Techniques of Preparation of Thin Films: Catalytic Combustion

Over the past several decades, an increasing amount of attention has been given to catalytic combustion as an environmentally friendly process. However, major impediments to large-scale application still arise on the materials side. Here, we review catalytic combustion on thin film catalysts in view of highlighting some interesting features. Catalytic films open the way for new designs of structured catalysts and the construction of catalysts for catalytic combustion. A special place is occupied by materials in the form of very thin films that reveal catalytic activity for various chemical reactions. In this review, we demonstrate the high catalytic activity of thin film catalysts in these oxidation reactions.

Cold Plasma Synthesis and Testing of NiOX-Based Thin-Film Catalysts for CO2 Methanation

An essential problem in managing CO2 and transforming it into methane as a useful fuel is the quest for adequately efficient and cheap catalysts. Another condition is imposed by the new designs of structured reactors, which require catalysts in the form of the thinnest possible films. The aim of this work was to produce Ni-based thin-film catalysts by the cold plasma deposition method (PECVD) from a volatile metal complex (Ni(CO)4) and to study their structure and catalytic properties in the CO2 methanation process. We tested three basic types of films: as-deposited, calcined in Ar, and calcined in air. The nanostructure and molecular structure of the films were investigated by electron microscopy (SEM), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS). The catalytic activity was evaluated in the methanation process (CO2 + H2), which was performed in a tubular reactor operating in the temperature range of 300–400 °C. The films calcined in air showed the highest activity in this process but behaved unstably. However, their regeneration by recalcination in air restored the initial catalytic activity. An important conclusion emerged from the obtained results, namely that the active phase in the tested films is Ni3+ (most likely in the form of Ni2O3), contrary to the common opinion that this phase is metallic Ni0. In our case, Ni0 quenches the catalytic activity.

Preparation of different thin film catalysts by direct current magnetron sputtering for hydrogen generation

In this study, thin films of Co, Ni, Pd, and Pt were prepared on Co3O4 support material in pellet form using the direct current (DC) magnetron sputtering method for use as catalysts for hydrogen generation from NaBH4.Characterization of the catalysts was carried out using X-ray diffraction (XRD), scanning electronic microscopy (SEM), and X-ray photoelectron spectroscopy (XPS). According to cross-sectional SEM images, catalyst thicknesses were observed in the range of approximately 115.3–495.8 nm. The particle sizes were approximately 25.0, 21.4, 33.9, and 9.5 nm for Ni-Co3O4, Co-Co3O4, Pd-Co3O4, and Pt-Co3O4 catalysts, respectively. The increase in NaOH initial concentration provides an increase in the rate of hydrogen generation for Co, Ni, and Pd catalysts. A maximum hydrogen generation rate of 1653 mL/gcat.min was obtained for the Pt-Co3O4 catalyst.

X-ray Absorption Spectroscopy Investigation of Platinum–Gadolinium Thin Films with Different Stoichiometry for the Oxygen Reduction Reaction

Alloys of platinum and lanthanides present a remarkable activity for the oxygen reduction reaction—both in the form of extended surfaces and nanoparticulate catalysts. Co-sputter-deposited thin film catalysts based on platinum and gadolinium show great oxygen reduction activity improvement over pure Pt. The sputter-deposition technique represents a viable and versatile approach for investigating model catalyst systems with different compositions. In this work, co-sputtered Pt5Gd and Pt7.5Gd thin films were investigated using X-ray absorption spectroscopy as well as standardized electrochemical techniques. These investigations revealed the importance of forming alloys with specific stoichiometry, supporting the need of forming compressively strained Pt overlayers in order to achieve optimum catalytic performances.