The
development of new catalyst materials for energy-efficient
chemical synthesis is critical as over 80% of industrial processes
rely on catalysts, with many of the most energy-intensive processes
specifically using heterogeneous catalysis. Catalytic performance
is a complex interplay of phenomena involving temperature, pressure,
gas composition, surface composition, and structure over multiple
length and time scales. In response to this complexity, the integrated
approach to heterogeneous dilute alloy catalysis reviewed here brings
together materials synthesis, mechanistic surface chemistry, reaction
kinetics, in situ and operando characterization, and theoretical calculations
in a coordinated effort to develop design principles to predict and
improve catalytic selectivity. Dilute alloy catalystsin which
isolated atoms or small ensembles of the minority metal on the host
metal lead to enhanced reactivity while retaining selectivityare
particularly promising as selective catalysts. Several dilute alloy
materials using Au, Ag, and Cu as the majority host element, including
more recently introduced support-free nanoporous metals and oxide-supported
nanoparticle “raspberry colloid templated (RCT)” materials,
are reviewed for selective oxidation and hydrogenation reactions.
Progress in understanding how such dilute alloy catalysts can be used
to enhance selectivity of key synthetic reactions is reviewed, including
quantitative scaling from model studies to catalytic conditions. The
dynamic evolution of catalyst structure and composition studied in
surface science and catalytic conditions and their relationship to
catalytic function are also discussed, followed by advanced characterization
and theoretical modeling that have been developed to determine the
distribution of minority metal atoms at or near the surface. The integrated
approach demonstrates the success of bridging the divide between fundamental
knowledge and design of catalytic processes in complex catalytic systems,
which can accelerate the development of new and efficient catalytic
processes.