Modulating metal-carrier interaction of high-loading Co-Al2O3-SiO2 catalysts for boosted N-propylcarbazole hydrogenation

[Display omitted] •High-loading Co-Al2O3-SiO2 was synthesized using the co-precipitation method.•Al incorporation modifies metal-carrier interaction and promotes Co dispersion.•The as-prepared Co70/Al4Si1O catalyst displayed the optimized catalytic performance.•The inherent reasons for the enhanced catalytic hydrogenation activity were revealed.•DFT calculations provide deep understanding for the catalytic hydrogenation process. We developed a series of high-loading Co-Al2O3-SiO2 catalysts to enhance the hydrogenation of N-propylcarbazole (NPCZ) by fine-tuning the Al/Si ratio. Our research reveals that adjusting this ratio can significantly modify the electronic structure of Co nanoparticles, as confirmed by XPS, H2-TPD, and CO-DRIFT analyses, thereby affecting the adsorption of hydrogen species and their interaction with unsaturated π-bonds of NPCZ intermediates. Optimal Al concentration promotes Co nanoparticles dispersion, while excessive Al leads to increased acidity and reduced surface area. The Co70/Al4Si1O catalyst, with an Al/Si ratio of 4, demonstrated superior hydrogenation efficiency by enabling fast and stable hydrogenation of NPCZ, achieving an activation energy of 64.53 kJ/mol and maintaining high performance over 10 cycles. Through DFT calculations, we explored the d-band center and Bader charge across 6 different Co10/Al-Si-O models and assessed the adsorption energies of NPCZ intermediates, along with the energetics of three stepwise reactions. The initial hydrogenation step from NPCZ to 4H-NPCZ is predominantly influenced by the catalyst's acidity/basicity, whereas the subsequent deeper hydrogenation steps of 4H-NPCZ and 8H-NPCZ are governed by the d-π feedback interaction between the metal and the adsorbate. This research offers critical guidance on selecting optimal supports for Co-based catalysts in LOHC hydrogenation.