Pd/TiO2 coatings with template-controlled mesopore structure as highly active hydrogenation catalyst

• New strategy for the direct synthesis of highly active wall-coated catalysts.
• Template-controlled mesoporous Pd/TiO2 catalysts.
• Space–time-yields exceed values reported in literature for butadiene hydrogenation.
• Approach is generic in nature and can be adapted to other noble metals and supports.

Micro-structured reactors offer excellent mass and heat transport capabilities and can therefore sustain very high reaction rates and space–time-yields also for highly exothermic catalytic reactions. However, such high rates cannot be reached when the reactors are coated or filled with conventional catalysts powders. We present a strategy for the direct synthesis of highly active wall-coated supported catalysts via co-deposition of a pore template (here micelles formed from PEO-b-PPO-b-PEO) and a precursors for the metal oxide (TiCl4) along with a compatible precursor for the active metal (PdCl2). The obtained catalytic coatings possess a template-controlled open pore structure and excellent mechanical stability. Moreover, the active metal is highly dispersed and well-distributed across the coating also at high Pd loadings. The corresponding high activity along with rapid mass transfer enabled by the open pore system results in the best space–time-yields in the gas-phase hydrogenation of butadiene reported so far in literature for a supported catalyst.

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