Method of making confined nanocatalysts within mesoporous materials and uses thereof

Patent metadata

Field	Value
Publication number	US-11406971-B2
Application number	US-201917041944-A
Country	US
Kind code	B2
Filing date	Mar 26, 2019
Priority date	Mar 26, 2018
Publication date	Aug 9, 2022
Grant date	Aug 9, 2022

Abstract

The present disclosure provides methods of making confined nanocatalysts within mesoporous materials (MPMs). The methods utilize solid state growth of nanocrystalline metal organic frameworks (MOFs) followed by controlled transformation to generate nanocatalysts in situ within the mesoporous material. The disclosure also provides applications of the nanocatalysts to a wide variety of fields including, but not limited to, liquid organic hydrogen carriers, synthetic liquid fuel preparation, and nitrogen fixation.

First claim

What is claimed is:

1. A method of preparing a confined metallic nanocatalyst within a mesoporous material (MPM) which comprises:
(a) impregnating at least one or more organic compound(s), comprising one or more multidentate ligand(s) selected from the group consisting of salts of terephthalate, benzene-1,3,5-tricarboxylate, 2,5-dioxibenzene dicarboxylate, biphenyl-4,4′-dicarboxylate, imidazolate, pyrimidine-azolate, triazolate, tetrazolate, and derivatives, thereof, capable of forming coordination bonds with at least one metal ion, on the mesoporous material to form a first intermediate complex in the MPM;
(b) exposing the first intermediate complex to an acid in gas phase to form a protonated second intermediate;
(c) adding to the protonated second intermediate complex a solvent solution of one or more metal ions selected from the group consisting of salts of Al, Au, Ce, Co, Fe, Ir, Mo, Ni, Pd, Rh, Ru, Ti, V, and Zr, so as to form coordination bonds with the one or more multidentate ligand(s) so as to produce a metal organic framework (MOF) precursor confined within a mesoporous material [MOF/MPM]; and
(d) treating the MOF precursor of step (c) [MOF/MPM] under either
(i) pyrolysis conditions under nitrogen or other inert gas at temperatures ranging from about 300° C. to about 1000° C.;
(ii) calcining conditions in the presence of oxygen at a temperature ranging from about 300° C. to about 600° C.; or
(iii) reductive conditions in an atmosphere containing hydrogen at a temperature ranging from about 25° C. to about 300° C.;

so as to form the confined metallic nanocatalyst within the mesoporous material.

2. The method of claim 1 , wherein step (c) further comprises step (c)(1) comprising contacting the MOF precursor of step (c) [MOF/MPM] with one or more organic compounds to make a second multidentate ligand capable of forming coordination bonds [MOF /MPM′]; and step (c)(2) adding a solvent solution of one or more additional metal ion to form a modified MOF precursor with one or more additional metals confined within the mesoporous material [MOF/MPM′].

3. The method of claim 2 , wherein one or more organic compounds in step (c)( 1 ) comprises a metal binding site for complexing a second metal ion.

4. The method of claim 1 , wherein the treating in step (d)(i), (d)(ii), or (d)(iii) causes greater than 90% of the carbon in the MOF to be released from the MOF/MPM.

5. The method of claim 1 , wherein the treating in step (d)(i), (d)(ii), or (d)(iii) causes 50%±10% of the carbon in the MOF to be released from the MOF/MPM.

6. The method of claim 1 , wherein the treating in step (d) is pyrolysis conditions under nitrogen or other inert as at a temperature of about 300° C. to about 1000° C.

7. The method of claim 1 , wherein the treating in step (d) is calcining conditions in the presence of oxygen calcining at a temperature of about 300° C. to about 600° C.

8. The method of claim 1 , wherein the treating in step (d) is with reductive conditions in an atmosphere containing hydrogen at a temperature of about 25° C. to about 300° C.

9. The method of claim 1 , wherein the confined nanocatalyst is monometallic.

10. The method of claim 1 , wherein the confined nanocatalyst is bimetallic.

11. The method of claim 1 , wherein the confined nanocatalyst has 3 or more metals.

12. The method of claim 1 , wherein the confined nanocatalyst within the mesoporous material has a diameter of less than 10 nm.

13. The method of claim 1 , wherein the mesoporous material is a mesoporous metal oxide, a mesoporous silica, a mesoporous carbon, a mesoporous polymer, a mesoporous silicoalumina (zeolite), a mesoporous organosilica, or a mesoporous aluminophosphate.

14. The method of claim 13 , wherein the mesoporous metal oxide is aluminum oxide, cerium oxide, titanium oxide, zirconium oxide, or magnesium oxide.

15. The method of claim 13 , wherein the mesoporous material is a mesoporous carbon.

16. The method of claim 1 , wherein the mesoporous material has a surface area of about 100 m 2 /g to about 1000 m 2 /g.

17. The method of claim 1 , wherein the metal ions in step (c) are selected from the group consisting of Al, Co, Fe, Ni, Ru, and Zr or combinations thereof.

18. The method of claim 1 , wherein the multidentate ligand for the MOF is selected from the group consisting of, terephthalate, benzene-1,3,5-tricarboxylate, 2,5-dioxibenzene dicarboxylate, biphenyl-4,4′-dicarboxylate, derivatives or combinations thereof.

19. The method of claim 1 , wherein the MOF is selected from HKUST-1, M 2 (dobpdc), MIL-100, MIL-101, MIL-53, MOF-74, NU-1000, PCN-222, PCN-224, UiO-66, UiO-67, ZIF-8, or ZIFs.

20. The method of claim 1 , wherein the mesoporous material is selected from the group consisting of, MCM-41, SBA-15, and or mesoporous silica.

21. The method of claim 1 , wherein the confined nanocatalyst confined within mesoporous material is further reacted with materials selected from the group consisting of polymers, organometallic ligand precursors, nitrogen-containing organic compounds, phosphorous-containing organic compounds, sulfur-containing organic compounds, boron-containing organic compounds, halide salts, organic halides, and metal atoms added via atomic layer deposition or chemical vapor deposition, under catalytic conditions.

22. A catalyst made by the method of claim 1 .

23. The catalyst of claim 22 , further comprising an added metal promotor.

24. A method of catalyzing a reaction selected from the group consisting of alkene ammoxidation reactions, alkene epoxidation, ammonia synthesis, carboxylation reactions, CO 2 methanation reactions, conversion of CO 2 to fuel, direct methanol synthesis from methane, dry-methane reforming, electrocatalytic ammonia oxidation, electrocatalytic oxygen reduction reactions, Fischer-Tropsch synthesis, hydro-/dehydrogenation of liquid organic hydrogen carriers, hydrotreating and hydroprocessing esterification reactions, methanol synthesis from syngas, reverse water-gas shift reactions, and water-gas shift reactions which comprises contacting reactants with the catalyst of claim 22 under catalytic conditions so to selectively convert the reactants to a desired product.

Assignees

• Res Triangle Inst

Inventors

• Luz Minguez Ignacio
• Soukri Mustapha
• Lail Marty
• Carpenter John R
• Parvathikar Sameer
• Carpenter Michael

Classifications

• B01J35/40

  characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77) · CPC title

• B01J35/19

  Catalysts containing parts with different compositions · CPC title

• B01J31/1691 Primary

  Coordination polymers, e.g. metal-organic frameworks [MOF] (preparation of metal complexes containing carboxylic acid moieties C07C51/418; MOF's per se C07F) · CPC title

• B01J35/77

  Compounds characterised by their crystallite size · CPC title

• B01J35/45

  Nanoparticles · CPC title