催化学报  2018, Vol. 39 Issue (7): 1228-1239   PDF    
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本文作者相关文章
Zeshu Zhang
Jingwei Li
Ting Yi
Liwei Sun
Yibo Zhang
Xuefeng Hu
Wenhao Cui
Xiangguang Yang
Surface density of synthetically tuned spinel oxides of Co3+ and Ni3+ with enhanced catalytic activity for methane oxidation
Zeshu Zhanga,b,c, Jingwei Lia,b, Ting Yia,b,d, Liwei Suna,b,c, Yibo Zhanga,b, Xuefeng Hua,b,c, Wenhao Cuid, Xiangguang Yanga,b     
a. State Key Laboratory of Rare Earth Resource Utilization, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022, Jilin, China;
b. Jilin Province Key Laboratory of Green Chemistry and Process, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022, Jilin, China;
c. University of Science and Technology of China, Hefei 230026, Anhui, China;
d. University of Chinese Academy of Sciences, Beijing 100049, China
* Corresponding author. Yibo Zhang, Tel: +86-431-85262687; E-mail: yibozhang@ciac.ac.cn;
Xiangguang Yang, Tel: +86-431-85262228; E-mail: xgyang@ciac.ac.cn
Foundation item: This work was supported by the National Key Research and Development Program of China (2016YFC0204301)
Abstract: Spinel oxides containing Co and Ni are a promising substitute as a noble metal catalyst for methane combustion. Achieving a complete oxidation of methane under 400℃ remains challenging, and whether Ni3+ or Co3+ is the active center for the catalytic combustion of methane is a controversial issue. Therefore, we designed a series of spinel oxide catalysts by exposing different amounts of Ni3+ and Co3+ deposited on the surface by hydrothermal and co-precipitation methods in order to study the influence of high oxidation state (Ni3+ and Co3+) on surface and catalytic activity. The catalytic performance increased almost linearly with increasing Ni3+ + Co3+ on the surface of the catalyst. Thus, we are convinced that Ni3+ and Co3+ both act as active centers. The amount of Ni3+ + Co3+ on a hydrothermal 60 h NiCo2O4 nanosheet surface is the highest, and reveals the best catalytic performance with T50 (50% methane conversion) at about 280℃. 10 vol% H2O added to the system has little impact on activity, especially at high space velocities due to the long hydrothermal time with less absorbed oxygen species and crystal defects. Overall, these results help clarify methane activation mechanisms and aid the development of more efficient low-cost catalysts.
© 2018, Dalian Institute of Chemical Physics, Chinese Academy of Sciences.
Published by Elsevier B.V. All rights reserved.
Key words: Spinel oxides    Catalytic combustion of methane    Porous nanosheets    Active center    Hydrothermal stability    
调控尖晶石Co3+和Ni3+表面密度来提高催化甲烷氧化活性
张泽树a,b,c, 李经纬a,b, 易婷a,b,d, 孙立伟a,b,c, 张一波a,b, 胡学风a,b,c, 崔文浩d, 杨向光a,b     
a. 中国科学院长春应用化学研究所, 稀土资源与利用国家重点实验室, 吉林长春 130022;
b. 中国科学院长春应用化学研究所, 吉林省绿色化学与过程重点实验室, 吉林长春 130022;
c. 中国科学技术大学, 安徽合肥 230026;
d. 中国科学院大学, 北京 100049
摘要:天然气资源丰富、价格低廉,因而被广泛用作燃料.天然气的主要成分是甲烷,未燃烧完的甲烷所产生的温室效应是二氧化碳的21倍,所带来的环境问题引起越来越多的研究者关注.但甲烷是最稳定的非极性有机小分子,C-H键能高达434kJ/mol,大多数催化剂很难将其在很低的温度在完全转化.C-H键的活化解离是催化甲烷燃烧最关键的一步,而活化C-H键方式主要有两大类:(1)均裂活化机制,一般用在贵金属催化剂上;(2)异裂活化机制,往往发生在过渡金属氧化物上.比较而言,贵金属催化剂,尤其是Pd,往往具有更优异的低温催化活性,但价格昂贵,从而限制了其广泛使用.因此,开发更加高效的非贵金属催化剂用于废气中未转化的甲烷完全氧化是亟待解决的问题. 含有Co和Ni的尖晶石氧化物具有良好的催化甲烷燃烧活性,有望代替贵金属催化剂,但要求在低于400℃完全转化,仍具有一定挑战.另一方面,Ni3+和Co3+哪个是活性中心,还具有一定争议.因此,我们通过水热法和共沉淀法合成一系列表面暴露不同数目的Ni3+和Co3+来探究表面高氧化态Co和Ni跟活性之间的关系. XRD和TEM结果表明,相比于水热法合成的Co3O4,水热法合成的NiCo2O4发生明显的晶格收缩现象,这是由于在尖晶石体相中大量小半径Ni3+(0.053nm)取代了大半径Co3+(0.055nm)所致.同时还发现,水热合成的尖晶石具有多孔纳米片层结构,相比于共沉淀法合成的尖晶石具有更大的比表面积,催化活性也更高.XPS分析发现,催化甲烷燃烧的活性随着表面(Ni3++Co3+)含量增加而提高.结合文献分析和本文的实验结果推测,表面的Ni3+和Co3+都可作为解离C-H键的活性中心.水热60小时合成的NiCo2O4纳米片表面Ni3++Co3+的数量最多,所以具有最优异的催化性能,大约在280℃甲烷转化50%.当加入10%(体积比)的水,在高空速工况下对催化活性影响不大,主要是因为长时间水热合成的尖晶石表面缺陷少,对水的吸附弱,这可通过O 1s图谱得到印证.总之,这些研究结果能够给甲烷活化和开发更加高效和低成本催化剂一些启示.
关键词尖晶石氧化物    催化甲烷燃烧    多孔纳米片    活性中心    水热稳定性    

