DOI:
10.1039/C6RA07358A
(Paper)
RSC Adv., 2016,
6, 75126-75132
Highly active and stable Au@CuxO core–shell nanoparticles supported on alumina for carbon monoxide oxidation at low temperature
Received
21st March 2016
, Accepted 27th July 2016
First published on 28th July 2016
Abstract
Au@CuxO (x = 1 or 2) core–shell heterostructure nanoparticles (NPs) are synthesized by a facile aqueous solution approach. γ-Alumina support Au@CuxO (Au@CuxO/γ-Al2O3) catalysts used for CO oxidation at low temperature are prepared by dispersing the core–shell NPs on the surface of γ-alumina. It proves that the formation of the core–shell structure has led to the interaction between Au and CuxO and the co-existence of Auδ+ and Au0, which accounts for the improvement in catalytic activity. It can even catalyze CO oxidation at room temperature and the conversion of CO can reach to 38%. In the same case, Au/γ-Al2O3 does not have any catalytic activity. In particular, the embedding of Au NPs into CuxO shells has also improved the catalytic stability of Au based catalysts remarkably, which remains unchanged after 108 hours of reaction. To the best of our knowledge, Au@CuxO/γ-Al2O3 is really one of the most stable catalysts with adequate activity at room temperature.
Introduction
More and more studies and applications that focus on Au NPs as catalysts have been reported since the earliest report on the outstanding catalytic activity for oxidizing CO at low temperature by Haruta in 1987.1 CO oxidation on Au based catalysts at room temperature generally proceeds by following the size-dependent reaction pathways2,3 and Au NPs tend to sinter into larger particles4–6 or change to bicarbonate-like species under the reaction conditions6–13 and thus leads to a substantial loss of activity,14 which is a major drawback of Au based catalysts and this undesirable characteristic has reduced their potential for industrial applications.8,15
To date, several strategies have been proposed to solve the deactivation problem of Au based catalysts, which includes (1) the replacement of Au particles with alloy or bimetallic particles,16–18 (2) the modification of the catalysts with other additives19,20 and (3) the fabrication of core–shell type structure particles using Au as the core.21–24 Actually, the first two methods can really improve the catalytic stability to some extent, but cannot completely avoid the deactivation caused by sintering or poisoning. Compared with the first 2 methods, the encapsulation of Au NPs as a core inside an oxide shell is more practical to maintain the size and shape of Au NPs as well as to protect them from poisoning, which leads to the stability and compatibility enhancement of Au based catalysts.25
Among the various types of core–shell NPs, metal@semiconductor particles represent a significant class of core–shell structures. The semiconductor shell plays both the role of the masker to protect the metal particles from sintering and poisoning and the role of additives is to improve the physical and chemical activities of the metal particles by interacting with them within nanoscale.26 It has been extensively demonstrated that the strong metal-support interaction (SMSI) plays a significant role in affecting catalytic performance.27–34 However, the SMSI between Au and support cannot normally exist because Au has a lower work function and surface energy.35,36 The encapsulation of Au NPs by metal oxides can strengthen the SMSI and thus lead to the electron transfer between Au and the support.37
Cu2O is an important p-type semiconductor with a direct band gap of 2.17 eV, which could find practical applications in many aspects such as solar energy conversion,38 hydrogen production by photocatalytic decomposition of water,39,40 and lithium-ion batteries as electrode materials.41 It is also a promising alternative to expensive noble metals as the catalyst for CO oxidation at moderate temperatures, owing to its higher natural abundance and lower price. It has been reported that Cu2O layers can grow epitaxially on the surface of Au–Cu particles with small lattice mismatch and the CO oxidation reactions can occur on the Cu2O–Au interfaces.42 CuO is also a good catalyst for CO oxidation.43 Consequently, CuxO (x = 1 or 2) is a reasonable choice as the shell material to improve the catalytic performance of Au NPs.
