
and CEDI.
The histograms show that the preparation of Pt on different supports
by impregnation, reductive deposition, and colloidal methods gives larger
particle size with larger size distributions. As an example, the Pt particle
size obtained by the impregnation method in different references has been
reported widely different (i.e., as small as 1 nm and as big as 20 nm). In con-
trast, the limited number of SEA papers used for Fig. 6 suggests that tight
size distributions are achieved by the SEA method. The average particle size
of the catalyst that was prepared by SEA is 1.5 nm for carbon, 1.8 nm for
silica, and 2.9 nm for alumina. These are much smaller particles than
those prepared by DI, 10.3, 10, and 10 nm, respectively. This reveals that
the development of supported catalysts by the SEA method is a promising
new approach that, in principle, allows for much better control of the
active metal phase during catalyst synthesis. Among the most exciting
prospects are the ability to tightly control the particle size distribution of
supported metal catalysts, with averages in the 1–3 nm or even sub-
nanometer range.
The histograms also show that the standard deviations from the average
particle size for the SEA method are much smaller in comparison to other
methods. The large standard deviations in the other methods suggest that
these methods do not have great control over particle size and size distribu-
tions and have resulted in widely different and sometimes contradicting
results.
Author's personal copy
12 Bahareh A.T. Mehrabadi et al.
Fig. 6 The average particle size and size distribution calculated for Pt catalysts for dif-
ferent preparation methods reported in the literature from 2014 to 2017, for (A) silica,
(B) alumina, (C) titania, and (D) carbon.
Fig. 6—Cont’d
and negatively charged above this characteristic pH value. This pH, at which
the surface is neutral, is termed the PZC. Brunelle explained that oxides
placed in solutions at pH values below their PZC would adsorb anions such
as hexachloroplatinate[PtCl6]2; at pH values above their PZC, the same
support would adsorb cations such as platinum tetrammine [Pt(NH3)4]2+.
Rational synthesis techniques were then developed by Regalbuto et al.
(29), initially to deposit Pt and Pd nanoparticles onto inorganic supports.
The technique is, however, quite versatile: it was adapted to various sup-
ports, like silica (30,31), alumina (32), and carbon (33,34), and can be
extended to other metals and to bimetallic nanoparticles (35,36).
Regalbuto et al. started with the chloroplatinic acid (H2PtCl6 or CPA)/
alumina system (37–39). In this system, anionic chlorides (PtCl6 6 ) and
oxychlorides (PtCl5(OH)2, PtCl4(OH)(H2O)) complexes adsorb over a
positively charged alumina surface in the low pH range. This method has
also extended to cationic platinum tetrammine ([(NH3)4Pt]2+ or PTA, from
platinum tetrammine chloride salt, Pt(NH3)4Cl2), over deprotonated and
negatively charged silica at high pH (30,31). The latter two works especially
demonstrate the practical consequence that when strongly adsorbed at the
optimal pH, the monolayer of adsorbed coordination complexes retains
its high dispersion through the catalyst pretreatment process such as drying
and reduction steps. Finally, the SEA method was applied to activated
carbon surfaces. Carbon has great potential for SEA because controlled
oxidation of the carbon surface at mild or rigorous conditions leads to a
lesser or greater amount of oxygen functional groups on the surface (40–42),
irreversibly altering the PZC and influencing the adsorption of Pt complexes
in a way that is systematic and controllable. In a previous work on activated
carbons (33), the highest PZC active carbons adsorb the largest amount of
anions [PtCl6]2 and the lowest amount of cations [Pt(NH3)4]2+, while the
lowest-PZC active carbons adsorb the lowest amount of anions and the
largest amount of cations. Pt uptakes reach a maximum with respect to pH
for a given metal precursor and active carbon PZC.
