Ohhun
Kwon
a,
Kyeounghak
Kim
b,
Sangwook
Joo
a,
Hu Young
Jeong
c,
Jeeyoung
Shin
d,
Jeong Woo
Han
b,
Sivaprakash
Sengodan
*a and
Guntae
Kim
*a
aSchool of Energy and Chemical Engineering, Ulsan National Institute of Science and Technology (UNIST), Ulsan, 44919, Republic of Korea
bDepartment of Chemical Engineering, Pohang University of Science and Technology (POSTECH), Pohang, 37673, Republic of Korea
cUNIST Central Research Facilities, UNIST, Ulsan, 44919, Republic of Korea
dDivision of Mechanical Systems Engineering, Sookmyung Women's University, Seoul, 04310, Republic of Korea
First published on 16th July 2018
In situ exsolved nanoparticles on metal oxide materials have received much attention in catalysis due to their well socketed structure and high catalytic activity. Recently, the demand for active nanoparticles with multiple functionalities in catalysis has increased, so exsolutions of intermetallic nanoparticles could be an effective strategy to meet the requirements. Herein, for the first time, we report exsolved Co–Ni alloy nanoparticles and their Gibbs free energy of alloy formation in a PrBaMn1.7Co0.1Ni0.2O5+δ layered double perovskite. These exsolved alloy nanoparticles have a high catalytic performance for fuel oxidation in fuel cells and in the dry reforming of methane. Furthermore, we probed the mechanism of the alloy formation in the exsolution using density functional theory (DFT). The theoretical calculations reveal that the Gibbs free energy of the surface alloy formation (ΔGaggr_surface) is more favorable than that of the bulk alloy formation (ΔGaggr_bulk), indicating that Co and Ni are exsolved separately from the bulk, and then aggregate to form a Co–Ni alloy on the surface.
An exsolution, the in situ formation of catalytic nanoparticles on a perovskite surface in a reducing atmosphere, has attracted an increasing amount of attention as a way to prepare catalysts.9–11 Various catalytic transition metals can be incorporated at the B-sites of perovskite oxides in air synthesis processes and then exsolved from the parent perovskite under a reducing atmosphere.12 The exsolved nanoparticles are socketed on the perovskite surface, preventing agglomeration of the nanoparticles and enhancing the carbon coking tolerance.13 Although several perovskite electrode materials have been developed using the exsolution approach, most of the exsolution approaches have generally been performed to exsolve a single metal from a simple perovskite lattice. In addition, comprehensive characterization of exsolutions of intermetallic compounds (referred to as alloys) has not been clearly reported, and has only focused on simple perovskites.14,15 Indeed, the mechanism of alloy formation for the entire perovskite family is still an open question in terms of experimental observations and theoretical calculations.
The goal of this work is to respond to this lack of information and to resolve this gap through detailed investigation of catalytic alloy nanoparticles exsolved from a layered double perovskite. Also, there is a need for the characterization of the phase stability, the phase transition at atomic levels, and alloy formation energies, which is essential for understanding the various physical and chemical properties of alloy nanoparticles. Previously, we demonstrated the exsolution trends of transition metals (Co, Ni, Fe, and Mn) in a PrBaMn2O5+δ (PBMO) layered double perovskite oxide.16 Among the transition metals, we selected Co and Ni for the alloy system because Co and Ni have high co-segregation energies (Co = −0.55 eV and Ni = −0.50 eV) for exsolution compared to Fe (−0.15 eV) and Mn (−0.47 eV). In the process of alloy exsolution, the Gibbs free energies of alloy formation at the surface and in the bulk were found to be −0.01 eV and +0.02 eV, respectively, indicating that alloy formation is more favorable at the surface than in the bulk. Combining the theoretical calculations and experimental observations, we found that Co and Ni are exsolved separately from the bulk, and then aggregate to form a Co–Ni alloy at the surface. The Co–Ni alloy nanoparticles decorated on the PrBaMn1.7Co0.1Ni0.2O5+δ (PBMCNO) oxide surface show a higher catalytic activity towards the dry reforming of methane, fuel oxidation in fuel cells (0.97 W cm−2 at 800 °C), and stability (>500 h at 800 °C).
