Catalyst deactivation is costly because catalysts must be regenerated or replaced, and because processes are shut down while these steps are taken.  Scientists at Argonne National Laboratory and Northwestern University have recently demonstrated that alumina (Al₂O₃) over-coating of supported metal nanoparticles effectively reduces deactivation by coking and sintering in high-temperature applications. When overcoated Pd catalysts were used for 1 hour at 650°C, coking was reduced by over 90% compared to the bare catalyst.  Moreover, no particle sintering was seen after reaction at 675°C for 28 hours.

J. Lu, B. Fu, M. C. Kung, G. Xiao, J. W. Elam, H. H. Kung, and P. C. Stair, ​“Coking and Sintering Resistant Palladium Catalysts Achieved Through Atomic Layer Deposition,” Science, 2012