SEA is normally performed with an excess of solution. This keeps
pH shifts to a minimum and facilitates sampling the solution. Thus, SEA
at high liquid/support ratios is a special case of WI in which the pH of
the solution is controlled to achieve strong electrostatic attraction between
precursor and surface. For benchtop experiments, surface loadings (SLs) are
generally held low (500–2000 m2/L) in order to minimize pH shifts for
the sake of convenience (i.e., surface loading is the amount of support
surface per liter of preparation solution). The SEA preparations give much
smaller particle size with much smaller standard deviations than the DI
Author's personal copy
Preparation of Supported Metal Catalysts 15
Fig. 7 The strong electrostatic adsorption procedure: (1) PZCs are determined and the
appropriate metal complex is selected (a cation for silica), (2) uptake–pH surveys are
conducted to determine the pH of strongest interaction, and (3) catalysts are synthe-
sized at this pH (10.5), and after mild reduction, ultra-small nanoparticles with a narrow
size distribution result (6). Based on Zhong, C. J.; et al. In Comprehensive Inorganic Chem-
istry II; Reedijk, J.; Poeppelmeier, R. K., Eds. Elsevier Inc., 2013; pp 75–102. Copyright 2013
Elsevier.
Fig. 8 The hydration sheaths and ligands attached to the metal core of the precursors
are removed via catalyst finishing, i.e., reduction or calcination to preserve the highly
dispersed metal nanoparticles.
Author's personal copy
16 Bahareh A.T. Mehrabadi et al.
1.8
1.6 PZC = 11
PZC = 9
1.4
1.2
G in mol/m2
PZC = 7
1
0.8 PZC = 1
PZC = 3
0.6
PZC = 5
0.4
PZC = 7
PZC = 5
0.2
PZC = 3
PZC = 9
PZC = 1
PZC = 11
0
0 2 4 6 8 10 12 14
pH
Fig. 9 Simulation of Pt uptake over carbons of various PZCs vs final pH, CPA (lower pH
range), or PTA (higher pH range) (34). Based on Hao, X.; Barnes, S.; Regalbuto, J. R. J. Catal.
2011, 279(1), 48–65. Copyright 2011 Elsevier.
Author's personal copy
Preparation of Supported Metal Catalysts 17
Fig. 10 The experimental results for Pt uptake over different alumina (38), silica (45),
carbon (34), and titania (21) supports. Data from Regalbuto, J. R.; et al. J. Catal. 1999,
184(2), 335–348. Copyright 1999 Elsevier; Schreier, M.; Regalbuto, J. R. J. Catal. 2004,
225(1), 190–202. Copyright 2004 Elsevier; Hao, X.; Barnes, S.; Regalbuto, J. R. J. Catal.
2011, 279(1), 48–65. Copyright 2011 Elsevier; and Regalbuto, J. R. In De Jong, K. P., Ed.:
Wiley-VCH Verlag GmbH & Co.: The Netherlands, 2009; pp 33–58. Copyright 2009 John
Wiley and Sons.
Author's personal copy
18 Bahareh A.T. Mehrabadi et al.
Fig. 11 The STEM results for Pt uptake over (A) silica, (B) alumina, (C), carbon, and
(D) titania supports.
Author's personal copy
Preparation of Supported Metal Catalysts 19
The SEA method also has been used for many other noble and base
metal precursors. Jiao et al. (48) extended the SEA method to the synthesis
of other silica-supported noble and base metal catalysts and investigated the
correlation between strong electrostatic interaction and highly dispersed
metals on reduced catalysts. Pd, Cu, Co, Ru, and Ni over SiO2 were
prepared via SEA and compared with those prepared via the traditional
dry impregnation method. Fig. 12 shows representative Z-contrast STEM
images of reduced catalyst samples prepared via SEA at monolayer loading
and the corresponding loading for DI preparations for Ru and Ni metals
(48). Metal particle sizes of the reduced catalysts prepared by SEA remain
relatively small, and the size distributions are limited to a narrow range.
These results also showed that reduced catalysts prepared by DI give much
Fig. 12 Data from representative STEM images and corresponding particle distributions
of reduced Ru and Ni catalyst samples: (A) 3.0% Ru, SEA preparation; (B) 3.0% Ru, DI
preparation; (C) 1.6% Ni, SEA preparation; and (D) 1.6% Ni, DI preparation (48). Jiao,
L.; Regalbuto, J. R. J. Catal. 2008, 260(2), 329–341. Copyright 2008 Elsevier.
Author's personal copy
20 Bahareh A.T. Mehrabadi et al.
larger particle sizes, and in a particular sample, the particle sizes occur in a
wide distribution, and the average particle size increases significantly with
increasing metal weight loading.