CH4 + CO2 ↔ 2CO + 2H2 (ΔH0298 K = 247 kJ mol−1) |
To obtain further information on the exsolved nanoparticles, high-resolution transmission electron microscopy (HR-TEM) and energy dispersive X-ray spectroscopy (EDS) were conducted. The EDS results shows that the Co and Ni elements coexist on the surface of PBMCNO (Fig. 2a), implying that Co–Ni alloy nanoparticles are exsolved in a reducing atmosphere. In the bright-field and high-resolution TEM image of PBMCNO (Fig. 2b and c), it is observed that some nanoparticles of 40 nm in diameter are socketed on the PBMCNO surface. The lattice spacing between the planes of the exsolved nanoparticles is 0.127 nm (Fig. 2d), and this value is consistent with the lattice constant of the (220) planes of a Co–Ni metal alloy. Meanwhile, in an attempt to produce a Co–Fe alloy in a Co and Fe co-doped PBMO layered double perovskite, only a Co exsolution, not an Fe or Co–Fe exsolution, was observed (Fig. S2†). This is in agreement with our previous study on exsolution trends and is due to the low co-segregation energy of Fe in the layered double perovskite system. In sharp contrast, Fe metal alloys can be easily exsolved in simple perovskite oxides (ABO3) such as Sr0.95(Ti0.3Fe0.63Ni0.07)O3−δ and La0.6Sr0.4Fe0.8Ni0.2O3−δ under the same experimental conditions, which is quite different from this work.14,22
Generally, most metals are immiscible with each other over a wide temperature range, and thus high temperature metallurgical methods are required to form bimetallic alloys.23 However, catalytic alloy nanoparticles prepared by conventional methods tend to agglomerate at high temperatures (above 600 °C), which increases the particle size and reduces the surface area. From the TEM results, we can identify that exsolution preparation is an efficient method to overcome the problems associated with the agglomeration of conventional nanocatalyst in metal/metal oxide systems at high temperature, because exsolved nanoparticles have a high tolerance to agglomeration due to their special surface morphology in which nanoparticles are well anchored and socketed.13
To form exsolved Co–Ni alloy nanoparticles, it can be reasonably thought that both the aggregation of two doped B-metals and their segregation toward the surface should occur simultaneously. However, the detailed mechanism for such phenomena is quantitatively unclear. To obtain a better understanding of the mechanism, two possible mechanisms, “Bulk alloy formation” and “Surface alloy formation”, were investigated, as shown in Fig. 3a and b. Here, we focused on the thermodynamic tendency to aggregate and segregate a pair of metals. Bulk alloy (Co–Ov–Ni) formation starts with the aggregation of Co–Ov–Co and Ni–Ov–Ni in the bulk of PBMCNO by locating each B metal into the nearest neighbor site with the sharing of an oxygen vacancy. Then, Co–Ov–Ni segregates toward the surface, which is essentially equivalent to the definition of co-segregation used in our previous work.16 On the other hand, surface alloy (Co–Ov–Ni) formation starts with the independent segregation of Co–Ov–Co and Ni–Ov–Ni toward the surface. It is then followed by the aggregation of Co–Ov–Co and Ni–Ov–Ni to form a nearest neighbored Co–Ov–Ni on the surface of PBMCNO. Although the initial and final states are the same for both pathways, the required energies for each step are quite different. The Gibbs energies of aggregation (ΔGaggr) of Co–Ov–Ni at the surface (surface alloy formation) and in the bulk (bulk alloy formation) are −0.01 and 0.02 eV, respectively, indicating that it is more favorable for Co and Ni to aggregate at the surface than in the bulk. Meanwhile, the Gibbs energies for co-segregation (ΔGseg) of Co, Ni, and Co–Ni with an oxygen vacancy are exothermic (−0.53, −0.39, and −0.48 eV, respectively), which is thermodynamically favorable for all cases. Thus, we can conclude that alloy formation is much harder than metal segregation, and “surface alloy formation” is preferred to “bulk alloy formation”, with no apparent thermodynamic energy requirements. To confirm the progress of alloy exsolution experimentally, a Pr0.5Ba0.5Mn0.85Co0.05Ni0.1O3 sample prepared in air was examined by in situ PXRD in humidified H2 (3% H2O) while elevating the temperature. As shown in Fig. 3c, the peaks of metallic cobalt located at 44.25° (JCPDS card # 15-0806) and metallic nickel located at 44.7° (JCPDS card # 04-0850) were observed at 700 °C, and then the two peaks merged to form a single peak at temperatures above 750 °C. Therefore, these in situ PXRD results confirm the mechanism of the surface alloy formation.
For the stability of exsolved nanoparticles as a metallic phase after co-segregation of the B-site metal and oxygen vacancies, a preference of oxygen vacancy formation near the segregated B-site metals is necessary.24 Therefore, we examined the oxygen vacancy formation energy (Evf) at various surface lattice O sites. Our results show that the most stable sites of oxygen vacancies are located between two B-metal atoms such as in Co–Ov–Co, Ni–Ov–Ni, and Co–Ov–Ni at the surface and in the bulk (Fig. S3†). In addition, oxygen vacancies are more easily formed at the surface (Evf = 2.97, 2.27, 2.68, and 2.23 eV for PBMO, PrBaMn1.7Co0.3O5+δ (PBMCO), PrBaMn1.7Ni0.3O5+δ (PBMNO), and PBMCNO, respectively) than in the bulk (Evf = 3.72, 2.71, 2.99, and 2.85 eV for PBMO, PBMCO, PBMNO, and PBMCNO, respectively). In particular, PBMCNO shows the lowest oxygen vacancy formation energy at the surface, implying that Co–Ni aggregation significantly stabilizes an oxygen vacancy near the surface. The oxygen vacancies are easily formed near Co–Ni aggregates that can be easily transformed to a metallic phase of Co–Ni alloy nanoparticles. In addition, the aggregation energy of Co–Ni at the surface is 0.23 eV in the absence of an oxygen vacancy, which is less favorable than that of Co–Ni at the surface (−0.01 eV) in the presence of an oxygen vacancy (Co–Ov–Ni). This supports that surface oxygen vacancies stabilize the formation of a Co–Ni alloy. In this regard, similar results have been reported where the introduction of surface oxygen vacancies significantly enhances the B-metal exsolution, as well as stabilizing the surface by changing the hybridized states of the segregated atoms.16,24,25 Consequently, on the PBMCNO surface, oxygen vacancies are more likely to accumulate near the segregated Co–Ni due to a relatively lower Evf (2.23 eV) value than that of the host Mn (2.97 eV), which results in both the facile formation and stabilization of metallic exsolved alloy nanoparticles.