1 Introduction

Natural gas, which contains mostly methane, is abundant in our planet and is widely used in power generation and other heating applications because of its low cost [1-3]. However, unburned CH4 is a more potent greenhouse gas because its global warming potential is twenty times higher than that of CO2; CH4 has become a serious environmental problem that has drawn the attention of many researchers [4-7]. Therefore, the development of catalysts for completely oxidizing unconverted CH4 at low temperatures has held great promise in the pursuit of highly efficient engine combustion and turbine-based energy devices, prompting the urgent need for low-cost, efficient, and robust catalytic emission control devices [8].

However, it is difficult to initiate oxidation of CH4 at low temperatures (less than 300 ℃) because CH4 is a typical nonpolar molecule, and the C-H bond in CH4 has the highest bond energy (434 kJ/mol) among all organic compounds [7, 9]. The activation of a C-H bond is the most critical step for the catalytic combustion of methane (CCM). The activation mechanism of the C-H bond can be summarized as follows: (1) homolytic activation mechanism over precious-metal-based catalysts and (2) heterolytic activation mechanism on oxides [10, 11]. Generally speaking, noble metals [12-16] (e.g., Pt, Pd), especially Pd-based catalysts [17, 18], can exhibit outstanding catalytic performance and complete oxidation of methane at low temperatures. In order to improve the catalytic efficiency of noble metals, three-dimensionally ordered micro/mesoporous (3-DOM) supported high dispersion noble metal nanoparticles have been reported by Dai' s group [19] and Li's group [20]. However, high costs have limited their wide application. Transition metal elements generally have multiple valence states and easily form a redox cycle between the high and low oxidation states, and lattice oxygen can be released and restored [21]. For example, LaMnO3 with mild citric acid etching showed good catalytic activity due to higher surface area, abundant vacancies, higher surface Mn4+/Mn3+ ratio, and more active oxygen species [22]. Li's group obtained Co3O4 nanosheets with exposed high index (112) crystal planes, which showed a high catalytic performance for CCM because the unusually high index crystal planes were more reactive than common planes such as (001) and (011) [23]. Fe-substituted hexaaluminates with superior thermal stability synthesized by a two-step strategy were shown to enhance surface area and show high catalytic activity [24, 25]. Other metals oxides, such as Cu, Cr, In, and Sn oxides, have been used as catalysts in the past decades [21, 26, 27]. However, the catalytic activity of those oxides for complete oxidation of CH4 above 450 ℃ occurred at relatively low gas hour space velocity (GHSV). Therefore, efforts to develop non-noble metal oxides catalysts for low temperature methane oxidation become more urgent.