Ling et al. (49) also made cobalt (Co) catalysts supported on silica by
using the SEA method. The TEM images of their samples showed that
the Co particle size is narrowly distributed and have an average value
of 5.2 nm with a standard deviation of 1.2 nm. In another work, Jiao
et al. (50) carried out the adsorption surveys of a series of metal ammines
(Pt, Pd, Cu, Co, Ru ammine complexes) at various pH values and further
characterized Pt/SBA-15, Pd/SBA-15, and Co/SBA-15 materials syn-
thesized at the optimal pH. Their results show that the SEA method
yields small metal particles, which appear to form homogeneously
throughout the pore volume of the SBA-15. Liu et al. (51) synthesized
supported Ru and Pt nanoparticles over amorphous SiO2 and SBA-15
supports by the method of SEA and subsequently treated them under dif-
ferent steaming-reduction conditions to achieve a series of catalysts with
controlled particle sizes, ranging from 1 to 8 nm. They demonstrated that
the SEA methodology allows the control of particle which can be applied
to high surface area supports with common metal precursors. Metal
particle sizes of the reduced catalysts prepared by SEA show very narrow
size distribution throughout the SBA-15 pore channels. The average
particle size for 9.7 wt% Ru/SBA-15 is 1.1 0.2 nm, and that of the
5.4 wt% Pt/SBA-15 is 1.3 0.3 nm.
The comparison of STEM images of Pt/SBA-15 made by SEA and DI,
Pd/SBA-15, and Ru/SBA-15 is shown in Fig. 13A–D respectively.
Miller et al. (31) synthesized Pt over silica by adsorption of PtðNH3 Þ4 2 +
from strongly basic impregnation solutions. They established that by
selecting the method of preparation and calcination temperature, very small
to large metallic nanoparticles can be prepared. Their results also showed
that the highest dispersions were obtained at lower Pt loading and drying
in air at 100°C followed by reduction in H2 at 250°C. With increasing cal-
cination temperature, there was a nearly linear decrease in the Pt dispersion.
It was suggested that the dispersion is dependent on the distribution of Pt
species on silica at the time of reduction. Klaigaew et al. (52) prepared
the Co supported on silica fibers (Co/SF) catalysts with different methods
of the SEA, DI, DP, and hydrothermal synthesis. The activity of Co/SF cat-
alysts were compared for Fischer–Tropsch synthesis (FTS) reaction, and the
results show that the catalysts prepared by the SEA method have the highest
Author's personal copy
Preparation of Supported Metal Catalysts 21
Fig. 13 Representative STEM images of reduced Pt particles: (A) 8.0 wt% Pt/SBA-15
(SEA, 1-h contact, reduced at 160°C) (50), (B) 8.0 wt% Pt/SBA-15 DI sample (1-h contact,
reduced at 350°C) (50), (C) 8.7 wt% Pd/SBA-15 (50), and (D) 9.7 wt% Ru/SBA-15 (51).
Based on Jiao, L.; et al. J. Catal. 2008, 260(2), 342–350. Copyright 2008 Elsevier;
Liu, Q. L.; et al. Phys. Chem. Chem. Phys. 2014, 16(48), 26431–26435. Copyright 2014 Royal
Society of Chemistry.
catalytic activity for FTS reaction. They also showed that the excellent cat-
alytic activity of Co/SF which has been prepared by SEA may be attributed
to the smaller size of cobalt particles and higher cobalt dispersion on this
catalyst.
Akbarzadeh et al. (53) used the SEA method for the deposition of Co
nanoparticles on carbon nanotubes (CNTs) support. Their TEM and
FESEM images indicated well-dispersed Co particles on the CNTs
support, and their TPR results was proven reduction peak at high temper-
ature (530°C), indicating strong interactions between Co and CNT support.
They proved that the SEA method is the desired method in preparing
supported cobalt catalysts. Zhang et al. (54) synthesized Pd nanoparticles
Author's personal copy
22 Bahareh A.T. Mehrabadi et al.
supported on CNTs by the SEA method. The TEM images of their catalysts
showed an average Pd size of around 1 nm. They also showed that a higher
Pd nanoparticle dispersion was obtained for the catalysts prepared by the
SEA method than the catalysts prepared by the IWI method, which contrib-
uted to the higher specific activity value for the Suzuki coupling reaction.