Herein, we report an entirely new design of Au based catalysts for CO oxidation at low temperatures. Instead of pure Au particles, Au@CuxO core–shell NPs are fabricated and dispersed on the surface of γ-alumina and a new type of CO oxidation catalyst (Au@CuxO/γ-Al2O3) is synthesized. By coating Au NPs with CuxO, both the catalytic activity and stability of Au particles are improved. It can not only catalyze CO oxidation at room temperature with 38% CO conversion, but it can also maintain its activity. The stability is tested for 108 hours and after the 108 hours' of application, the catalytic activity did not decrease. As a comparison, the general Au based catalyst without CuxO has no catalytic activity at room temperature.
Experimental section
Materials preparation
Preparation of Au NPs. Au NPs were synthesized following the previously reported traditional Frens's citrate reduction synthesis method. Briefly, 150 mL of aqueous HAuCl4 (0.25 mM) was prepared in a 250 mL beaker and brought to the boil in a 100 °C water bath under magnetic stirring. Then, 7.5 mL of 0.1 M sodium citrate solution was added rapidly. When the reaction mixture began to change color and finally reached a red wine color, it signalled the end of the reaction. The solution was stirred for 30 min, cooled to room temperature, and then Au colloids were collected by centrifugation, washed with anhydrous ethanol and water for 3 times, and finally redispersed in 7 mL of water.
Preparation of Au@CuxO core–shell NPs. Au@CuxO was prepared using the method reported by Zhang et al.26 1.0 g of polyvinylpyrrolidone (PVP, average M.W. 40000, TCI Shanghai) was dissolved in 50 mL of 0.01 M Cu(NO3)2 (Sinopharm Chemical Reagent Co., Ltd.) aqueous solution under constant magnetic stirring and stirred for another 10 min to ensure that the PVP solution was uniform. Subsequently, 17 μL of N2H4·H2O solution (85 wt%, Sinopharm Chemical Reagent Co., Ltd.) was immediately introduced into the reaction mixtures after 6 mL of fresh prepared Au colloid solution was added. The colloidal solution turned dark green within 10 s, which is the characteristic color of Au@CuxO core–shell NPs typically. The reaction liquid was kept stirring for 2 min, and then the Au@CuxO core–shell NPs were washed with anhydrous ethanol and water 3 times and finally redispersed in anhydrous ethanol and kept in a freezer at 6 °C.
Preparation of γ-Al2O3. The amorphous Al2O3 (Sinopharm Chemical Reagent Co., Ltd.) was calcined from room temperature to 550 °C with a heating rate of 5 °C min−1 in air and maintained for 6 hours and then cooled to room temperature naturally.
Preparation of Au@CuxO/γ-Al2O3. Au@CuxO ethanol solution was taken in a beaker with a certain amount of γ-Al2O3 and stirred at room temperature until ethanol is entirely volatilized. Then, Au@CuxO/γ-Al2O3 was produced. Au contents were measured by the Inductively Coupled Plasma-Atomic Emission Spectrometry (ICP-AES).
Preparation of Au/γ-Al2O3. Au colloid was added to the beaker with a certain amount of γ-Al2O3 and stirred at room temperature until the solution was completely volatilized.
Preparation of CuxO/γ-Al2O3. CuxO solution was prepared using the method of Au@CuxO preparation wherein adding Au is omitted and the solution was added to the beaker with a certain amount of γ-Al2O3 and stirred at room temperature until the solution completely volatilized.
Catalytic activity test
For the CO activity measurement, about 0.1 g catalyst specimen (40–60 mesh) was placed into a stainless flow reactor (Φ 8 × 150 mm) with a fixed bed. Then, the gas mixture comprising 2 vol% CO and 98 vol% air was introduced into the reactor with a flow rate of 50 mL min−1, and the GHSV (Gaseous Hourly Space Velocity) is 30600 mL g−1 h−1. The activity tests of the samples were carried out in continuous flow reactors from room temperature to the temperature at which CO was completely converted into CO2 with the heat-up period of 1 °C min−1 and analyzed by gas chromatography (GC).