Spinel oxides with catalytic activity even higher than the precious-metal-based catalysts are promising candidates for CCM at low temperature, although relatively little research has been conducted on this catalytic material [21]. Tao's group first reported that NiCo2O4 spinel oxides exhibited higher catalytic activity at relatively low temperature. This results from the integration of Ni3+, on which methane dissociates to methyl and couples with the surface lattice oxygen atoms to form -CH3O, and CO2 forms after dehydrogenation and oxidation [28]. McEwen et al. [29] also presented some evidence that a high oxidation state of Ni is more effective for the first C-H cleavage in methane using both experiments and density functional theory (DFT) calculations. In containing the Co spinel structure, however, most researchers agreed that Co3+ association with catalytic activity was essential [23, 30]. Lim et al. [3, 31] controlled the Co to Ni ratio and used mesoporous silica KIT-6 as the hard template to synthesize ordered mesoporous NiCo2O4, which showed higher activity due to the high amount of Co3+ and surface oxygen species on the surface. Furthermore, others also reported methane more easily dissociates to methyl on Co cations compared to Ni cations based on results from DFT calculations [8]. Therefore, the relative catalytic activities of Ni3+ and Co3+ is still a controversial issue.

In order to investigate the relationship between catalytic performance and number of high state valence cations, we designed a series of spinel oxides catalysts by exposing different amounts of Ni3+ and Co3+ deposited on the surface by hydrothermal method and co-precipitation method. We also focused on preparation methods and the relationship between structure and catalytic properties of spinel oxides [32, 33]. Through hydrothermal synthesis, we successfully obtained multiporous spinel oxide nanosheets with high surface area. There are few reports of complete methane oxidation under 350 ℃ using porous spinel oxides nanosheets. At the same time, these novel porous nanosheets may also be utilized in other systems, such as an electrode material in pseudo capacitors and in oxygen evolution reduction (OER) [33-35].

2 Experimental
2.1 Catalyst preparation

All the chemicals were of analytical grade and used as received without further purification.

Co(NO3)2·6H2O (10 mmol, 2.91 g), Ni(NO3)2·6H2O (5 mmol, 1.45 g) and urea (100 mmol, 6 g) were physically mixed and completely dissolved in 70 mL deionized water for hydrothermal synthesis of NiCo2O4. The obtained solutions were transferred into 100 mL autoclaves with a Teflon liner at 120 ℃ and kept for 10, 20, 36, 60, and 72 h. The resulting product was centrifuged and washed with deionized water 3 times, was then dried overnight at room temperature, and was finally calcined in air at 350 ℃ for 2 h. For synthesis of Co3O4, Co(NO3)2·6H2O (10 mmol, 2.91 g) and urea (100 mmol, 6 g) were dissolved in 70 mL deionized water. The rest of the synthetic procedure was similar to that used for synthesis of the NiCo2O4.

Co(NO3)2·6H2O(10 mmol, 2.91 g) and Ni(NO3)2·6H2O (5 mmol, 1.45 g) were dissolved in 20 ml deionized water under magnetic stirring for 1 h to synthesize NiCo2O4 by co-deposition precipitation. Then 50 mL NaOH (1 mol/L) was added to the solution under continuous stirring. The precipitate was collected by centrifuging and washing 3 times, was dried overnight at room temperature, and was finally calcined in air at 350 ℃ for 2 h. For synthesis of Co3O4, the above procedure was used without the added Ni(NO3)2·6H2O.

2.2 Catalyst characterization

The surface areas of the samples were determined from N2 adsorption isotherms at 197 ℃ with the Brunauer-Emmett-Teller (BET) method using a Micromeritics ASAP 2010 analyzer. Prior to the measurement, the samples were outgassed at 300 ℃ for 2 h under a reduced pressure of 10-5 Torr.

The crystal structure of the catalysts was examined using powder X-ray diffraction (XRD). XRD analysis was carried out on a Bruker D8 Advance with Cu Kα radiation source (λ = 1.5406 Å). A scan rate of 10°/min from 10° to 80° allowed us to obtain the XRD pattern. The crystal structure parameters of the samples were calculated using the MDI Jade 6.5.

The hydrogen temperature-programmed reduction (H2-TPR) experiments were performed on a Micromeritics AutoChem 2920 instrument. Prior to reduction, the samples were pretreated at 300 ℃ for 1 h in an argon flow of 30 mL/min and then cooled down to room temperature. They were then reduced with 10% H2/Ar until the temperature reached 500 ℃ at a rate of 3 ℃/min.

