Oxide supports are well known to significantly influence the structure and properties of active oxide overlayers through strong oxide-support interactions. However, the effect of oxide overlayers on the underlying active oxide substrates remains poorly understood. Here, we report the controllable formation of ceria (CeO2) overlayers on a hematite (Fe2O3) surface (CeO2/Fe2O3) via a melting-wetting method. Submonolayer CeO2 patches facilitate the partial reduction of surrounding Fe2O3 to active magnetite (Fe3O4) while effectively suppress further reduction of Fe3O4 to inactive metallic iron (Fe0) under harsh high-temperature water-gas shift (HT-WGS) conditions. We demonstrate this stabilization effect of surface oxide patches (MOx, M = Ce, Cr, Mn, Mg, Al and Zn) on surrounding active Fe oxide sites via creating a shielding zone around each oxide patch. As a result, Fe2O3 catalysts covered with a small amount of CeO2 surface overlayers (~1.8 wt%) exhibit remarkable stability at 450 °C for over 100 h, in contrast to rapid deactivation observed in pure Fe2O3 and industrial iron-chromium (6.5 wt% Cr) catalysts. Building on these findings, we have developed an advanced HT-WGS process that utilizes Cr-free catalysts and significantly reduces steam consumption. This study highlights the critical role of surface oxide overlayers in modulating the redox behavior and reactivity of underlying active oxide substrates, developing an interface confinement strategy for the design of robust and efficient oxide catalysts.
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