Kyriakidou et al. (55) used the SEA method for deposition of Ag on different
oxide supports. They showed that the SEA with Ag diammines at high pH is
demonstrated to be a simple, reliable method to synthesize small Ag
nanoparticles (3.8 nm) over all oxide supports, but reacts to form large par-
ticles on carbon.
As supported metal nanoparticles prepared by SEA have high dispersion
and narrow size distribution, therefore, they are desirable as seeds for addi-
tion of secondary metals using methods like ED, since the prepared bime-
tallic catalysts should be of similar dispersion as the base, or seed, catalyst.
Ryapan et al. (56) prepared the uniform deposition of Ag on the surfaces
of small Pd particles using the combined methods of SEA and ED resulted
in significant improvement of the bimetallic Ag–Pd surface for the selective
hydrogenation of acetylene. Mager et al. (57) provided Ru on nanocarbon
support catalysts from water-soluble molecular clusters by pH-controlled
impregnations in order to probe the interactions occurring between the sup-
ports and the clusters and to maximize them. They showed that in addition
to the interactions in the form of π-bond coordination between the cluster
and the carbon aromatics, electrostatic interactions however play a deter-
mining role, allowing more or less adsorption in the case of attractive or
repulsive interactions, respectively.
In addition to the adsorption of single metals on single supports, the SEA
method can also be used for the selective adsorption of single metals over
composite supports. Feltes et al. (35) suggested that pH control for selective
adsorption in the preparation of promoted catalysts is a viable strategy for the
synthesis of any other promoted and/or bimetallic catalyst systems where
intimate contact between the different catalyst components is highly desired.
They investigated the preparation of a Mn-promoted Co/TiO2 catalyst for
FTS using pH control for deposition of Mn selectively onto Co to enhance
promoter–metal interaction.
Samad et al. (58,59) have explored the potential to control the location
and mechanism of Pt adsorption on mixed oxides silica–alumina composites
through the choice of metal precursor and simple pH adjustment. They
also showed that mixed oxides intimate mixing between the two phases
Author's personal copy
Preparation of Supported Metal Catalysts 23
Fig. 14 Controlled deposition of platinum (Pt) on either the zeolite Y or the alumina
component of Y/A extrudates. (A, B) Pt-Y/A. The HAADF-STEM image (A) is of a
70-nm-thick section of a Pt-Y/A sample, with Pt particles of 2.5 nm residing exclusively
within the zeolite crystals, as evident from the EDX map (B) showing Pt (yellow), Si
(green), and Al (red) signals. (C, D) Pt-A/Y. Shown are an HAADF-STEM image (C) and
EDX map (D) of a 70-nm-thick section of Pt-A/Y, with Pt particles (yellow) of 3.5 nm
residing exclusively on the alumina platelets (red), while the zeolite crystals (green)
are empty. Scale bars, 50 nm (60). Data from Zecevic, J.; et al. Nature 2015, 528(7581),
245–248. Copyright 2015 Nature.
increase the Pt loading from 7 to 15 and then 22.5 wt%. They showed that in
each case, the metal particles were found to be highly dispersed (particle size
2 nm); in addition, their results showed that the average particle size did
not change upon repeated impregnation. Fig. 15 presents TEM micrographs
of samples from first and third cycles. These pictures show that both catalysts
are well dispersed and present an extremely low degree of agglomeration;
the particles are homogeneous in size and shape. Both samples contain
Pt particles with 2 nm in diameter, the number of which increases
with the Pt weight percentage while keeping the same metal dispersion.
Author's personal copy
Preparation of Supported Metal Catalysts 25
Fig. 15 TEM micrographs of the catalysts: (A) after one impregnation (X-Pt-1) and
(B) after three successive impregnations (X-Pt-3) (61). Data from Job, N.; et al. Catal.
Today 2010, 150(1–2), 119–127. Copyright 2010 Elsevier.