X-ray photoelectron spectroscopy (XPS) was performed using a VG Thermo ESCALAB 250 spectrometer. The instrument uses a focused monochromatic Al Kα X-ray (1486.7 eV) source operated at 120 W and outputs a 500 μm-diameter beam. The binding energy scale was calibrated using the known standard carbon C 1s line at 284.6 eV. Deconvolution of the XPS peak was performed with XPSPEAK.

Transmission electron microscopy (TEM) was performed using an FEI Tecnai G2 with an accelerating voltage of 200 kV. The lattice spacing and lattice planes of the samples were analyzed using DigitalMicrograph.

2.3 Catalytic activity measurements

Methane combustion catalytic activity was measured using a conventional quartz tubular reactor (i.d., 6 mm; length, 300 mm) at atmospheric pressure. The reagent gas mixture (1 %CH4/air vol%) was flowed over 100 mg catalysts at a gas hourly space velocity (GHSV) of 24000 mL g-1h-1. The reaction of methane combustion was stabilized for 20 min, and activity data were obtained at steady state conditions from 200 ℃ to 500 ℃, with temperature increased in increments of 25 ℃. The reactants and reaction products were analyzed by an on-line gas chromatograph. Kinetic studies of complete oxidation of methane were conducted in the kinetics control regime (conversion < 15%). The CCM reaction rates were calculated using Eq. (1):

(1)

Xf is the feed concentration of CH4 and G is the gas flow rate (mL/h). C is the CH4 conversion and Wcat is the weight of the spinel oxides catalysts (g). The number of (Co3+ + Ni3+) atoms of surface were calculated using Eq. (2):

(2)

Q is the (Ni3+ + Co3+) to (Ni + Co + O) ratio on the surface obtained from XPS, ABET is the surface area (m2/g) determined from the BET method, and K is the number of atoms per unit area (atom/m2), which we can estimate from the solid surface model (see Figs. S1 and S2 in supporting information)

3 Results and discussion
3.1 Structural properties of the catalysts

Fig. 1 shows the XRD patterns of the samples synthesized at different hydrothermal times. Obviously, the five patterns indicate pure NiCo2O4 because all the diffraction peaks can be indexed to NiCo2O4 and match well with a cubic crystal structure (JCPDS No. 73-1702). However, the differences, such as in lattice parameters and crystallite sizes, obtained from the Jade refinement of the XRD patterns are listed in Table 1. The lattice parameter decreased with hydrothermal time increasing up to in 60 h (8.093 Å). Until the hydrothermal time up to 72 h, the lattice parameter increased to 8.104 Å. The lattice parameter associated with ionic size and ionic radius of Co 3+ (0.055 nm) is larger than that of Ni3+ (0.053 nm), but is smaller than Ni2+ (0.069 nm) [3, 36]. Previous studies show that Ni ions occupy octahedral sites of the spinel structure, while Co ions occupy both tetrahedral and octahedral sites [37, 38], and we can reasonably infer that the large size of Ni2+ occupy octahedral sites. Thus, there is a very low amount of Ni3+ in the spinel structure at the beginning of the hydrothermal process. The amount of Ni3+ in the lattice cell increases with hydrothermal time, and the number of Ni3+ is maximum at 60 h hydrothermal time. The XRD patterns of the of NiCo2O4 and Co3O4 prepared by hydrothermal method and the co-precipitation method are presented in Fig. 2, and the lattice parameter and crystalline size also listed in Table 1. For 60 h hydrothermal NiCo2O4, a slight shift in the diffraction peak toward higher angles is observed in comparison to 60 h hydrothermal Co3O4. This result matched well with the spinel structure of Co3O4 (JCPDS No. 80-1542), resulting in smaller lattice parameter (8.093 Å) than that of 60 h hydrothermal Co3O4 (8.110 Å). Some Ni3+ ions insert themselves into the Co3O4 spinel structure, leading to a decrease in the lattice parameter. For co-precipitation of NiCo2O4, however, the diffraction peak shifted towards low angles compared to co-precipitated Co3O4, which matched with another spinel structure of Co3O4 (JCPDS 71-0816) with a larger lattice parameter (8.071 Å) than that of co-precipitated Co3O4 (8.064 Å). The reason is that large Ni2+ ions occupy the octahedral sites in the Co3O4 spinel structure. It is worthy to note that co-precipitation synthesized spinel oxides have relatively small crystalline cells due to the large number of defects in the crystalline cell. The crystal formed by the hydrothermal method tends to crystallize better and form fewer defects [39].

