Activation by O₂ of Ag_xPd_1–x Alloy Catalysts for Ethylene Hydrogenation

A composition spread alloy film (CSAF) spanning all of AgxPd1-x composition space, xPd = 0 → 1, was used to study catalytic ethylene hydrogenation with and without the presence of O2 in the feed gas. High-throughput measurements of the ethylene hydrogenation activity of AgxPd1-x alloys were performed at 100 Pd compositions spanning xPd = 0 → 1. The extent of ethylene hydrogenation was measured versus xPd at reaction temperatures spanning T = 300 → 405 K and inlet hydrogen partial pressures spanning PH2in = 70 → 690 Torr. The inlet ethylene partial pressure was constant at PC2H4in = 25 Torr, and the O2 inlet partial pressure was either PO2in = 0 or 15 Torr. When PO2in = 0 Torr, only those alloys with xPd ≥ 0.90 displayed observable ethylene hydrogenation activity. As expected, the most active catalyst was pure Pd, which yielded a maximum conversion of ∼0.4 at T = 405 K and PH2in = 690 Torr. Adding a constant O2 partial pressure of PO2in = 15 Torr to the feed stream dramatically increased the catalytic activity across the CSAF at all experimental conditions and catalyst compositions without inducing catalytic ethylene combustion and without measurable O2 consumption. The presence of PO2in = 15 Torr more than doubled the maximum achievable conversion on Pd to ∼0.9 and activated alloys with as little as xPd = 0.6 for ethylene hydrogenation. Measurement of the reaction order with respect to hydrogen, nH2, showed that nH2 ≈ 0 when PO2in = 15 Torr on high xPd alloys but that nH2 increases to values between 0.5 and 1 as xPd decreases or when PO2in = 0 Torr. We attribute this PO2in-induced change in nH2 to a change in the reaction mechanism resulting from different functional catalyst surfaces: one that is O2-activated and Pd-rich and one that is Ag-capped with low activity. Both are extremely sensitive to the bulk alloy composition, xPd, and the reaction temperature, T. These results show that the activity of AgPd catalysts for ethylene hydrogenation depends strongly on the operational conditions. Furthermore, we demonstrate that the exposure of AgPd catalysts to 15 Torr of O2 at moderate temperatures leads to enhanced catalyst performance, presumably by stimulating both Pd segregation to the topmost surface and Pd activation for ethylene hydrogenation.