The replacement of noble metal catalysts by abundant iron as an active compound in CO oxidation is of ecologic and economic interest. However, improvement of their catalytic performance to the same level as state-of-the-art noble metal catalysts requires an in depth understanding of their working principle on an atomic level. As a contribution to this aim, a series of iron oxide catalysts with varying Fe loadings from 1 to 20 wt% immobilized on a γ-Al₂O₃ support is presented here, and a multidimensional structure–activity correlation is established. The CO oxidation activity is correlated to structural details obtained by various spectroscopic, diffraction, and microscopic methods, such as PXRD, PDF analysis, DRUVS, Mössbauer spectroscopy, STEM-EDX, and XAS. Low Fe loadings lead to less agglomerated but high percentual amounts of isolated, tetrahedrally coordinated iron oxide species, while the absolute amount of isolated species reaches its maximum at high Fe loadings. Consequently, the highest CO oxidation activity in terms of turnover frequencies can be correlated to small, finely dispersed iron oxide species with a large amount of tetrahedrally oxygen coordinated iron sites, while the overall amount of isolated iron oxide species correlates with a lower light-off temperature.

This work presents a new and facile route for the preparation of iron oxide-based catalysts supported on alumina, which enables the targeted synthesis of catalysts with an increased amount of isolated tetrahedrally coordinated iron centers compared to a conventional impregnation procedure, and therefore leads to an increase in activity for CO oxidation reaction. By a multi-step impregnation–calcination protocol, the catalysts were synthesized with iron loadings of between 1 and 10 wt%, and their catalytic activity was then compared with a 10 wt% loaded catalyst prepared by conventional single impregnation. With a loading of 8 wt%, the presented catalysts showed an improved catalytic activity regarding light-off and full conversion temperatures compared to this reference. Through the application of several analytical methods (PXRD, PDF, DRUVS, SEM, XAFS), the improved catalytic activity can be correlated with an increased amount of isolated iron centers and a significantly reduced fraction of agglomerates or particles.