Fig. 1. XRD patterns of NiCo2O4 samples formed after different hydrothermal times: (1) 72 h, (2) 60 h, (3) 36 h, (4) 20 h, and (5) 10 h.
Table 1
Lattice parameter (a) and crystalline size (D) of catalysts calculated by fitting the XRD patterns using the Jade program.
Fig. 2. XRD patterns of the spinel oxides crystals formed by 60 h hydrothermal and co-precipitation method.

Obviously, the TEM pictures shown in Fig. 3, also demonstrated that 60 h hydrothermal spinel oxides had relatively smaller particles than co-precipitation spinel oxides. The crystalline sizes of 60 h hydrothermal NiCo2O4 and 60 h hydrothermal Co3O4 almost have the same about of 10-20 nm. There is a good correlation between crystalline size of the hydrothermal spinel oxide samples calculated by XRD and TEM. Generally speaking, the (220) interplanar lattice spacing in the NiCo2O4 spinel structure (JCPDS No. 73-1702) is 0.287 nm and (311) is 0.244 nm. However, lattice fringes with an interplanar lattice spacing of 0.281 nm corresponding to the (220) atomic planes and 0.238 nm corresponding to the (311) atomic planes were observed in HRTEM image (Fig. 3(b)), and all the lattice fringe spacings of the 60 h hydrothermal NiCo2O4 decrease. One possible cause is that the partial Co3+ ions are replaced by smaller Ni3+ ions. This indicates consistency with lattice contraction, which leads to a decrease in the lattice parameter by the calculated XRD results. However, there is no obvious change in the lattice fringe spacing of the 60 h hydrothermal Co3O4. Moreover, the selected area fast Fourier transform (FFT) confirms that 60 h hydrothermal NiCo2O4 and 60 h hydrothermal Co3O4 consist of the single-crystalline particles (insert of Fig. 3(b) and (d)). The angle labeled in the FFT pattern is 65°, which is in agreement with the theoretical angle between the (220) and (311) planes. The set of diffraction spots can be indexed as the (114), which also indicated dominant exposed planes of 60 h hydrothermal NiCo2O4 are (114). Meanwhile, the dominant exposed planes of the Co3O4 nanosheets are (112), which is consistent with Li's results [23]. From the above analysis of the exposed planes, we can build up a solid surface model (Fig. S1 and S2) with XPS and H2-TPR results to understand the correlation between structure and catalytic activity.

Fig. 3. TEM, HRTEM and FFT (insert) images of 60 h hydrothermal NiCo2O4 (a, b), 60 h hydrothermal Co3O4 (c, d), co-precipitated NiCo2O4 (e) and Co3O4 (f).

Furthermore, the morphology of samples is clearly visible in the TEM images. Hydrothermal synthesis of spinel oxide nanosheets occurs by assembling by a large number of small particles, resulting in a disordered mesoporous structure, while co-precipitated samples have no definite morphology. SEM images of the 60 h hydrothermal NiCo2O4 (Fig. S3(a)) and Co3O4 (Fig. S3(b)) samples further confirm their sheet-shaped structures. Generally speaking, the nanosheet has a larger surface area than other nanoshapes. The BET surface area of the samples are summarized in Table 2. Obviously, the hydrothermal samples have larger surface area than the co-precipitated sample, and 60 h hydrothermal NiCo2O4 catalysts have the highest surface area among all samples.

Table 2
Summary of the determination and quantitative analysis of surface Co and Ni from XPS results.
3.2 Redox properties of the catalysts

