Spatial segregation of three-dimensional Al2O3 supported PtSn catalyst for improved sintering-resistant at high temperature

Many catalytic reactions operate within high-temperature environment, inevitably leading to the sintering of small nanoparticles. Consequently, the design of sintering-resistant metal nanocatalysts at elevated temperatures pose significant challenges. Herein, we introduce an approach, employing a 3D flower-shaped Al2O3 (F-Al2O3), to stabilize nanoparticles by establishing a spatial separation in propane dehydrogenation (PDH). The PDH reaction conducted is just a test system at non-relevant conditions. Both ex-situ and in-situ TEM analyses evidence that PtSn nanoparticles on the F-Al2O3 exhibit remarkable resistance to sintering under high-temperature oxidative and reductive conditions. The propane conversion of PtSn/F- Al2O3 fully rebounds to its initial state and the average particle diameter of PtSn/F- Al2O3 remains virtually unchanged after seven PDH cycles. In contrast, 2D Al2O3 nanosheets (C-Al2O3) experience severe PtSn nanoparticle sintering. Computational studies highlight the effectiveness of the 3D flower-shaped Al2O3 in obstructing particle migration and ripen through spatial segregation. This strategy involving the construction of three-dimensional space support presents a promising avenue for the design of sintering-resistant nanocatalysts. [Display omitted] •Spatial separation was established to stabilize nanoparticles at high temperature.•Flower-shaped Al2O3 exhibited remarkable resistance to metal sintering under high-temperature conditions.•Both ex-situ and in-situ analyses revealed the evolution of Pt species under redox conditions.•The principle of anti-sintering of flower-shaped Al2O3 was proved by the combination of theory and experiment.