Catalysts for Production of Lower Olefins from Synthesis Gas: A Review

Homogeneity of Supported Single-Atom Active Sites Boosting the Selective Catalytic Transformations

Selective conversion of specific functional groups to desired products is highly important but still challenging in industrial catalytic processes. The adsorption state of surface species is the key factor in modulating the conversion of functional groups, which is correspondingly determined by the uniformity of active sites. However, the non-identical number of metal atoms, geometric shape, and morphology of conventional nanometer-sized metal particles/clusters normally lead to the non-uniform active sites with diverse geometric configurations and local coordination environments, which causes the distinct adsorption states of surface species. Hence, it is highly desired to modulate the homogeneity of the active sites so that the catalytic transformations can be better confined to the desired direction. In this review, the construction strategies and characterization techniques of the uniform active sites that are atomically dispersed on various supports are examined. In particular, their unique behavior in boosting the catalytic performance in various chemical transformations is discussed, including selective hydrogenation, selective oxidation, Suzuki coupling, and other catalytic reactions. In addition, the dynamic evolution of the active sites under reaction conditions and the industrial utilization of the single-atom catalysts are highlighted. Finally, the current challenges and frontiers are identified, and the perspectives on this flourishing field is provided.

Fischer-Tropsch synthesis to olefins boosted by MFI zeolite nanosheets

Catalytic reactions are severely restricted by the strong adsorption of product molecules on the catalyst surface, where promoting desorption of the product and hindering its re-adsorption benefit the formation of free sites on the catalyst surface for continuous substrate conversion^1,2. A solution to this issue is constructing a robust nanochannel for the rapid escape of products. We demonstrate here that MFI zeolite crystals with a short b-axis of 90-110 nm and a finely controllable microporous environment can effectively boost the Fischer-Tropsch synthesis to olefins by shipping the olefin molecules. The ferric carbide catalyst (Na-FeC_x) physically mixed with a zeolite promoter exhibited a CO conversion of 82.5% with an olefin selectivity of 72.0% at the low temperature of 260 °C. By contrast, Na-FeC_x alone without the zeolite promoter is poorly active under equivalent conditions, and shows the significantly improved olefin productivity achieved through the zeolite promoter. These results show that the well-designed zeolite, as a promising promoter, significantly boosts Fischer-Tropsch synthesis to olefins by accelerating escape of the product from the catalyst surface.

Insights into the mechanism of carbon chain growth on zeolite-based Fischer-Tropsch Co/Y catalysts

In a zeolite-based Fischer-Tropsch bifunctional catalyst, zeolites, as the support of the active metal, can interact with the metal cluster to affect the electronic properties and structural effect of the catalyst, thus affecting the Fischer-Tropsch synthesis reaction. In this work, the Fischer-Tropsch synthesis process using a Co catalyst supported by Y-zeolite was simulated by the DFT method from the microscopic point of view. The reaction network was designed to investigate the reaction mechanism in terms of four parts consisting of H-assisted CO dissociation, C₁ hydrogenation, CH_x-CH_x coupling, and C₂-C₄ growth. It was found that the introduction of Y-zeolite enhanced the adsorption capacity of the catalyst for most species. Moreover, the catalytic mechanism of the Co/Y catalyst was clarified, and we found that the introduction of the Y-zeolite mainly reduced the reaction energy barriers of the CH-CH coupling and C₂-C₄ carbon chain growth process, which also explained the high proportion of long carbon chain hydrocarbons in the Fischer-Tropsch synthesis products after Y-zeolite was introduced.

Favoring the Methane Oxychlorination Reaction over EuOCl by Synergistic Effects with Lanthanum

The direct conversion of CH4 into fuels and chemicals produces less waste, requires smaller capital investments, and has improved energy efficiency compared to multistep processes. While the methane oxychlorination (MOC) reaction has been given little attention, it offers the potential to achieve high CH4 conversion levels at high selectivities. In a continuing effort to design commercially interesting MOC catalysts, we have improved the catalyst design of EuOCl by the partial replacement of Eu3+ by La3+. A set of catalytic solid solutions of La3+ and Eu3+ (i.e., La x Eu1-x OCl, where x = 0, 0.25, 0.50, 0.75, and 1) were synthesized and tested in the MOC reaction. The La3+-Eu3+ catalysts exhibit an increased CH3Cl selectivity (i.e., 54-66 vs 41-52%), a lower CH2Cl2 selectivity (i.e., 8-24 vs 18-34%), and a comparable CO selectivity (i.e., 11-28 vs 14-28%) compared to EuOCl under the same reaction conditions and varying HCl concentrations in the feed. The La3+-Eu3+ catalysts possessed a higher CH4 conversion rate than when the individual activities of LaOCl and EuOCl are summed with a similar La3+/Eu3+ ratio (i.e., the linear combination). In the solid solution, La3+ is readily chlorinated and acts as a chlorine buffer that can transfer chlorine to the active Eu3+ phase, thereby enhancing the activity. The improved catalyst design enhances the CH3Cl yield and selectivity and reduces the catalyst cost and the separation cost of the unreacted HCl. These results showcase that, by matching intrinsic material properties, catalyst design can be altered to overcome reaction bottlenecks.