30 30 30
A B C
Number of particles (%)
20 20 20
10 10 10
0 0 0
0 1 2 3 4 5 6 0 1 2 3 4 5 6 0 1 2 3 4 5 6
Size (nm) Size (nm) Size (nm)
Fig. 16 Pt particle size distributions of the Pt/carbon xerogel catalyst issued from the
image analysis of TEM micrographs: (A) X-Pt-1, (B) X-Pt-2, and (C) X-Pt-3 (61). Based
on Job, N.; et al. Catal. Today 2010, 150(1–2), 119–127. Copyright 2010 Elsevier.
Fig. 16 shows their particle size distributions of the three catalysts obtained
by image analysis of TEM micrographs. In each case, the particle size ranges
from 1 to 5 nm, and no significant statistical difference is detected in the size
distributions (61).
Author's personal copy
26 Bahareh A.T. Mehrabadi et al.
Finally, the SEA method can be used for bimetallic catalyst preparations
(62,63) by simply mixing metal precursors in solution and adsorbing them
into a mixed monolayer. Recently, simultaneous electrostatic adsorption
(co-SEA) of two metals has been applied to Pt and Pd precursors on silica,
alumina, and carbon supports by Cho et al. (62) and Wong et al. (64). The
former work showed that co-SEA yields well-dispersed, homogeneously
alloyed Pt–Pd particles on silica, carbon, and alumina supports (two of
which, silica and carbon, are shown in Fig. 17), while co-DI gives large,
agglomerated, inhomogeneous particles.
Fig. 17 Pt/Pd-alloyed nanoparticles over (A) silica, with an X-ray line scan and
(B) carbon, with an X-ray map of an individual nanoparticle (62). From Cho, H.R; et al.
Catal. Today 2015, 246,143–153. Copyright 2015 Elsevier.
Author's personal copy
Preparation of Supported Metal Catalysts 27
That is, a minimal amount of solution is employed, that to just fill the pore
volume of the support, but the solution is sufficiently acidified or basified, as
the case may be, to charge the surface and so induce electrostatic attraction.
They synthesized 2 wt% Pt catalysts supported on oxidized active carbon or
γ-alumina.
Fig. 18 shows the difference between the SEA and CEDI methods sche-
matically. In the CEDI method, the optimal impregnation pH was first
determined, and then dry impregnation was performed.
Zhu et al. (65) also showed that the average size of nanoparticles prepared
by CEDI are much smaller than those prepared by DI. Fig. 19 shows rep-
resentative Z-contrast STEM images for Pt on different support syntheses by
DI and CEDI.
Cao et al. (66) showed CEDI synthesis of highly dispersed Pt/carbon
xerogel catalysts with relatively high Pt loading without any noble metal loss.
In another work, Cao et al. (64) used CEDI to prepare Pd/Mo carbon-
supported bimetallics. Their results for the oxygen reduction reaction indi-
cated that increased activity of the CEDI-prepared samples compared
DI-prepared catalysts, which they claimed to be due to the CEDI method
giving stronger interactions between Pd and Mo. The CEDI sizes are not
quite as small as those obtained from SEA but are close and at any rate
are far better than those obtained with DI. Samad et al. (46) demonstrated
that high metal loadings are achievable even at high SLs. Hence, a well-
dispersed 5.3% Pt (PTA) on silica catalyst at incipient wetness (for which
Fig. 19 STEM image of Pt catalysts after reduced at 200°C. (A) Pt/C DI, (B) Pt/C CEDI,
(C) Pt/SiO2 DI, (D) Pt/SiO2 CEDI, (E) Pt/Al2O3 DI, and (F) Pt/Al2O3 CEDI (65). From
Zhu, X. R.; et al. ACS Catal. 2013, 3(4), 625–630. Copyright 2013 American Chemical Society.
Fig. 20 STEM images of (A) 5 wt% Co + 5 wt% Pd, (B) 5 wt% Co + 2.5 wt% Pd, (C) 5 wt%
Co + 1.25 wt% Pd, and (D) 5 wt% Co supported on Vulcan XC-72 carbon black (VXC) pre-
pared by CEDI (67). Data from D’Souza, L.; et al. Catalysts 2016, 6(5), 72, https://doi.org/10.
3390/catal6050072. Open access publication.
