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

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 Pt SA /CeZrO 2 catalyst, featuring isolated Pt single atoms (Pt SA ) on a Ce 0.8 Zr 0.2 O 2 support with an ordered macroporous (OM) structure. Firstly, Zr-stabilized dynamic low-coordinated Pt SA 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 g Pt /L, compared with 0.9 g Pt /L in commercial diesel oxidation catalysts. As a result, the Pt SA /CeZrO 2 maintains 92% conversion at 450 °C even after 50 h aging at 800 °C with 10 vol.% H 2 O. Finally, the catalyst is integrated into a 3.4-liter commercial cordierite monolith for developing and scaling robust catalytic converters.