The practical application of Pd/FAU catalysts for the gas-phase indirect oxidative carbonylation of methanol to dimethyl carbonate (DMC) is limited by two major challenges: the formation of Brønsted acid sites during catalyst preparation, which reduces DMC selectivity, and the reduction of Pd2+ active sites with subsequent formation of large Pd nanoparticles under reaction conditions, leading to catalyst deactivation. To address these issues, we developed a simple and versatile solid-phase grinding method to incorporate a cobalt promoter, yielding Pd-Co/FAU catalysts. Comprehensive characterization using in situ infrared spectroscopy, thermogravimetric analysis-mass spectrometry (TG-MS), and X-ray photoelectron spectroscopy (XPS) confirmed that this approach effectively eliminates Brønsted acid sites through solid-phase ion exchange between Co2+ and bridged Si–(OH)–Al groups (CoCl2 + 2Si–(OH)–Al → Co(Si–(O)–Al)2 + 2HCl↑), and stabilizes electron-deficient Pd(2+δ)+ (0 < δ ≤ 2) species via electron transfer from Pd to Co. Compared to the parent Pd/FAU catalyst, the modified Pd-Co/FAU catalyst exhibits significantly improved performance, maintaining 97 % CO conversion and 81 % DMC selectivity for over 100 h with a turnover frequency of 0.26 s−1. This enhanced stability originates from the inhibition of Pd sintering, evidenced by a reduction in Pd particle size from 11.2 nm in Pd/FAU to highly dispersed species in Pd-Co/FAU, and the preservation of active Pd(2+δ)+ sites. The improved selectivity results from the suppressed decomposition of the CH3ONO reactant due to the elimination of Brønsted acidity. Furthermore, in situ infrared spectroscopy indicated that DMC formation proceeds via coupling of COOCH3* (*, active sites) and OCH3* intermediates on these stabilized electron-deficient Pd sites.
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