To investigate the reducibility of the Ni and Co species in the spinel oxides catalysts, we performed H2-TPR measurements at slow heating rate 3 ℃/min. Through slow heating, the Ni3+ and Co3+ peaks can be obviously distinguished in the H2-TPR profiles. As shown in Fig. 4(c), there are two reduction peaks both in the 60 h hydrothermal and co-precipitated Co3O4, which correspond to stepwise reduction of Co3O4. The first peak position at 224 ℃ is related to the Co3+ to Co2+ transition, and the second is attributed to full reduction of Co2+ to Co0. There are a few peaks in the NiCo2O4 profile (Fig. 4(a)), which is different from others previous studies [40, 41]. In order to verify the first peak in the 60 h hydrothermal NiCo2O4 corresponding to Ni3+ reduction, we compared with NiO, where calcination at low temperatures (< 350 ℃) can form a few Ni3+ on the surface [42]. It is noteworthy that there are two peaks in the case of NiO. The large reduction peak at 224 ℃ overlaps with the Co3+ reduction peak, and a smaller peak at 169 ℃ is due to a small number of Ni3+ on the surface that reduce quickly compared to NiCo2O4. Thus, we confirmed that the first peak is attributed to the reduction of Ni3+ to Ni2+. Obviously, the reduction peak intensity at 177 ℃ for 60 h hydrothermal NiCo2O4 is greater than the intensity for co-precipitated NiCo2O4. This indicates that 60 h hydrothermal NiCo2O4 possesses a greater quantity of Ni3+. H2-TPR spectra from hydrothermal NiCo2O4 samples are shown in Fig. S4. The results indicate that the 60 h hydrothermal NiCo2O4 contains the largest amount of Co2+ among all samples, and it has the largest amount of Ni3+. This agrees with the XRD and TEM results. In co-precipitated NiCo2O4 and Co3O4, the first reduction peak occurs earlier because there are a larger number of adsorbed oxygen species on the solid surface, resulting in very easy reduction, which is consistent with the observed O 1s XPS spectra.

Fig. 4. H2-TPR profile of spinel oxide samples and first peak analysis. (a) NiCo2O4, (b) 60 h hydrothermal spinel oxides and NiO, (c) Co3O4, (d) first peak position and initial point.

We performed XPS to derive insights into the adsorbed species and metal oxidation states of catalysts, which is an effective technique to gain surface information [43]. Fig. 5(c) illustrates the XPS results from Ni 2p3/2 for 60 h hydrothermal NiCo2O4 and co-precipitated NiCo2O4 (other hydrothermal samples are shown in Fig. S5). The coexistence of Ni(Ⅱ) and Ni(Ⅲ) in 60 h hydrothermal and co-precipitated NiCo2O4 catalysts is indicated by the shoulder observed on the main peak at 853.6 eV, which is assigned to the Ni(Ⅱ) species. The higher binding energy (BE) peak at 861.0 eV and its shakeup satellites are due to overlapping Ni(Ⅱ) and Ni(Ⅲ) satellites. The surface Ni3+/(Ni + Co + O) molar ratio in 60 h hydrothermal NiCo2O4 is approximately 8.22%, which is the largest among all samples. The lowest ratio occurs in the co-precipitated NiCo2O4 with 3.82% (Table 2). This result agrees well with the H2-TPR results. Co 2p XPS spectra of four spinel oxide samples are shown in Fig. 5(a). One should note that the Co3+/(Ni + Co + O) ratio for 60 h hydrothermal Co3O4 is the highest in all samples, and the value in the co-precipitated NiCo2O4 sample is higher than in the co-precipitated Co3O4 sample, which agrees well with results reported by others [31].

Fig. 5. XPS spectra of spinel oxide samples. (a) Co 2p, (b) O 1s, (c) Ni 2p3/2, (d) summary of determination and quantitative analysis for surface O from the O 1s XPS.

In the O 1s XPS spectra (Fig. 5(b)), the broad peaks can be decomposed into four major components by deconvolution. These peaks correspond to lattice oxygen, a surface OH group, defective oxygen, and adsorbed moisture. Quantitative analysis in Fig. 5(d) reveals the lattice oxygen percentage obviously increases for hydrothermal synthesis of spinel oxides compared to the co-precipitation method, and co-precipitated spinel oxides have more adsorbed oxygen species on the surface. Generally speaking, surface oxygen is very important in catalytic oxidation because surface oxygen is more reactive than gaseous oxygen [44]. As is well known, the adsorbed oxygen species increase with increasing oxygen pressure. Therefore, in order to investigate the effect of adsorbed oxygen species on the catalytic reaction, we measured the CH4 reaction rate under different oxygen pressures, as shown in Fig. 6(a). It suggests that the reaction rate is unaffected by O2 pressure when O2 pressure is greater than 15 kPa, which means adsorbed oxygen species are not crucial for the whole catalytic system under catalytic reaction conditions (O2 pressure about 20 kPa). Moreover, the CH4 reaction rate is proportional to the CH4 pressure shown in Fig. 6(b), which is consistent with previous findings that activation and dissociation of the C-H bond is the rate-limiting step [28, 44].