4. SUMMARY
The nanoparticle synthesis methods reviewed in this chapter have
been compared one against the other in Table 1 which has been excerpted
from Ref. (6). For simplicity’s sake, reductive deposition and deposition
precipitation have been combined into one column. Each method can be
Author's personal copy
Table 1 A Comparison of Methods for Nanoparticle Synthesis on High Surface Area Supports
Single Metals
Charge-Enhanced Deposition
Dry Impregnation Wet Impregnation Strong Electrostatic Dry Impregnation Precipitation
Colloidal (DI) (WI) Adsorption (SEA) (CEDI) (DP)
Simplicity ++ + + ++
Scalability ++ + + ++ +
Reproducibility
Macroscopic ++ + + ++ ++ ++
Nanoparticle ++ ++ + ++
Efficacy
Size + ++ + +
Loading ++ ++ + ++ ++
Author's personal copy
Preparation of Supported Metal Catalysts 31
rated for the simplicity of the procedure and its scalability to large quan-
tities (both related to expense), reproducibility from both a macroscopic
level (composition) and a microscopic level (tightness of nanoparticle
size distribution), and efficacy of metal utilization or dispersion (higher
for smaller particles) as well as the ability to achieve high metal loadings.
The range of marks varies from “++” for the best to “ ” for the worst.
Comparing the methods for each criterion (row by row), the very simplest
method to synthesize metal nanoparticles is the fundamentally one-step
method of DI, while the most complexes are the solution methods which
require multiple steps in solution followed by painstaking removal of
the scaffolds (although deposition of bare metal nanoparticles from aqueous
solutions is an exception to this). WI and SEA are a bit more complicated
in that they involve a filtering step after the adsorption step, and the pH
control necessitated by DP makes that method a bit more complicated
than SEA.
The methods of DI, WI, SEA, and CEDI are as applicable to large quan-
tities of catalyst support as they are to small quantities. Scalability is a likely to
be more complex in the solution synthesis of encapsulated metal particles in
large batches, and also in controlling pH for DP at large scale. All methods in
theory are reproducible, though lower marks are given for DI and WI as
drying conditions can exhibit deleterious effects on metal particle size and
distribution in systems in which there is no precursor–support interaction.
Microscopic reproducibility is a measure of the tightness of particle size dis-
tributions, and there is wide variation of rankings for this. Narrow particle
size distributions of supported nanoparticles can also be achieved by SEA and
DP. Dry and wet impregnation methods frequently give poorly dispersed
particles with wide particle size distributions including large agglomerates
of metal. Efficacy in terms of size refers to metal utilization, or metal disper-
sion, with the smallest sizes giving highest dispersion. For metal utilization
over high surface area supports, there is perhaps no method more effective
than SEA. Finally, the best methods simply in terms of depositing high metal
loadings are DI, CEDI, and DP. DP and CEDI are especially effective for
synthesizing relatively small nanoparticles.
Summarizing the table on a column-by-column (method) basis, DI is a
cheap, simple method that very often gives poor and uneven metal disper-
sion as no provision is made to achieve precursor–support interaction. WI
possesses no advantages over DI but has the additional disadvantages of
requiring a filtration step and being limited to low metal loadings. SEA is
more complex than DI, but the payoff of an additional filtration step is
Author's personal copy
32 Bahareh A.T. Mehrabadi et al.
the production of ultra-small metal particles with possibly the tightest size
distributions that can be attained for preparations with high surface area sup-
ports. The results for CEDI obtained to date suggest that particle size is
somewhat larger than can be achieved with SEA conducted in excess liquid.
DP is also a higher complexity method but can give relatively small particles
at relatively high metal loadings.
REFERENCES
1. Nalwa, H. S. Handbook of Surfaces and Interfaces of Materials. Vol. 1. Academic Press:
United States, 2001.
2. Ertl, G.; Kn€ ozinger, H.; Sch€uth, F.; Weitkamp, J. Handbook of Heterogeneous Catalysis.
Wiley-VCH Verlag GmbH & Co. KGaA: Weinheim, Germany, 2008; p 4270.