Characterization
Nitrogen adsorption–desorption isotherms using the Barrett–Emmett–Teller (BET) technique on a Micromeritics ASAP2020 V4.00 surface areas and porosity analyzer were used to detect the specific surface areas of the samples. X-ray diffraction (XRD) patterns were collected on a Dandong Haoyuan Instrument Co., Ltd. DX-2200V/PC diffractometer with Cu Kα radiation (λ = 0.154056 nm). Transmission electron microscopy (TEM), high-resolution transmission electron microscopy (HRTEM), energy dispersive spectroscopy (EDS) and high angle annular dark field scanning transmission electron microscopy (HAADF-STEM) were conducted on a JEM-2010F transmission electron microscope with an acceleration voltage of 200 kV. The surface morphology of the samples was observed with a ULTRA55-36-69 Zeiss field-emission scanning electron microscope (FESEM). Au content was measured by a Perkin-Elmer Optima 7300DV inductively coupled plasma-atomic emission spectrometer (ICP-AES). X-ray photoelectron spectroscopy (XPS) measurements are carried out on a Thermo ESCALAB 250 spectrometer using monochromatic Al Kα (hν = 1486.6 eV). All binding energies (BE) were calibrated by the C 1s signal (BE = 284.8 eV).
Results and discussion
Characterization of Au@CuxO core–shell NPs and Au@CuxO/γ-Al2O3 catalysts
Au@CuxO core–shell structure NPs are fabricated and dispersed on γ-Al2O3. Herein, γ-Al2O3 is used as the catalyst support to anchor Au@CuxO particles so as to increase the surface area and decrease the Au use to reduce costs. Au content in the catalysts is measured by the ICP-AES. As reference, Au/γ-Al2O3 and CuxO/γ-Al2O3 are also prepared with the same method and same Au or CuxO content.
Fig. 1 shows the structural characterizations of Au@CuxO core–shell NPs, Au/γ-Al2O3 and Au@CuxO/γ-Al2O3 catalyst. As shown in Fig. 1a, Au@CuxO core–shell NPs with multiple Au cores are formed. According the report of Zhang et al.26 reducing HAuCl4·3H2O with sodium citrate leads to the formation of quasi-spherical Au NPs and the subsequent reduction of Cu(NO3)2 with N2H4·H2O results in the formation of CuxO shells via a self-assembly process, which deposits on the Au surface to form core–shell like particles with multiple cores. The Au particle size is mainly concentrated at 20 nm (Fig. 1d) and the distribution interval is narrow. The diameter of Au@CuxO nanospheres varies within the range of 60–120 nm and mainly concentrates at 100 nm (Fig. 1e). The average shell thickness is about 40 nm and the core–shell structure is not uniform. The greater details of the Au@CuxO core–shell structures can be observed by the HAADF-STEM (Fig. 1b) and HR-TEM (Fig. 1c) images. The HR-TEM image recorded on the Au core region indicates that the interplanar spacing is about 0.235 nm corresponding to the (111) planes of face-centered cubic Au.44 The (111) planes of Cu2O with a spacing of 0.248 nm are found to grow epitaxially on the facets of Au.45 EDS line scan of an individual Au@CuxO core–shell heterostructure reveals strong Cu and O signals across the entire particle. The signal for Au appears only in the central region of the particle, where the Au core is located (Fig. 1b). It further confirms the formation of the core–shell structure.
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| Fig. 1 Structural characterization of Au@CuxO and the catalysts. (a) Bright-field TEM image of Au@CuxO core–shell NPs, (b) high-magnification HAADF-STEM image of an individual Au@CuxO core–shell NPs with spatial elemental distribution analysis by EDS line-scan, (c) HR-TEM image of the Au core and CuxO shell, (d) the particle size distribution of pure Au NPs, (e) the particle size distribution of Au@CuxO core–shell structure particles, (f) HAADF-STEM image of Au@CuxO/γ-Al2O3, (g) TEM image of Au/γ-Al2O3, (h) the particle size distribution of Au in Au/γ-Al2O3. | |
Fig. 1f and g are the HAADF-STEM image of Au@CuxO/γ-Al2O3 and TEM image of Au/γ-Al2O3 catalyst, respectively. It shows that the core shell structure of Au@CuxO and the diameter of Au particles and Au@CuxO nanospheres do not change after dispersing on γ-Al2O3. The particle size of Au is mainly concentrated at 20 nm (Fig. 1h).
