Nano-array based monolithic catalysts: Concept, rational materials design and tunable catalytic performance

•A timely and comprehensive overview of nano-array based monolithic catalysts.•Cost-effective and binder-free deposition of nano-array catalysts via a generic and scalable hydrothermal process.•High materials utilization efficiency, robustness and tunable catalytic performance in nano-array catalysts.•Industrially relevant scale-up of nano-array catalysts.•Dopant occupancy and population understanding in metal oxide nano-arrays for rational catalysts design.

Monolithic catalysts, also known as structured catalysts, represent an important catalyst configuration widely used in automotive, chemical, and energy industries. However, several issues associated with washcoat based monolithic catalyst preparation are ever present, such as compromised materials utilization efficiency due to a less-than-ideal wash coating process, difficulty in precise and optimum microstructure control and lack of structure–property correlation. In this mini-review, we introduce the concept of nano-array catalyst, a new type of monolithic catalyst featuring high catalyst utilization efficiency, good thermal/mechanical robustness, and catalytic performance tunability. A comprehensive overview is presented with detailed discussion of the strategies for nano-array catalyst preparation and rational catalytic activity adjustment enabled by the well-defined nano-array geometry. Specifically their scalable fabrication processes are reviewed in conjunction with discussion of their various catalytic oxidation reaction performances at low temperature. We hope this review will serve as a timely and useful research guide for rational design and utilization of the new type of monolithic catalysts.

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