Dual-Atom Catalyst Breakthrough Transforms Nitrile Production Under Ambient Conditions

Revolutionary Catalyst Design Overcomes Traditional Limitations

Researchers have developed a groundbreaking CoRu-N-C dual-atom catalyst that significantly enhances nitrile production through ambient ammoxidation processes. Unlike conventional single-atom catalysts, this innovative material features low-coordinated Co₁Ru₁ active sites bridged by single nitrogen atoms, creating a synergistic effect that dramatically improves catalytic efficiency. The catalyst demonstrates exceptional performance in converting various aldehydes into valuable nitriles under mild conditions, representing a major advancement in sustainable chemical synthesis., according to recent studies

Advanced Synthesis and Structural Characterization

The catalyst was synthesized using a sophisticated support-sacrificial method involving ultrasonic mixing of cobalt acetate, ruthenium acetylacetonate, 1,10-phenanthroline, and magnesium hydroxide precursors, followed by pyrolysis under nitrogen atmosphere and subsequent MgO removal. This precise manufacturing process ensures the formation of the unique dual-atom structure while maintaining atomic-level dispersion of both metal species., according to recent developments

Comprehensive characterization through multiple analytical techniques confirmed the catalyst’s exceptional properties. XRD analysis revealed the amorphous carbon structure with complete absence of metal nanoparticles or clusters. BET surface area measurements showed that CoRu-N-C possesses an impressive 939 m²/g surface area, more than double that of its single-metal counterparts, while pore volume measurements indicated significantly enhanced porosity at 1.465 cm³/g., as covered previously

Atomic-Level Insights Reveal Synergistic Mechanism

Advanced electron microscopy and X-ray absorption spectroscopy provided unprecedented insights into the catalyst’s atomic structure. AC-HAADF-STEM imaging clearly revealed both isolated single atoms and dual-atom sites, with atomic distance measurements confirming characteristic spacing of 2.5 ± 0.4 Å between Co and Ru atoms. Elemental mapping demonstrated homogeneous distribution of both metals throughout the carbon support., according to technology trends

The synergistic interaction between Co and Ru atoms forms the foundation of the catalyst’s exceptional performance. XAFS analysis determined that cobalt coordinates with three nitrogen atoms (Co-N₃) while ruthenium forms a planar Ru-N structure. This specific configuration enables complementary functions: the CoN₃ sites efficiently adsorb oxygen and facilitate superoxide radical formation, while the RuN₃ sites preferentially adsorb imine intermediates.

Superior Catalytic Performance and Practical Applications

In practical testing for furfural ammoxidation under ambient conditions (1 bar air, 35°C), the dual-atom catalyst demonstrated remarkable efficiency. While conversion rates were comparable to single-atom catalysts at approximately 88%, the FAN yield skyrocketed to 59% compared to 23-25% for single-metal catalysts. More impressively, the FAN productivity reached 47 mmol/g/h, representing 36-fold, 8-fold, and 94-fold improvements over commercial Ru/C, Pt/C, and Pd/C catalysts respectively., according to industry developments

Time-dependent studies revealed the catalyst’s ability to rapidly convert imine intermediates to nitriles, with CoRu-N-C achieving 94% FAN yield within 12 hours and reaching 98% yield after 16 hours. The catalyst maintained excellent performance across a temperature range from 25-45°C, demonstrating its robustness and practical applicability., according to recent studies

Broad Substrate Scope and Industrial Potential

The catalyst’s versatility extends beyond furfural to encompass a wide range of substrates including aromatic aldehydes, aliphatic aldehydes, and heterocyclic aldehydes. This broad applicability highlights the multifunctional nature of the dual-atom design and its potential for various industrial applications. The ability to selectively produce nitriles from diverse starting materials under mild conditions represents a significant advancement over traditional methods that often require harsh conditions and specialized catalysts for different substrate types.

Exceptional Stability and Reusability

Perhaps most impressively, the catalyst demonstrated outstanding stability through multiple reaction cycles. After five consecutive uses under conditions designed to accelerate deactivation, CoRu-N-C maintained approximately 62% FAN yield with negligible metal leaching. Comprehensive analysis of the recovered catalyst confirmed preservation of structural integrity, elemental composition, and oxidation states, validating its potential for long-term industrial use.

The development of this dual-atom catalyst represents a paradigm shift in heterogeneous catalysis, demonstrating how precise atomic-level engineering can overcome fundamental limitations in chemical processes. By unlocking competitive adsorption constraints that have long challenged conventional catalysts, this technology opens new possibilities for sustainable chemical manufacturing and efficient nitrile production.

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