The XRD patterns of Au@CuxO/γ-Al2O3, Au/γ-Al2O3, CuxO/γ-Al2O3 and pure γ-Al2O3 are shown in Fig. 2. The peaks at 37.6°, 45.8° and 67.0° of all the samples are due to the (311), (400), (440) reflections of γ-Al2O3. As the content of Au and CuxO in the samples is very low (0.11 and 0.088 wt%), their diffraction peaks could not be clearly made out, which suggests a well dispersed metal phase.46
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| Fig. 2 XRD patterns of Au@CuxO/γ-Al2O3 with 0.11 wt% Au and 0.088 wt% CuxO, Au/γ-Al2O3 with 0.11 wt% Au, CuxO/γ-Al2O3 with 0.088 wt% CuxO and γ-Al2O3. The intensity scale for all the samples are the same. | |
Fig. 3 shows the SEM images of Au@CuxO/γ-Al2O3, Au/γ-Al2O3, CuxO/γ-Al2O3 and pure γ-Al2O3. The crystal surface of all the samples is rough and their shapes show a perceptible similarity to each other, which are stacked loosely by irregular alumina particles and we could not clearly observe the Au, CuxO or Au@CuxO core–shell NPs. Otherwise, the addition of a little amount of Au, CuxO or Au@CuxO has no effect on the morphology of alumina support.
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| Fig. 3 The SEM image of (a) Au@CuxO/γ-Al2O3 with 0.11 wt% Au and 0.088 wt% CuxO, (b) Au/γ-Al2O3 with 0.11 wt% Au, (c) CuxO/γ-Al2O3 with 0.088 wt% CuxO and (d) γ-Al2O3. All SEM images share the same scale-bar in panel (a). | |
To further study the physical properties of Au@CuxO/γ-Al2O3 catalyst, Brunauer–Emmett–Teller (BET) surface area and pore structure of the catalyst is measured by nitrogen adsorption at 77 K and is compared with that of pure γ-Al2O3. Fig. 4 displays a type of IV isotherms with a hysteresis loop at relative pressure (P/P0) between 0.5 and 1, indicating the presence of mesopores. BET surface area is calculated to be 118 m2 g−1 for Au@CuxO/γ-Al2O3, which is almost same as that of pure γ-Al2O3. In the Barret–Joyner–Halenda (BJH) pore size distribution analysis, the sharp peak at about 4.6 nm and 4.9 nm for pure γ-Al2O3 and Au@CuxO/γ-Al2O3, as shown in the inset in Fig. 4, suggests a relatively narrow pore size distribution interval. It shows that Au@CuxO has little effect on the pore structure of the alumina support, whereas the relatively high surface area of alumina will provide abundant active sites for catalytic reactions.47
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| Fig. 4 Nitrogen adsorption isotherms and pore size distribution of (a) pure γ-Al2O3 and (b) Au@CuxO/γ-Al2O3 with 0.11 wt% Au and 0.088 wt% CuxO. | |
CO oxidation on Au@CuxO/γ-Al2O3 catalysts
Fig. 5a shows the catalytic activity of Au@CuxO/γ-Al2O3, Au/γ-Al2O3, CuxO/γ-Al2O3 and pure γ-Al2O3. Here, 90% CO conversion temperature (T90%) is used to estimate the catalytic activity of the catalysts. A low T90% indicates a high activity of the catalyst. T90% of pure γ-Al2O3 is about 216 °C, and the introduction of a little amount Au (0.11 wt%) decreases the T90% to 203 °C, which indicates a small improvement in the catalytic activity. In general, the Au content in the Au based catalysts is equal to or greater than 1 wt%, and it even reaches 5 wt% in some catalysts;48–50 the low catalytic activity of Au/γ-Al2O3 here can be ascribed to the low Au content. On the other hand, the large Au particle size (∼20 nm) is also a cause that leads to the low catalytic activity of Au/γ-Al2O3 because the CO oxidation on the simple supported Au catalyst at low temperatures generally follows the size-dependent reaction pathways.2,3 For this type of catalysts, 3–5 nm Au particles are more active. The introduction of a little amount of CuxO (0.088 wt%) has no obvious effect on the catalytic activity of pure γ-Al2O3. T90% of CuxO/γ-Al2O3 is about 220 °C, which is even a little higher than that of pure γ-Al2O3. In brief, the effect of a little amount of (0.11 wt%) pure Au or pure CuxO (0.088 wt%) alone on the catalytic activity of γ-Al2O3 is weak. However, the combination of these two types of material and the fabrication of Au@CuxO core–shell structure generate a material more suitable to be used as CO oxidation catalysts. Although the content and particles size of Au in Au@CuxO/γ-Al2O3 is the same as Au/γ-Al2O3, the catalytic activity has been greatly improved. T90% of Au@Cu2O/γ-Al2O3 is only 158 °C, which is 58 °C lower than that of pure γ-Al2O3. It indicates that Au@CuxO hybrid NPs exhibit good catalytic activity due to the combination of the properties from the individual components and nanoscale interactions between the disparate metal and semiconductor components.