Fig. 6. CH4 reaction rates as a function of O2 pressure (a) and CH4 pressure (b) for 60 h hydrothermal NiCo2O4 at 250 ℃. The catalyst 20 mg + quartz 500 mg, gas flow rate 100 mL/min, space velocity 300, 000 mL h-1 g-1. The CH4 pressure is fixed at 3 kPa when changing the O2 pressure. The O2 pressure is fixed at 10 kPa when changing the CH4 pressure.
3.3 Catalytic activity for methane oxidation

Fig. 7(a) shows the light-off curves for methane combustion in samples with various hydrothermal synthesis times. We can conclude that the catalytic activity improves as hydrothermal time increases, and 60h hydrothermal synthesis time resulted in 100% methane conversion at 340 ℃. From the catalytic activity and XRD results, we can reasonably infer that exposing many high valence state ions on the surfaces of spinel oxide can be attributed to a proper hydrothermal synthesis time, which results in more active centers for CCM. Moreover, as can be seen from Fig. 7(b), the hydrothermal and co-precipitation syntheses of spinel oxides show different light-off curves during CCM. The catalytic performance of hydrothermally synthesized spinel oxides is much better than their co-precipitated counterparts. The co-precipitated sample containing NiCo2O4 performs better than co-precipitated Co3O4. This result agrees well with previous studies, where results show that the concentration of surface Ni3+ is responsible for high catalytic performance [28]. However, it also should be noted that 60 h hydrothermal NiCo2O4 catalytic activity corresponds closely to 60 h hydrothermal Co3O4 with 90% methane conversion at 325 ℃, which is different from previous reports [3, 8, 28]. In order to understand the difference, we compared 60 h hydrothermal NiCo2O4 with 60 h hydrothermal Co3O4 at different GHSV values (Fig. 7(c)). Clearly, when working at relatively high GHSV (e.g., 84000 mL h-1 g-1), hydrothermal NiCo2O4 catalytic performance is higher than that of Co3O4. We try to use previous studies on Co3+ or Ni3+ as an active center for CCM to explain our experimental results. If Co3+ ions of the spinel oxides surface were active centers, 60 h hydrothermal Co3O4 and co-precipitated Co3O4 both would have better catalytic performance than NiCo2O4. If the active sites were Ni3+, co-precipitated NiCo2O4 would be superior to 60 h hydrothermal Co3O4. Therefore, we infer that Co3+ and Ni3+ maybe both are active sites in the spinel structure. Then we calculated the (Ni3+ + Co3+) to (Ni + Co + O) ratio on the surface from the XPS spectra. Table 2 clearly indicates that the (Ni3+ + Co3+) to (Ni + Co + O) ratio in the 60 h hydrothermal Co3O4 is the highest among all samples. It seems that 60 h hydrothermal Co3O4 would have the best catalytic activity. However, this was not the case. While we take the surface area and crystal plane into account to calculate the number of (Ni3+ + Co3+) ions on the surface, the methane combustion light-off curves give a relatively rational explanation. As indicated in Fig. 8(b), as the (Ni3+ + Co3+) content increases on the surface, the reaction rate also increases. Thus, this is direct evidence that Ni3+ and Co3+ both serve as active centers on the surface of spinel oxides. The apparent activation energy of all the samples are very similar in Fig. 8(a), which indicate they have similar activation modes and the same active center [45]. This indirect evidence also supports our conclusion that Ni3+ and Co3+ both serve as active centers.

Fig. 7. Methane conversion over spinel oxide catalysts: (a) NiCo2O4 with different hydrothermal times and GHSV 24000 mL h-1 g-1; (b) Spinel oxides with hydrothermal and co-precipitation methods and GHSV 24000 mL h-1 g-1; (c) Hydrothermal spinel oxide tests at different GHSV values; (d) Stability test for hydrothermal spinel oxides.
Fig. 8. (a) Arrhenius plots for the reaction kinetics; (b) The relationship between the reaction rate and number of Co3+ + Ni3+ atoms on the surface.