3. Ozkan, U. S. Design of Heterogeneous Catalysts. Wiley-VCH: Weinheim, 2009.
4. Regalbuto, J. R. Catalyst Preparation Science and Engineering. CRC Press: Boca Raton,
FL, 2007.
5. De Jong, K. P. Synthesis of Solid Catalysts. Wiley-VCH Verlag GmbH & Co.:
Netherland, 2009.
6. Zhong, C. J.; et al. In: Comprehensive Inorganic Chemistry II; Reedijk, J.,
Poeppelmeier, R. K., Eds.; Elsevier Inc., 2013; pp 75–102.
7. Munnik, P.; de Jongh, P. E.; de Jong, K. P. Chem. Rev. 2015, 115(14), 6687–6718.
8. Schwarz, J. A.; Contescu, C.; Contescu, A. Chem. Rev. 1995, 95(3), 477–510.
9. Regalbuto, J. R. Catalyst Preparation, Science and Engineering. CRC Press, Taylor &
Francis Group: Boca Raton, FL, 2007.
10. Galhenage, R. P.; et al. Phys. Chem. Chem. Phys. 2015, 17(42), 28354–28363.
11. Tengco, J. M. M. Synthesis of Well Dispersed Supported Metal Catalysts by Strong Electrostatic
Adsorption and Electroless Deposition, Ph.D. Dissertation. University of South Carolina,
SC, United States, 2016.
12. Chan, K. Y.; et al. J. Mater. Chem. 2004, 14(4), 505–516.
13. Louis, C. Catalyst Preparation: Science and Engineering. CRC Press: Boca Raton, 2006.
14. Diao, W. Preparation and Characterization of Pt-Ru Bimetallic Catalysts Using Electroless
Deposition Methods and Mechanistic Study of Re and Cs Promoters for Ag-Based, High Selec-
tivity Ethylene Oxide Catalysts. Ph.D. Dissertation. University of South Carolina, SC,
United States, 2015.
15. Hong, X.; et al. Catal. Sci. Technol. 2016, 6, 3606–3615.
16. Sunagawa, Y.; et al. Catal. Today 2008, 132(1–4), 81–87.
17. Dong-Wook Lee, M.-H. J.; Lee, Y.-J.; Park, J.-H.; Lee, C.-B.; Park, J.-S. Sci. Rep.
2016, 6(26474), 1–9.
18. Agnihotri, S.; et al. RSC Adv. 2014, 4(8), 3974–3983.
19. Liu, H. S.; et al. J. Power Sources 2006, 155(2), 95–110.
20. Luo, J.; et al. Chem. Mater. 2005, 17(21), 5282–5290.
21. Regalbuto, J. R. In: Synthesis of Solid Catalysts; De Jong, K. P. Ed.; Wiley-VCH Verlag
GmbH & Co.: The Netherlands, 2009; pp 33–58.
22. Regalbuto, J. R. In: Silica and Silicates in Modern Catalysis; Halasz, I. Ed.; Transworld
Research Network: Kerala, India, 2010.
23. Regalbuto, J. R. In: Catalyst Preparation Science and Engineering; Regalbuto, J. R. Ed.;
CRC Press: Boca Raton, FL, 2007; pp 297–318.
24. Regalbuto, J. R. In: Surface and Nanomolecular Catalysis; Richards, R. Ed.; Taylor and
Francis Group/CRC Press: Boca Raton, FL, 2006; pp 161–194.
Author's personal copy
Preparation of Supported Metal Catalysts 33
25. Regalbuto, J.R., in Surface and Nanomolecular Catalysis, R. Richards, 2006, CRC
Press: Boca Raton, FL.
26. Brunelle, J. P. Pure Appl. Chem. 1978, 50(9–10), 1211–1229.
27. Heise, M. S.; Schwarz, J. A. J. Colloid Interface Sci. 1985, 107(1), 237–243.
28. Heise, M. S.; Schwarz, J. A. J. Colloid Interface Sci. 1986, 113(1), 55–61.
29. Regalbuto, J. R. In: Synthesis of Solid Catalysts; de Jong, K. P. Ed.; Wiley-VCH:
Weinheim, Germany, 2009.
