Stability and Reactivity of ϵ−χ−θ Iron Carbide Catalyst Phases in Fischer−Tropsch Synthesis: Controlling μC

In Situ Active Site for CO Activation in Fe-Catalyzed Fischer-Tropsch Synthesis from Machine Learning

In situ-formed iron carbides (FeC_x) are the key components responsible for Fischer-Tropsch synthesis (FTS, CO + H₂ → long-chain hydrocarbons) on Fe-based catalysts in industry. The true active site is, however, highly controversial despite more than a century of study, which is largely due to the combined complexity in both FeC_x structures and mechanism of CO hydrogenation. Herein powered by machine learning simulation, millions of structure candidates for FeC_x bulk and surfaces are explored under FTS conditions, which leads to resolving the active site for CO activation. This is achieved without a priori input from experiment by first constructing the thermodynamics convex hull of bulk phases, followed by identifying the low surface energy surfaces and evaluating the adsorption ability of CO and H, and finally determining the lowest energy reaction pathway of CO activation. Rich information on FeC_x structures and CO hydrogenation pathways is gleaned: (i) Fe₅C₂, Fe₇C₃, and Fe₂C are the three stable bulk phases under FTS in producing olefins, where Fe₇C₃ and Fe₂C have multiple energetically nearly degenerate bulk crystal phases; (ii) only three low surface energy surfaces of these bulk phases, namely, χ-Fe₅C₂(510), χ-Fe₅C₂(111), and η-Fe₂C(111), expose the Fe sites that can adsorb H atoms exothermically, where the surface Fe:C ratio is 2, 1.75, and 2, respectively; (iii) CO activation via direct dissociation can occur at the surface C vacancies (e.g., with a barrier of 1.1 eV) that are created dynamically via hydrogenation. These atomic-level understandings facilitate the building of the structure-activity correlation and designing better FT catalysts.

Evolution of the Local Structure in the Sol-Gel Synthesis of Fe3C Nanostructures

The sol–gel synthesis of iron carbide (Fe₃C) nanoparticles proceeds through multiple intermediate crystalline phases, including iron oxide (FeO_x) and iron nitride (Fe₃N). The control of particle size is challenging, and most methods produce polydisperse Fe₃C nanoparticles of 20–100 nm in diameter. Given the wide range of applications of Fe₃C nanoparticles, it is essential that we understand the evolution of the system during the synthesis. Here, we report an in situ synchrotron total scattering study of the formation of Fe₃C from gelatin and iron nitrate sol–gel precursors. A pair distribution function analysis reveals a dramatic increase in local ordering between 300 and 350 °C, indicating rapid nucleation and growth of iron oxide nanoparticles. The oxide intermediate remains stable until the emergence of Fe₃N at 600 °C. Structural refinement of the high-temperature data revealed local distortion of the NFe₆ octahedra, resulting in a change in the twist angle suggestive of a carbonitride intermediate. This work demonstrates the importance of intermediate phases in controlling the particle size of a sol–gel product. It is also, to the best of our knowledge, the first example of in situ total scattering analysis of a sol–gel system.

In situ total scattering analysis has uncovered the importance of iron oxide as an intermediate phase in the synthesis of Fe₃C nanoparticles from sol−gel precursors. A sudden increase in order is observed between 300 and 350 °C, associated with the crystallization of iron oxide nanoparticles. The local structure of the Fe₃N intermediate is also investigated.

The Electrophilicity of Surface Carbon Species in the Redox Reactions of CuO-CeO2 Catalysts

Electronic metal–support interactions (EMSI) describe the electron flow between metal sites and a metal oxide support. It is generally used to follow the mechanism of redox reactions. In this study of CuO‐CeO₂ redox, an additional flow of electrons from metallic Cu to surface carbon species is observed via a combination of operando X‐ray absorption spectroscopy, synchrotron X‐ray powder diffraction, near ambient pressure near edge X‐ray absorption fine structure spectroscopy, and diffuse reflectance infrared Fourier transform spectroscopy. An electronic metal–support–carbon interaction (EMSCI) is proposed to explain the reaction pathway of CO oxidation. The EMSCI provides a complete picture of the mass and electron flow, which will help predict and improve the catalytic performance in the selective activation of CO₂, carbonate, or carbonyl species in C1 chemistry.