Our catalysts are compared with some previously reported catalysts, including noble metal catalysts, as summarized in Table 3. To examine the catalytic performance of NiCo2O4 in the complete oxidation of CH4 from the exhaust of a natural gas engine, we measured the catalytic performance of complete CH4 oxidation on NiCo2O4 in two different gas mixtures (Fig. 9). First, 1% CH4 and 10% H2O balanced with air at a flow rate 40 mL/min (Fig. 9(a)) is used to evaluate the influence of H2O in the catalytic system. It is clear that the addition of H2O causes the T90 to lag behind about 50 ℃ compared to the case without H2O. We also noted that the initial activity starts at a low temperature of about 200 ℃, which indicates the added H2O will not cover the active sites and maybe only take more heat from the catalyst surface, resulting in a slight increase in complete oxidation temperature at relatively low GHSV. Second, results with 0.2% CH4, 5% O2, 10% H2O, and 15% CO2 balanced with N2 at high GHSV (60000 mL h-1 g-1) (Fig. 9(b)) show that H2O has a minor impact on catalytic performance, especially for 60 h hydrothermal Co3O4, and CH4 can be completely oxidized to CO2 and H2O at 450 ℃. Generally, H2O is easily absorbed on the catalyst surface, which tends to reduce catalytic activity. However, it is worth noting that the activity of 60 h hydrothermal NiCo2O4 and Co3O4, the first C-H cleavage remains at 200 ℃, which means H2O cannot completely cover the active sites. On the other hand, our catalysts prepared by long hydrothermal treatments showed a very low content of adsorbed moisture on the catalyst surface, as indicated by the O 1s XPS results. This means that H2O is weakly adsorbed on the catalyst surface, especially at high temperature. These gas compositions are typically used in the evaluation of catalytic performance of Pd- and Pt-based catalysts for complete oxidation of CH4 in the exhaust of natural gas engines [46-48]. Thus, it is evident that 60 h hydrothermal spinel oxide catalysts show higher activity than some noble metal catalysts.

Table 3
Overview of catalytic activities for our samples and the samples reported in the literature.
Fig. 9. Catalytic performance of 60 h hydrothermal spinel oxides in exhaust gases from natural gas engines. (a) CH4 1%, H2O 10%, Air 79%, flow rate of the mixture 40 mL/min, catalyst 100 mg; (b) CH4 0.2%, O2 5%, H2O 10%, CO2 15%, N2 69.8%, flow rate of the mixture 100 mL/min, catalyst 100 mg.

Furthermore, the stability performance shown in Fig. 7(d) indicates that both 60 h hydrothermal NiCo2O4 and Co3O4 are able to completely oxidize CH4 to CO2, and catalytic activity does not obviously decline for 12 h under feed gas including 10 vol% H2O at 425 ℃ (GHSV = 24000 mL h-1 g-1). On the other hand, our catalysts were repeatedly used several times at different GHSV and different feed gas compositions, which also exhibit good stability. We can confirm that the stability of spinel oxides improves as the extensive hydrothermal time results in highly crystalline structures. This is supported by the appearance of a larger lattice oxygen peak in the O 1s XPS spectra.

The correlation between structure and catalytic activity is established for 60 h hydrothermal spinel oxides by combining the activity measurements with the characterization results. As observed in TEM, the 60 h hydrothermal spinel oxides investigated here both exhibit disordered nanosheet structure due to their disordered assembly from small nanoparticles. 60 h hydrothermal NiCo2O4 have higher surface area as confirmed with BET measurements. In general, a high surface area often results in greater catalytic activity because more active sites are exposed during the catalytic reaction [49]. For hydrothermal synthesis of spinel oxides, both have high valence ion content on the surface based on analysis of the XPS, H2-TPR, XRD, and TEM results, as well as the solid surface model (Fig. S1 and S2), which leads to excellent catalytic performance. It can be concluded that a strong correlation exists between activity and structure and, more significantly, that a high concentration of valence ions and high surface area are responsible for high methane combustion activity.

4 Conclusions

In summary, we synthesized a series of spinel oxide catalysts with different amounts of Ni3+ and Co3+ cations by hydrothermal and co-precipitation methods. As the amount of (Ni3+ + Co3+) on the surface increases, the catalytic activity for methane combustion also increases. The (Ni3+ + Co3+) content on the 60 h hydrothermal NiCo2O4 surface is the highest among all samples, thus it exhibits the best catalytic performance and results in complete CH4 conversion at 340 ℃. Therefore, we are convinced that Co3+ and Ni3+ can both function as active sites on the surface of spinel oxides. Moreover, multiporous spinel oxide nanosheets without any surfactants and templates were obtained from hydrothermal synthesis and were nearly unaffected by water in low-temperature methane combustion. This occurred because the long hydrothermal treatment results in less adsorbed oxygen on spinel oxides. Finally, multiporous nanosheet spinel oxides with high surface areas and our conclusion that both Co3+ and Ni3+ function as active sites may be applicable in other catalytic oxidation systems in the future.

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