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| Fig. 5 Catalytic activity of the catalysts. (a) 90% CO conversion temperature of Au@CuxO/γ-Al2O3 with 0.11 wt% Au and 0.088 wt% CuxO, Au/γ-Al2O3 with 0.11 wt% Au, and CuxO/γ-Al2O3 with 0.088 wt% CuxO and γ-Al2O3, (b) the influence of Au content on 90% CO conversion temperature of Au@CuxO/γ-Al2O3, and (c) the CO conversion at different temperature on Au@CuxO/γ-Al2O3 with 1.24 wt% Au. | |
To improve the catalytic activity further, Au@CuxO/γ-Al2O3 catalysts with different Au content are prepared and the influence of Au content on the catalytic activity for CO oxidation is studied. Fig. 5b shows that T90% decreases with Au content, which means that the catalytic activity can be improved by increasing the Au content. T90% of Au@Cu2O/γ-Al2O3 with 1.24 wt% Au is only 144 °C. The most important thing is that CO conversion on this type of catalyst can reach up to 18% at room temperature (Fig. 5c).
For CO oxidation at low temperatures, the catalytic activity of Au based catalyst is high enough but the stability is still lower. Wang et al.18 improved the catalytic stability of Au/Al2O3 by adding Rh into the catalyst and Lin et al. improved the catalytic stability of Au/Al2O3 by adding LaFeO3 into alumina.50 However, the stability of the catalyst is still limited. To study the catalytic performance of Au@CuxO/γ-Al2O3 deeply, Au@CuxO/γ-Al2O3 with 1.24 wt% Au is chosen as an example to study the catalytic stability at both 144 °C and room temperature. It can be seen from Fig. 6a that after 72 h reaction at 144 °C, the catalytic activity has not suffered any loss, which means that the high temperature stability of the catalyst is quite high.
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| Fig. 6 Catalytic stability of Au@CuxO/γ-Al2O3 with 1.24 wt% Au. (a) At 144 °C and (b) at room temperature. | |
The catalytic stability test of the catalyst at room temperature in Fig. 6b shows that the catalytic activity increases rather than decreases before 30 hours. CO conversion on this catalyst can reach up to 38% at room temperature after 30 hours' application and then hold the line to 108 h. To the best of our knowledge, this is one of the most stable Au based catalysts with high catalytic activity. The catalytic performance improvement of the catalyst may be ascribed to the reason that the interaction between Au and CuxO led to the high catalytic activity and the protection of Au by CuxO has led to the high stability.
CO oxidation mechanism on Au@CuxO/γ-Al2O3
In spite of a great number of contributions to reveal the origin of the high CO oxidation activity of Au catalysts, the reaction mechanism is still debated. The main debatable topics include the active Au species, the mechanism of activation of oxygen molecules, the role of the support and the Au-support interface, the interaction between supports and Au particles and the possible CO oxidation pathway. The difference between the catalytic systems and the reaction conditions may be the mandatory reason that leads to the controversies.
