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

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/CeZrO₂ catalyst, featuring isolated Pt single atoms (Pt_SA) on a Ce_0.8Zr_0.2O₂ 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/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.