In Situ Active Site for Fe-Catalyzed Fischer-Tropsch Synthesis: Recent Progress and Future Challenges

Fischer-Tropsch synthesis (FTS) that converts syngas into long-chain hydrocarbons is a key technology in the chemical industry. As one of the best catalysts for FTS, the Fe-based composite develops rich solid phases (metal, oxides, and carbides) in the catalytic reaction, which triggered the quest for the true active site in catalysis in the past century. Recent years have seen great advances in probing the active-site structure using modern experimental and theoretical tools. This Perspective serves to highlight these latest achievements, focusing on the geometrical structure and thermodynamic stability of Fe carbide bulk phases, the exposed surfaces, and their relationship to FTS activity. The current reaction mechanisms on CO activation and carbon chain growth are also discussed, in the context of theoretical models and experimental evidence. We also present the outlook regarding the current challenges in Fe-based FTS.

General Synthetic Strategy to Ordered Mesoporous Carbon Catalysts with Single-Atom Metal Sites for Electrochemical CO2 Reduction

The electrochemical carbon dioxide reduction reaction (CO₂ RR) is a transformative technology to reduce the carbon footprint of modern society. Single-site catalysts have been demonstrated as promising catalysts for CO₂ RR, but general synthetic methods for catalysts with high surface area and tunable single-site metal composition still need to be developed to unambiguously investigate the structure-activity relationship crossing various metal sites. Here, a generalized coordination-condensation strategy is reported to prepare single-atom metal sites on ordered mesoporous carbon (OMC) with high surface areas (average 800 m²  g^-1 ). This method is applicable to a broad range of metal sites (Fe, Co, Ni, Cu, Pt, Pd, Ru, and Rh) with loadings up to 4 wt.%. In particular, the CO₂ RR to carbon monoxide (CO) Faradaic efficiency (FE) with Ni single-site OMC catalyst reaches 95%. This high FE is maintained even under large current density (>140 mA cm^-2 ) and in a long-term study (14 h), which suits the urgently needed large-scale applications. Theoretical calculations suggest that the enhanced activity on single-atom Ni sites results from balanced binding energies between key intermediates, COOH and CO, for CO₂ RR, as mediated by the coordination sphere.

Production of Light Olefins via Fischer-Tropsch Process Using Iron-Based Catalysts: A Review

The production of light olefins, as the critical components in chemical industries, is possible via different technologies. The Fischer–Tropsch to olefin (FTO) process aims to convert syngas to light olefins with high selectivity over a proper catalyst, reduce methane formation, and avoid the production of excess CO2. This review describes the production of light olefins through the FTO process using both unsupported and supported iron-based catalysts. The catalytic properties and performances of both the promoted and bimetallic unsupported catalysts are reviewed. The effect of support and its physico-chemical properties on the catalyst activity are also described. The proper catalyst should have high stability to provide long-term performance without reducing the activity and selectivity towards the desired product. The good dispersion of active metals on the surface, proper porosity, optimized metal-support interaction, a high degree of reducibility, and providing a sufficient active phase for the reaction are important parameters affecting the reaction. The selection of the suitable catalyst with enhanced activity and the optimum process conditions can increase the possibility of the FTO reaction for light-olefins production. The production of light olefins via the FTO process over iron-based catalysts is a promising method, as iron is cheap, shows higher resistance to sulfur, and has a higher WGS activity which can be helpful for the feed gas with a low H2/CO ratio, and also has higher selectivity towards light olefins.

CeO2-Promoted PtSn/SiO2 as a High-Performance Catalyst for the Oxidative Dehydrogenation of Propane with Carbon Dioxide

The oxidative dehydrogenation of propane with CO₂ (CO₂-ODP) has been extensively investigated as a promising green technology for the efficient production of propylene, but the lack of a high-performance catalyst is still one of the main challenges for its industrial application. In this work, an efficient catalyst for CO₂-ODP was developed by adding CeO₂ to PtSn/SiO₂ as a promoter via the simple impregnation method. Reaction results indicate that the addition of CeO₂ significantly improved the catalytic activity and propylene selectivity of the PtSn/SiO₂ catalyst, and the highest space-time yield of 1.75 g(C₃H₆)·g(catalyst)^-1·h^-1 was achieved over PtSn/SiO₂ with a Ce loading of 6 wt%. The correlation of the reaction results with the characterization data reveals that the introduction of CeO₂ into PtSn/SiO₂ not only improved the Pt dispersion but also regulated the interaction between Pt and Sn species. Thus, the essential reason for the promotional effect of CeO₂ on CO₂-ODP performance was rationally ascribed to the enhanced adsorption of propane and CO₂ originating from the rich oxygen defects of CeO₂. These important understandings are applicable in further screening of promoters for the development of a high-performance Pt-based catalyst for CO₂-ODP.