In general, the size of the Au particles, the valence state of Au and the interaction between Au and support are the main factors that dramatically influence the activity of the catalysts, which are difficult to isolate because they are normally intertwined together.51 To study the possible reaction mechanism, XPS is employed to detect the surface elements and their valence states. The XPS profile of Au 4f region is shown in Fig. 7a. The main peaks near 83.8 eV and 87.5 eV corresponded to Au 4f7/2 and Au 4f5/2 of metal Au and the peaks at 84.3 eV and 88.0 eV corresponded to Au 4f7/2 and Au 4f5/2 of Auδ+. The Au signal of Au@CuxO/γ-Al2O3 is weaker than that of Au/γ-Al2O3 due to the encapsulation of Au into CuxO. However, the catalytic activity of the former is higher. It may be ascribed to the reason that the Au species on the 2 samples are quite different. All the surface Au of Au/γ-Al2O3 are Au0, and there are 2 types of Au species (Au0 and Auδ+) on the surface of Au@CuxO/γ-Al2O3. This indicates that the interaction between Au and CuxO led to the co-existence of Auδ+ and Au0. The ratio of Auδ+/Au0 is 1.1 and the co-existence of the 2 types of Au species makes the catalyst more active. Au cations52 and a pair of Au atoms and Au cations53 have also been proposed as active sites by other researchers.
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| Fig. 7 The XPS spectra of different catalysts. (a) Au 4f, (b) Cu 3d and (c) O 1s. | |
Fig. 7b shows the XPS profile of Cu 3d region of CuxO/γ-Al2O3 and Au@CuxO/γ-Al2O3. The peaks at 932.3, 933.4 and 935.5 eV are ascribed to Cu+ of Cu2O, Cu2+ of CuO and Cu2+ of CuCO3 and Cu(OH)2, respectively. As the catalytic activity of the sample without CuxO is lower, the function of Cu species may be ascribed to the interaction between Au and CuxO, which plays a crucial role in the electronic properties of Au particles and strongly affects the catalytic activity. The reducing nature of CuxO can donate54–58 and withdraw59–65 charges from Au and build up the possible charge at the metal/oxide interface.
As shown in Fig. 7c, the O 1s XPS spectra are fitted with two peaks contributions. One peak at BE = 531.8–531.7 eV can be ascribed to adsorbed oxygen. The other peak at BE = 530.7–530.8 eV may belong to lattice oxygen O2− of CuxO. Li et al.66 have shown unambiguously that with the promotion of Au NPs, the surface lattice oxygen of FeOx participates directly in the CO oxidation via an Fe3+ ⇌ Fe2+ redox mechanism even when well below the room temperature, and this redox mechanism predominates in low temperature CO oxidation on Au/FeOx. As CuxO is similar to FeOx, the same reaction mechanism may also occur via a Cu2+ ⇌ Cu+ redox mechanism.
Fig. 8 is the diagrammatic sketch for CO oxidation mechanism on Au@CuxO/γ-Al2O3. To sum up, the pairs of Au atoms and Au cations are the active sites. Au clusters act as a reservoir of charge through the catalytic cycle facilitating both reduction processes involving the O2 molecule and oxidation process such as the transformation of CO to CO2. The detailed process is that CuxO donate and withdraw charge from Au and build up the possible charge at the metal/oxide interface. CO molecules quickly attach to the oxygen species bond at the interface. It has been proved that CO can react with the bonded oxygen and release CO2 within 4 Ps.67
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| Fig. 8 Schematic for CO oxidation mechanism on Au@CuxO/γ-Al2O3. | |
Conclusion
In summary, Au/γ-Al2O3 and CuxO/γ-Al2O3 do not have any catalytic activity at room temperature and their 90% CO conversion temperature (T90%) is almost the same as pure γ-Al2O3. Au@CuxO/γ-Al2O3 can not only decrease T90% but can also catalyze CO oxidation at room temperature and the stability is very high. The high catalytic activity of Au@CuxO/γ-Al2O3 can be ascribed to the reason that the formation of Au@CuxO core–shell structure led to the interaction between Au and CuxO, which generates the Auδ+ and Au0 pairs and the co-existence of the 2 types of Au species makes the catalyst more active. The protective function of CuxO shell may be one reason that accounts for the catalytic stability improvement.
Acknowledgements
This research is supported by the National Natural Science Foundation of China (21103104). We also acknowledge the Instrumental Analysis and Research Center of Shanghai University for providing measurement services.
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Footnote |
† These authors contributed equally to this work and should be considered co-first authors. |
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