This study explains a co-promoting interaction of cerium and barium additives in a cobalt catalyst used for ammonia synthesis. The results show that a synergistic effect of Ce and Ba promoters in the catalyst is associated with an emergence of a third promoter—BaCeO₃—which forms in situ from its individual components during catalyst activation. The influence of perovskite-type barium cerate is substantial due to its strong basic properties, i.e. high electron-donating ability and a tendency to stabilize the Co hcp cobalt phase (more active in ammonia synthesis than the Co fcc phase). BaCeO₃ diversifies the structure of adsorption sites on the cobalt surface by contributing to the exposure of facets with more favourable adsorption and binding energies with regards to rate-limiting reactions steps. It allows to a more fluent formation and transfer of species unrestricted by the hydrogen or product poisoning consequently accelerating the entire ammonia synthesis process.

This work presents a size effect, i.e., catalyst surface activity, as a function of active phase particle size in a cobalt catalyst for ammonia synthesis. A series of cobalt catalysts supported on carbon and doped with barium was prepared, characterized (TEM, XRPD, and H₂ chemisorption), and tested in ammonia synthesis (9.0 MPa, 400 °C, H₂/N₂ = 3, 8.5 mol% of NH₃). The active phase particle size was varied from 3 to 45 nm by changing the metal loading in the range of 4.9–67.7 wt%. The dependence of the reaction rate expressed as TOF on the active phase particle size revealed an optimal size of cobalt particles (20–30 nm), ensuring the highest activity of the cobalt catalyst in the ammonia synthesis reaction. This indicated that the ammonia synthesis reaction on cobalt is a structure-sensitive reaction. The observed effect may be attributed to changes in the crystalline structure, i.e., the appearance of the hcp Co phase for the particles with a diameter of 20–30 nm.

The influence of the calcination process on the physicochemical properties and catalytic behavior of the Co/Mg/La catalysts for ammonia synthesis has been investigated. The catalysts were prepared using the different thermal pre-treatment methods prior to the activation, i.e., drying and calcination, and the respective activities for ammonia synthesis were assessed. It was found out that changing from air calcination prior to activation to direct activation of the co-precipitated species led to the different catalytic performances. The most favorable catalytic performance was achieved with Co/Mg/La prepared by calcination in air. Detailed characterization methods, employing e.g., XRPD, H₂-TPD, N₂-TPD, CO₂-TPD, SEM, and TEM, showed that the superior catalytic behavior of this catalyst was attributed to its strong basicity and favorable adsorption properties toward hydrogen and nitrogen.