Efficient CO2 catalytic hydrogenation over CuOx–ZnO/silicalite-1 with stable Cu+ species

Efficient and stable CuOx–ZnO/S-1 catalysts for CO2 hydrogenation were inexpensively prepared, in which the ZnO–Cu2O interface and silanol nests play key roles.

Advances in Zeolite-Supported Metal Catalysts for Propane Dehydrogenation

Propylene is one of the building blocks of the modern industrial mansion, which is the feeding stock for polypropylene, acrylonitrile, and other important chemicals. Propane dehydrogenation (PDH) is one of...

A mechanistic study of syngas conversion to light olefins over OXZEO bifunctional catalysts: insights into the initial carbon–carbon bond formation on the oxide

NMR experiments reveal a mechanism of syngas conversion in which CO reacts with OCH3 on the oxide surface, generating ketene intermediates, which can either form acetate or diffuse into zeolite.

Effects of alkaline-earth metals on CoMn-based catalysts for the Fischer–Tropsch synthesis to olefins

Alkaline-earth metal promoted CoMn catalysts with higher surface basicity benefit the carburization of CoMn oxides to form more Co2C nanoprisms for olefin formation, especially for long-chain olefins.

Unravelling the metal–support interactions in χ-Fe5C2/MgO catalysts for olefin synthesis directly from syngas

The structural and electronic modifications of χ-Fe5C2 by MgO contribute to the high selectivity towards lower olefins and the high catalyst stability.

Enhanced stability of a fused iron catalyst under realistic Fischer–Tropsch synthesis conditions: insights into the role of iron phases (χ-Fe5C2, θ-Fe3C and α-Fe)

The performance and stability of fused-Fe catalyst in FTS reaction are enhanced through the control synthesis of iron phases (χ-Fe5C2, θ-Fe3C and α-Fe).

Nano-scale insights regarding coke formation in zeolite SSZ-13 subject to the methanol-to-hydrocarbons reaction

The methanol-to-hydrocarbons (MTH) process, commonly catalyzed by zeolites, is of great commercial interest and therefore widely studied both in industry and academia. However, zeolite-based catalyst materials are notoriously hard to study at the nano-scale. Atom probe tomography (APT) is uniquely positioned among the suite of characterization techniques, as it can provide 3D chemical information with sub-nm resolution. In this work, we have used APT to study the nano-scale coking behavior of zeolite SSZ-13 and its relation to bulk coke formation on the macro-/micro-scale studied with operando and in situ UV-vis spectroscopy and microscopy. Radial distribution function analysis (RDF) of the APT data revealed short carbon–carbon length scale affinities, consistent with the formation of larger aromatic molecules (coke species). Using nearest neighbor distribution (NND) analysis, an increase in the homogeneity of carbon was found with increasing time-on-stream. However, carbon clusters could not be isolated due to spatial noise and limited clustering. Therefore, it was found that the coke formation in zeolite SSZ-13 (CHA) is reasonably homogeneous on the nano-scale, and is rather similar to the silicoaluminophosphate analogue SAPO-34 (CHA) but different in nano-scale coking behavior compared to previously studied zeolite ZSM-5 (MFI).

A correlation between the micro- and nano-scale coking behavior of SSZ-13 was discovered with in situ/operando spectroscopy and atom probe tomography (APT), which allows for spatial reconstruction and analysis of relations between framework elements and carbon atoms.

Effective conversion of CO2 into light olefins over a bifunctional catalyst consisting of La-modified ZnZrOx oxide and acidic zeolite

Addition of proper amount of La produces more oxygen vacancies on ZnZrOx(nLa), hence promoting the formation of methanol. Upon coupling with H-SAPO-34, ZnZrOx(0.3La)/H-SAPO-34 catalyst shows a C2=–C4= selectivity in hydrocarbons as high as 83.2%.

Roles of ethanol in coke formation and HZSM-5 deactivation during n-heptane catalytic cracking

Compared with n-heptane, ethanol easily interacted with the acid site of HZSM-5, promoting alkene and external coke formation.

