Supported Co catalysts were prepared for sodium borohydride and ammonia borane hydrolysis by magnetron sputtering for the first time under different conditions. Ni foam was selected as support. Deposition conditions (time, pressure, and power) were varied to improve catalytic activity. A decrease in deposition power from 200 to 50 W, leads to a decrease in crystallite and column size and a higher activity of catalysts. The increase in deposition pressure from 1.5x10-2 to 4.5x10-2 mbar produces same effect but in this case the enhancement in activity is higher because amorphous materials were obtained. The highest activity for SB hydrolysis was 2650 ml.min-1 .g cat-1 for the 50W Co 4.5 (4h) sample (E a =60±2 kJ.mol-1). For AB hydrolysis activity for the 50W Co 3.2 (4h) sample was similar. Durability of the thin films was tested for both reactions upon cycling (14 cycles). Diluted acid washing was effective to recover the activity for sodium borohydride reaction but not for ammonia borane hydrolysis. The strong Co-NH 3 interactions explain the non-efficiency of the acid washing.
The magnetron sputtering (MS) methodology is a powerful tool for tailor-made fabrication of Co-based thin film catalysts with controlled microstructures and compositions for sodium borohydride (SBH) hydrolysis.
Deactivation of a Co catalyst prepared as thin film by magnetron sputtering was studied for the sodium borohydride (SB) hydrolysis reaction under different conditions. Under high SB concentration in single run experiments, the formation of a B-O passivating layer was observed after 1.5 and 24 h use. This layer was not responsible for the catalyst deactivation. Instead, a peeling-off mechanism produced the loss of cobalt. This peeling-off mechanism was further studied in cycling experiments (14 cycles) under low SB concentrations. Ex-situ study of catalyst surface after use and solid reaction products (precipitates) was performed by X-Ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM). The presence of cobalt hydroxide and oxyhydroxide was detected as major components on the catalyst surface after use and as precipitates in the supernatant solutions after washing. Cobalt borate, cobalt carbonate and oxycarbonate *Revised Manuscript Click here to view linked References were also formed but in lesser amounts. These oxidized cobalt species were formed and further detached from the catalyst at the end of the reaction and/or during catalyst washing by decomposition of the unstable in-situ formed cobalt boride. Leaching of cobalt soluble species was negligible. Thin film mechanical detachment was also found but in a smaller extent. To study the influence of catalyst composition on deactivation processes, cycling experiments were performed with CoB and Co-C catalysts, also prepared as thin films. We found that the deactivation mechanism proposed by us for the pure Co catalyst also occurred for a different pure Co (prepared at higher pressure) and the CoB and Co-C samples in our experimental conditions.
In this work, we prepared a series of Ni foam supported Ru-Co, Ru-Co-B and Ru-Co-C catalysts in the form of columnar thin films by magnetron sputtering for the hydrolysis of sodium borohydride. We studied the activity and durability upon cycling. We found a strong activation effect for the Ru-Co-C sample which was the highest ever reported. This catalyst reached in the second cycle an activity 5 times higher than the initial (maximum activity 9310 ml.min−1.gCoRu−1 at 25 °C). Catalytic studies and characterization of the fresh and used samples permitted to attribute the strong activation effect to the following factors: (i) small column width and amorphous character (ii) the presence of Ru and (iii) dry state before each cycle. The presence of boron in the initial composition is detrimental to the durability. Our studies point out to the idea that after the first cycle the activity is controlled by surface Ru, which is the most active of the two metals. Apart from the activation effect, we found that catalysts deactivated in further cycles. We ascribed this effect to the loss of cobalt in the form of hydroxides, showing that deactivation was controlled by the chemistry of Co, the major surface metal component of the alloy. Alloying with Ru is beneficial for the activity but not for the durability, and this should be improved.
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