Furthermore, the formation energies of Co–Ni alloys were also investigated to determine whether the formation of alloys depends on intrinsic cohesion characteristics between Co and Ni (Fig. 3d). We examined the alloy formation of Co3Ni, CoNi, and CoNi3 in their most stable crystalline states of FCC, BCC, and FCC with equilibrium lattice constants of 3.500, 2.802, and 3.520 Å, respectively.26,27 The Gibbs energies of alloy formation for Co3Ni, CoNi, and CoNi3 are all positive numbers (0.10, 0.41, and 0.18 eV, respectively), which means that Co–Ni alloy formation without PBMO is thermodynamically unfavorable compared to both the surface and bulk alloy pathways in PBMCNO. Therefore, to induce the formation of thermodynamically favorable alloy nanoparticles, it is very important to find valuable support materials, such as PBMO.
Fig. 4a shows the equilibrium oxygen non-stoichiometry of PBMCNO as a function of p(O2) at temperatures of 650–750 °C. The measured δ increases upon an increase in the oxygen partial pressure. This behavior is similar to the relationship between the oxygen content and oxygen partial pressure of other layered double perovskites.1,20,21 Oxygen vacancies formed under reducing atmospheres are accompanied by the reduction of Mn4+ to Mn3+, and Mn3+ to Mn2+ ions. The interaction between the defect species and the oxygen in PBMCNO can be expressed as follows:
![]() | (1) |
![]() | (2) |
![]() | (3) |
The ΔH and ΔS values are calculated from the oxygen nonstoichiometric plot using the above equations (Fig. 4b). From the calculation results, ΔH was found to range between −301 to −247 kJ mol−1 and ΔS was found to range between −109 to −118 J mol−1 K−1. The calculated partial molar enthalpies suggest that the energy required to lift the oxygen from the lattice becomes larger with decreasing δ, and the partial molar entropies suggest that the probability of the oxygen vacancy formation reaction is almost constant as the reduction proceeds.
The electrochemical performance of single cells was characterized using an La0.9Sr0.1Ga0.8Mg0.2O3−δ (LSGM) electrolyte-supported cell in ambient air as the oxidant and humidified H2 (3% H2O) as the fuel with the compositions (PBMO and PBMCNO)/La0.4Ce0.6O2−δ (LDC)/LSGM/NdBa0.5Sr0.5Co1.5Fe0.5O5−δ–Ce0.9Gd0.1O2−δ. The impedance spectra and I–V curves of the single cells at 800 °C are presented in Fig. S4† and 4c, respectively. The non-ohmic resistance of PBMCNO (0.170 Ω cm2) is lower than that of PBMO (0.302 Ω cm2) and the maximum power density of PBMCNO (0.97 W cm−2) is higher than that of PBMO (0.50 W cm−2). The exsolved Co–Ni alloy nanoparticles act as a catalyst for fuel oxidation, decreasing the anode polarization resistance.28–30 To exemplify the remarkable improvement in the catalytic activity of the Co–Ni alloy exsolved from PBMCNO, the dry reforming of methane using a fixed-bed reactor was evaluated at various temperatures (800–900 °C) with a fixed molar ratio of CH4/CO2 1:
1. As shown in Fig. 4d, the CO2 conversion and CO selectivity increase upon an increase in the temperature for both PBMO and PBMCNO. The CO2 conversion of PBMCNO is almost four times higher than that of PBMO, showing that the exsolved Co–Ni alloy nanoparticles on the surface enhance the catalytic capability of hydrocarbon oxidation. Furthermore, no significant degradation in the carbon coking was observed under a constant voltage of 0.4 V at 800 °C in CH4 for more than 500 h (Fig. S5†). As shown in the SEM images (Fig. S6†), no carbon depositions are observed in the PBMCNO anode, indicating excellent carbon coking tolerance in the hydrocarbon fuel.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/c8ta05105d |
This journal is © The Royal Society of Chemistry 2018 |