Probing combustion and catalysis intermediates by synchrotron vacuum ultraviolet photoionization molecular-beam mass spectrometry: recent progress and future opportunities

Soft photoionization molecular-beam mass spectrometry (PI MBMS) with synchrotron vacuum ultraviolet light (SVUV) has has a significant development and broad applications in recent decades. Particularly, the tunability of SVUV enables...

Catalytic selective ethane dehydrogenation at low-temperature with low coke formation

Catalytic ethane dehydrogenation (EDH) was investigated to improve the efficient production of ethylene, an extremely important chemical feedstock. The perovskite oxide YCrO₃ was found to be more suitable than earlier reported catalysts because it exhibits greater activity and C₂H₄ selectivity (94.3%) in the presence of steam at 973 K. This catalyst shows the highest activity than ever under kinetic conditions, and shows very high ethane conversion under integral reaction conditions. Comparison with EDH performance under conditions without steam revealed that steam plays an important role in stabilizing the high activity. Raman spectra of spent catalysts indicated that steam prevents coke formation, which is responsible for deactivating YCrO₃. Transmission IR and XPS measurements also revealed a mechanism by which H₂O forms surface oxygen species on YCrO₃, consequently removing C₂H₆-derived coke precursors rapidly and inhibiting coke accumulation.

Catalytic ethane dehydrogenation for improving efficient production of ethylene, an extremely important chemical feedstock.

Activation and catalytic transformation of methane under mild conditions

In the last few decades, worldwide scientists have been motivated by the promising production of chemicals from the widely existing methane (CH₄) under mild conditions for both chemical synthesis with low energy consumption and climate remediation. To achieve this goal, a whole library of catalytic chemistries of transforming CH₄ to various products under mild conditions is required to be developed. Worldwide scientists have made significant efforts to reach this goal. These significant efforts have demonstrated the feasibility of oxidation of CH₄ to value-added intermediate compounds including but not limited to CH₃OH, HCHO, HCOOH, and CH₃COOH under mild conditions. The fundamental understanding of these chemical and catalytic transformations of CH₄ under mild conditions have been achieved to some extent, although currently neither a catalyst nor a catalytic process can be used for chemical production under mild conditions at a large scale. In the academic community, over ten different reactions have been developed for converting CH₄ to different types of oxygenates under mild conditions in terms of a relatively low activation or catalysis temperature. However, there is still a lack of a molecular-level understanding of the activation and catalysis processes performed in extremely complex reaction environments under mild conditions. This article reviewed the fundamental understanding of these activation and catalysis achieved so far. Different oxidative activations of CH₄ or catalytic transformations toward chemical production under mild conditions were reviewed in parallel, by which the trend of developing catalysts for a specific reaction was identified and insights into the design of these catalysts were gained. As a whole, this review focused on discussing profound insights gained through endeavors of scientists in this field. It aimed to present a relatively complete picture for the activation and catalytic transformations of CH₄ to chemicals under mild conditions. Finally, suggestions of potential explorations for the production of chemicals from CH₄ under mild conditions were made. The facing challenges to achieve high yield of ideal products were highlighted and possible solutions to tackle them were briefly proposed.

Functionalized Carbon Materials in Syngas Conversion

Functionalized carbon materials are widely used in heterogeneous catalysis due to their unique properties such as adjustable surface properties, excellent thermal conductivity, high surface areas, tunable porosity, and moderate interactions with guest metals. The transformation of syngas into hydrocarbons (known as the Fischer-Tropsch synthesis) or oxygenates is an exothermic reaction and is typically catalyzed by transition metals dispersed on functionalized supports. Various carbon materials have been employed in syngas conversions not only for improving the performance or decreasing the dosage of expensive active metals but also for building model catalysts for fundamental research. This article provides a critical review on recent advances in the utilization of carbon materials, in particular the recently developed functionalized nanocarbon materials, for syngas conversions to either hydrocarbons or oxygenates. The unique features of carbon materials in dispersing metal nanoparticles, heteroatom doping, surface modification, and building special nanoarchitectures are highlighted. The key factors that control the reaction course and the reaction mechanism are discussed to gain insights for the rational design of efficient carbon-supported catalysts for syngas conversions. The challenges and future opportunities in developing functionalized carbon materials for syngas conversions are briefly analyzed.

The origin of the particle-size-dependent selectivity in 1-butene isomerization and hydrogenation on Pd/Al2O3 catalysts

The selectivity of 1-butene hydrogenation/isomerization on Pd catalysts is known to be particle size dependent. Here we show that combining well-defined model catalysts, atmospheric pressure reaction kinetics, DFT calculations and microkinetic modeling enables to rationalize the particle size effect based on the abundance and the specific properties of the contributing surface facets.