Breaking the Structure–Activity Relationship in Toluene Hydrogenation Catalysis by Designing Heteroatom Ensembles Based on a Single-Atom Alloying Approach

Hydrogenation of toluene (TOL) to methylcyclohexane (MCH) is one of the hydrogen carrier systems desired for social integration. Supported Pt nanoparticle catalysts are effective for this application. However, Pt is rare, expensive, and in short supply, limiting its practical applications. Therefore, the key issue for TOL hydrogenation is how to substantially reduce the amount of Pt required for the catalyst. Because a specific ensemble of Pt atoms, that is dominantly formed on the surface of the Pt nanoparticle, is required for achieving higher catalytic performance, there is a limit to the number of precious Pt that can be conserved by simply reducing the particle size. The structure sensitivity established in the existing heterogeneous catalyst so far makes it difficult to design precious metal-conserving catalysts with both high activity and atomic efficiency. Here, a strategy for breaking the above limitations is reported. Our approach uses the heteroatom ensemble (HAE) on Pt single-atom alloyed 3d transition-metal nanoparticle catalysts (Pt1M SAAs, M = Co, Ni, Cu). The role of the TOL fixation/activation site is assigned to the atomic M sites on HAE, whereas the H2-activation site is to the Pt single-atom site on HAE. The atomic-scale division of roles within the HAE improves the efficiency of competitive adsorption of TOL/H2, which is important for boosting TOL hydrogenation. To maximize the synergistic effect at the adjacent sites, the atomic composition, geometric configuration, and electronic state of these active sites as well as the density of the HAE were tuned by the chemical composition and particle size of Pt1M SAAs. High activity was observed on the Pt1Co SAA with a particle size of 1.8 nm and Pt/Co molar ratio of 0.002. The Pt mass-specific activity reached 219 mol/gPt/h, which was 23 times higher than that in a conventional Pt nanoparticle-supported catalyst. Using a set of well-defined Pt1M SAAs, high-angle annular dark-field scanning transmission electron microscopy, Pt LIII-edge X-ray absorption fine structure spectroscopy, coupled with periodic density functional theory and ab initio molecular dynamics simulation, we proved the origin of the structure sensitivity at an atom-to-nanometer scale. The present work sheds light on the significance of regulations of the coordination environment of the Pt single-atom site, atomic composition, and particle size of Pt1M SAA for creating high activity, durability, and Pt-utilization efficiency for catalytic applications relevant to hydrogen carrier systems.