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

Baojian Zhang, Rui Liu, Liangwei Li, Weihong Guo, Biluan Zhang, Bosheng Chen, Weidong Yuan, Pan Li, Shaowen Zhang, Jinlong Wang, Ji Yang, Zhu Luo () and Yanbing Guo ()
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Baojian Zhang: Central China Normal University
Rui Liu: Central China Normal University
Liangwei Li: Central China Normal University
Weihong Guo: Central China Normal University
Biluan Zhang: Central China Normal University
Bosheng Chen: Central China Normal University
Weidong Yuan: Central China Normal University
Pan Li: Central China Normal University
Shaowen Zhang: Central China Normal University
Jinlong Wang: Central China Normal University
Ji Yang: Central China Normal University
Zhu Luo: Central China Normal University
Yanbing Guo: Central China Normal University

Nature Communications, 2025, vol. 16, issue 1, 1-14

Abstract: 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.

Date: 2025
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DOI: 10.1038/s41467-025-63112-y

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