30. Schreier, M.; Regalbuto, J. R. J. Catal. 2004, 225(1), 190–202.
31. Miller, J. T.; et al. J. Catal. 2004, 225(1), 203–212.
32. Spieker, W. A.; et al. Appl. Catal. A Gen. 2003, 243(1), 53–66.
33. Hao, X.; et al. J. Mol. Catal. A Chem. 2004, 219(1), 97–107.
34. Hao, X.; Barnes, S.; Regalbuto, J. R. J. Catal. 2011, 279(1), 48–65.
35. Feltes, T. E.; et al. J. Catal. 2010, 270(1), 95–102.
36. D’Souza, L. and J.R. Regalbuto, Scientific Bases for the Preparation of Heterogeneous
Catalysts: Proceedings of the 10th International Symposium, 2010. 175: p. 715–718.
37. Spieker, W. A.; Regalbuto, J. R. Chem. Eng. Sci. 2001, 56(11), 3491–3504.
38. Regalbuto, J. R.; et al. J. Catal. 1999, 184(2), 335–348.
39. Hao, X.; Spieker, W. A.; Regalbuto, J. R. J. Colloid Interface Sci. 2003, 267(2), 259–264.
40. Sepulveda-Escribano, A.; Coloma, F.; Rodriguez-Reinoso, F. Appl. Catal. A Gen.
1998, 173(2), 247–257.
41. Figueiredo, J. L.; et al. Carbon 1999, 37(9), 1379–1389.
42. Fraga, M. A.; et al. J. Catal. 2002, 209(2), 355–364.
43. Park, J.; Regalbuto, J. R. J. Colloid Interface Sci. 1995, 175(1), 239–252.
44. Santhanam, N.; et al. Catal. Today 1994, 21(1), 141–156.
45. Schreier, M.; Regalbuto, J. R. J. Catal. 2004, 225(1), 190–202.
46. Lambert, S.; et al. J. Catal. 2009, 261(1), 23–33.
47. Samad, J. E.; Hoenig, S.; Regalbuto, J. R. ChemCatChem 2015, 7(21), 3460–3463.
48. Jiao, L.; Regalbuto, J. R. J. Catal. 2008, 260(2), 329–341.
49. Ling, C. K.; Zabidi, N. A. M.; Mohan, C. J. Appl. Sci. 2011, 11(8), 1436–1440.
50. Jiao, L.; et al. J. Catal. 2008, 260(2), 342–350.
51. Liu, Q. L.; et al. Phys. Chem. Chem. Phys. 2014, 16(48), 26431–26435.
52. Klaigaew, K.; et al. Chem. Eng. J. 2015, 278, 166–173.
53. Akbarzadeh, O.; et al. Process Adv. Mater. Eng. 2014, 625, 328–332. https://doi.org/
10.4028/www.scientific.net/AMM.625.328.
54. Zhang, L. Y.; et al. ChemCatChem 2014, 6(9), 2600–2606.
55. Kyriakidou, E. A.; et al. J. Catal. 2016, 344, 749–756.
56. Riyapan, S.; et al. Catal. Sci. Technol. 2016, 6(14), 5608–5617.
57. Mager, N.; et al. Phys. Chem. Chem. Phys. 2016, 18(47), 32210–32221.
58. Samad, J. E.; et al. J. Catal. 2016, 342, 213–225.
59. Samad, J. E.; et al. J. Catal. 2016, 342, 203–212.
60. Zecevic, J.; et al. Nature 2015, 528(7581), 245–248.
61. Job, N.; et al. Catal. Today 2010, 150(1–2), 119–127.
62. Cho, H. R.; et al. Catal. Today 2015, 246, 143–153.
63. Wong, A.N.; Kyriakidou, E.A.; Toops, T.J.; Regalbuto, J.R.; Catal. Today 2017, 267,
145–156.
64. Cao, C. J.; et al. Appl. Catal. B Environ. 2014, 150, 101–106.
65. Zhu, X. R.; et al. ACS Catal. 2013, 3(4), 625–630.
66. Cao, C. J.; et al. J. Power Sources 2014, 272, 1030–1036.
67. D’Souza, L.; et al. Catalysts 2016, 6(5). https://doi.org/10.3390/catal6050072.
Author's personal copy
34 Bahareh A.T. Mehrabadi et al.