Vinyl
acetate monomer (VAM), an important chemical intermediate
in industry, is produced by the well-established commercial process
of acetoxylation of ethylene with Pd–Au/SiO2 and
a KOAc promoter. No paper has since decades defined the true effects
of Au and KOAc, despite numerous attempts to clarify them. The role
of subsurface carbon as a catalyst booster for enhanced catalytic
performance in VAM synthesis was found by us for the first time. X-ray
diffraction and X-ray absorption fine structure studies revealed that
carbon atoms spontaneously doped into the Pd–Au alloy lattice
while maintaining the alloy’s size, metallic state, and alloy
composition. Additionally, during the process, the KOAc addition dramatically
raised the equilibrium carbide fraction. Because of the high carbide
fraction, KOAc/Pd0.8Au0.2/SiO2 had
a 5.6-fold higher formation rate (89.0% selectivity) than Pd0.8Au0.2/SiO2 (69.2% selectivity) due to high
carbide fraction. Surprisingly, kinetic and theoretical analyses showed
that the coupling of acetate and ethylene, which is a rate-determining
step, is effectively promoted by the synergistic contributions of
Au (electronic/geometric effects) and interstitial carbon (electronic
effect). Additionally, the synergy inhibits ethylene dehydrogenation,
which ultimately slows the formation of CO2. The contentious
debates about the roles of Au and KOAc in the acetoxylation of ethylene
have been resolved thanks to experimental and theoretical insights
into the roles of Pd–Au formation, Au/Pd ratio, and interstitial
carbon atoms. These insights also open the door for the logical design
of catalysts with desirable catalytic performance.