Top-down vs. bottom-up synthesis of Ga–based supported catalytically active liquid metal solutions (SCALMS) for the dehydrogenation of isobutane

•Isobutane dehydrogenation catalyzed by supported liquid alloys (SCALMS).•Comparison between two synthesis protocols.•Distribution of alloy particles either inside or outside of support material.•Evidence for pore blocking from detailed sorption and intrusion studies.•Catalytic performance correlates with alloy distribution. Supported catalytically active liquid metal solutions (SCALMS) catalysts consist of a liquid metal solution of an active metal (e.g., Pd, Rh, Pt, Ni) in a low melting metal (e.g., Ga, In, Sn) deposited on a porous support material. In the current study, we extend and optimize the recently developed top-down synthesis protocol (ultrasonication of gallium metal) to prepare GaPd, GaRh and GaPt SCALMS systems. We compare the morphological differences in the obtained catalyst materials achieved between this approach and the more traditional bottom-up synthesis protocol (in situ thermal decomposition of triethylamino-gallane complex) using electron microscopy. Moreover, the spatial distribution of the catalytically active material in the porous alumina support is evaluated using high resolution argon physisorption measurements. Both techniques strongly indicate that the bottom-up approach leads to a high degree of pore penetration while the gallium droplets are largely on the outer surface in case of the top-down method. Changes to the surface chemistry of the support were also investigated by means of NH3/CO2 temperature programmed desorption. All catalytic systems synthesized by the two synthesis methods, i.e., GaPd, GaRh and GaPt, were tested in a quartz, fixed-bed tubular reactor for isobutane dehydrogenation. All SCALMS materials, irrespective of their individual synthesis protocol, were significantly more active than their pure metal counterparts. The SCALMS catalyst prepared using the bottom-up approach showed initial productivity of 407gbutenes molM–1 min−1, 832gbutenes molM–1 min−1, and 963gbutenes molM–1 min−1 for the GaPd, GaRh and GaPt respectively. These values represent more than twice the initial activity obtained with the top-down synthesized counterparts. This activity difference can be explained by the analytically determined difference in liquid metal droplet size distribution.