Effects of Structure and Particle Size of Iron, Cobalt and Ruthenium Catalysts on Fischer–Tropsch Synthesis

This review emphasizes the importance of the catalytic conversion techniques in the production of clean liquid and hydrogen fuels (XTF) and chemicals (XTC) from the carbonaceous materials including coal, natural gas, biomass, organic wastes, biogas and CO2. Dependence of the performance of Fischer–Tropsch Synthesis (FTS), a key reaction of the XTF/XTC process, on catalyst structure (crystal and size) is comparatively examined and reviewed. The contribution illustrates the very complicated crystal structure effect, which indicates that not only the particle type, but also the particle shape, facets and orientation that have been evidenced recently, strongly influence the catalyst performance. In addition, the particle size effects over iron, cobalt and ruthenium catalysts were carefully compared and analyzed. For all Fe, Co and Ru catalysts, the metal turnover frequency (TOF) for CO hydrogenation increased with increasing metal particle size in the small size region i.e., less than the size threshold 7–8 nm, but was found to be independent of particle size for the catalysts with large particle sizes greater than the size threshold. There are some inconsistencies in the small particle size region for Fe and Ru catalysts, i.e., an opposite activity trend and an abnormal peak TOF value were observed on a Fe catalyst and a Ru catalyst (2 nm), respectively. Further study from the literature provides deeper insights into the catalyst behaviors. The intrinsic activity of Fe catalysts (10 nm) at 260–300 °C is estimated in the range of 0.046–0.20 s−1, while that of the Co and Ru catalysts (7–70 nm) at 220 °C are 0.1 s−1 and 0.4 s−1, respectively.

Kinetics and Selectivity Study of Fischer–Tropsch Synthesis to C5+ Hydrocarbons: A Review

Fischer–Tropsch synthesis (FTS) is considered as one of the non-oil-based alternatives for liquid fuel production. This gas-to-liquid (GTL) technology converts syngas to a wide range of hydrocarbons using metal (Fe and Co) unsupported and supported catalysts. Effective design of the catalyst plays a significant role in enhancing syngas conversion, selectivity towards C5+ hydrocarbons, and decreasing selectivity towards methane. This work presents a review on catalyst design and the most employed support materials in FTS to synthesize heavier hydrocarbons. Furthermore, in this report, the recent achievements on mechanisms of this reaction will be discussed. Catalyst deactivation is one of the most important challenges during FTS, which will be covered in this work. The selectivity of FTS can be tuned by operational conditions, nature of the catalyst, support, and reactor configuration. The effects of all these parameters will be analyzed within this report. Moreover, zeolites can be employed as a support material of an FTS-based catalyst to direct synthesis of liquid fuels, and the specific character of zeolites will be elaborated further. Furthermore, this paper also includes a review of some of the most employed characterization techniques for Fe- and Co-based FTS catalysts. Kinetic study plays an important role in optimization and simulation of this industrial process. In this review, the recent developed reaction rate models are critically discussed.

Adjusting the CO2 hydrogenation pathway via the synergic effects of iron carbides and iron oxides

The synergic effects of iron carbides and iron oxides were used to adjust the reaction pathway to form alkenes or ethanol.

Surface activation by electron scavenger metal nanorod adsorption on TiH2, TiC, TiN, and Ti2O3

Metal/oxide support perimeter sites are known to provide unique properties because the nearby metal changes the local environment on the support surface. In particular, the electron scavenger effect reduces the energy necessary for surface anion desorption, and thereby contributes to activation of the (reverse) Mars-van Krevelen mechanism. This study investigated the possibility of such activation in hydrides, carbides, nitrides, and sulfides. The work functions (WFs) of known hydrides, carbides, nitrides, oxides, and sulfides with group 3, 4, or 5 cations (Sc, Y, La, Ti, Zr, Hf, V, Nb, and Ta) were calculated. The WFs of most hydrides, carbides, and nitrides are smaller than the WF of Ag, implying that the electron scavenger effect may occur when late transition metal nanoparticles are adsorbed on the surface. The WF of oxides and sulfides decreases when reduced. The surface anion vacancy formation energy correlates well with the bulk formation energy in carbides and nitrides, while almost no correlation is found in hydrides because of the small range of surface hydrogen vacancy formation energy values. The electron scavenger effect is explicitly observed in nanorods adsorbed on TiH2 and Ti2O3; the surface vacancy formation energy decreases at anion sites near the nanorod, and charge transfer to the nanorod happens when an anion is removed at such sites. Activation of hydrides, carbides, and nitrides by nanorod adsorption and screening support materials through WF calculation are expected to open up a new category of supported catalysts.

