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Ultra-stable low-coordinated PtSA/CeZrO2 ordered macroporous structure integrated industrial-scale monolithic catalysts for high-temperature oxidation

Author

Listed:
  • Baojian Zhang

    (Central China Normal University
    Central China Normal University
    Wuhan Institute of Photochemistry and Technology)

  • Rui Liu

    (Central China Normal University
    Central China Normal University
    Wuhan Institute of Photochemistry and Technology)

  • Liangwei Li

    (Central China Normal University
    Central China Normal University
    Wuhan Institute of Photochemistry and Technology)

  • Weihong Guo

    (Central China Normal University
    Central China Normal University
    Wuhan Institute of Photochemistry and Technology)

  • Biluan Zhang

    (Central China Normal University
    Central China Normal University)

  • Bosheng Chen

    (Central China Normal University
    Central China Normal University)

  • Weidong Yuan

    (Central China Normal University
    Central China Normal University)

  • Pan Li

    (Central China Normal University
    Central China Normal University
    Wuhan Institute of Photochemistry and Technology)

  • Shaowen Zhang

    (Central China Normal University
    Central China Normal University)

  • Jinlong Wang

    (Central China Normal University
    Central China Normal University
    Wuhan Institute of Photochemistry and Technology)

  • Ji Yang

    (Central China Normal University
    Central China Normal University
    Wuhan Institute of Photochemistry and Technology)

  • Zhu Luo

    (Central China Normal University
    Central China Normal University
    Wuhan Institute of Photochemistry and Technology)

  • Yanbing Guo

    (Central China Normal University
    Central China Normal University
    Wuhan Institute of Photochemistry and Technology)

Abstract

Platinum-group metals (Pt) commonly used in thermal catalytic processes often suffer from catalyst deactivation, such as Pt sintering, Pt overoxidation, and Pt loss under high-temperature conditions. To address these, we present a novel PtSA/CeZrO2 catalyst, featuring isolated Pt single atoms (PtSA) on a Ce0.8Zr0.2O2 support with an ordered macroporous (OM) structure. Firstly, Zr-stabilized dynamic low-coordinated PtSA releases more free d-electrons by reducing Pt-O bond occupation, thereby preserving peroxide activity at high temperatures and enhancing propane C–H activation. Additionally, the OM structure prevents Pt loss and reduces Pt loading to 0.4 gPt/L, compared with 0.9 gPt/L in commercial diesel oxidation catalysts. As a result, the PtSA/CeZrO2 maintains 92% conversion at 450 °C even after 50 h aging at 800 °C with 10 vol.% H2O. Finally, the catalyst is integrated into a 3.4-liter commercial cordierite monolith for developing and scaling robust catalytic converters.

Suggested Citation

  • Baojian Zhang & Rui Liu & Liangwei Li & Weihong Guo & Biluan Zhang & Bosheng Chen & Weidong Yuan & Pan Li & Shaowen Zhang & Jinlong Wang & Ji Yang & Zhu Luo & Yanbing Guo, 2025. "Ultra-stable low-coordinated PtSA/CeZrO2 ordered macroporous structure integrated industrial-scale monolithic catalysts for high-temperature oxidation," Nature Communications, Nature, vol. 16(1), pages 1-14, December.
    • Handle: RePEc:nat:natcom:v:16:y:2025:i:1:d:10.1038_s41467-025-63112-y
    DOI: 10.1038/s41467-025-63112-y
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    References listed on IDEAS

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    1. Son Hoang & Yanbing Guo & Andrew J. Binder & Wenxiang Tang & Sibo Wang & Jingyue (Jimmy) Liu & Huan Tran & Xingxu Lu & Yu Wang & Yong Ding & Eleni A. Kyriakidou & Ji Yang & Todd J. Toops & Thomas R. P, 2020. "Activating low-temperature diesel oxidation by single-atom Pt on TiO2 nanowire array," Nature Communications, Nature, vol. 11(1), pages 1-10, December.
    2. Wei Tan & Shaohua Xie & Duy Le & Weijian Diao & Meiyu Wang & Ke-Bin Low & Dave Austin & Sampyo Hong & Fei Gao & Lin Dong & Lu Ma & Steven N. Ehrlich & Talat S. Rahman & Fudong Liu, 2022. "Fine-tuned local coordination environment of Pt single atoms on ceria controls catalytic reactivity," Nature Communications, Nature, vol. 13(1), pages 1-16, December.
    3. Xu Li & Xavier Isidro Pereira-Hernández & Yizhen Chen & Jia Xu & Jiankang Zhao & Chih-Wen Pao & Chia-Yu Fang & Jie Zeng & Yong Wang & Bruce C. Gates & Jingyue Liu, 2022. "Functional CeOx nanoglues for robust atomically dispersed catalysts," Nature, Nature, vol. 611(7935), pages 284-288, November.
    4. Rui Lang & Wei Xi & Jin-Cheng Liu & Yi-Tao Cui & Tianbo Li & Adam Fraser Lee & Fang Chen & Yang Chen & Lei Li & Lin Li & Jian Lin & Shu Miao & Xiaoyan Liu & Ai-Qin Wang & Xiaodong Wang & Jun Luo & Bot, 2019. "Non defect-stabilized thermally stable single-atom catalyst," Nature Communications, Nature, vol. 10(1), pages 1-10, December.
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