Novel Magnetic Nanohybrids: From Iron Oxide to Iron Carbide Nanoparticles Grown on Nanodiamonds

The synthesis and characterization of a new line of magnetic hybrid nanostructured materials composed of spinel-type iron oxide to iron carbide nanoparticles grown on nanodiamond nanotemplates is reported in this study. The realization of these nanohybrid structures is achieved through thermal processing under vacuum at different annealing temperatures of a chemical precursor, in which very fine maghemite (γ-Fe2O3) nanoparticles seeds were developed on the surface of the nanodiamond nanotemplates. It is seen that low annealing temperatures induce the growth of the maghemite nanoparticle seeds to fine dispersed spinel-type non-stoichiometric ~5 nm magnetite (Fe3−xO4) nanoparticles, while intermediate annealing temperatures lead to the formation of single phase ~10 nm cementite (Fe3C) iron carbide nanoparticles. Higher annealing temperatures produce a mixture of larger Fe3C and Fe5C2 iron carbides, triggering simultaneously the growth of large-sized carbon nanotubes partially filled with these carbides. The magnetic features of the synthesized hybrid nanomaterials reveal the properties of their bearing magnetic phases, which span from superparamagnetic to soft and hard ferromagnetic and reflect the intrinsic magnetic properties of the containing phases, as well as their size and interconnection, dictated by the morphology and nature of the nanodiamond nanotemplates. These nanohybrids are proposed as potential candidates for important technological applications in nano-biomedicine and catalysis, while their synthetic route could be further tuned for development of new magnetic nanohybrid materials.

Stabilization of ε-iron carbide as high-temperature catalyst under realistic Fischer-Tropsch synthesis conditions

The development of efficient catalysts for Fischer–Tropsch (FT) synthesis, a core reaction in the utilization of non-petroleum carbon resources to supply energy and chemicals, has attracted much recent attention. ε-Iron carbide (ε-Fe₂C) was proposed as the most active iron phase for FT synthesis, but this phase is generally unstable under realistic FT reaction conditions (> 523 K). Here, we succeed in stabilizing pure-phase ε-Fe₂C nanocrystals by confining them into graphene layers and obtain an iron-time yield of 1258 μmol_CO g_Fe⁻¹s⁻¹ under realistic FT synthesis conditions, one order of magnitude higher than that of the conventional carbon-supported Fe catalyst. The ε-Fe₂C@graphene catalyst is stable at least for 400 h under high-temperature conditions. Density functional theory (DFT) calculations reveal the feasible formation of ε-Fe₂C by carburization of α-Fe precursor through interfacial interactions of ε-Fe₂C@graphene. This work provides a promising strategy to design highly active and stable Fe-based FT catalysts.

ε-Fe₂C has been identified as the highly active phase for Fischer-Tropsch synthesis (FTS), but is stable only at low-temperature. Here, the authors show that ε-Fe₂C phase can be stabilized even at ~ 573 K by being encapsulated inside graphene layers, and retains high activity in FTS.

Role of C-Defective Sites in CO Adsorption over ϵ-Fe2 C and η-Fe2 C Fischer-Tropsch Catalysts

Herein, we report the crucial importance of C-defective sites on the CO adsorption over ϵ-Fe₂ C and η-Fe₂ C Fischer-Tropsch catalysts via systematic DFT calculations. The simulated XRD and Wulff construction show the significant differences in their equilibrium shapes and most exposed surfaces. It is observed that the ϵ-Fe₂ C exposes a high proportion (89 %) of facets (1 2 ‾ 1) with similar structure to that of η-Fe₂ C (011) which has been proved to be the active surface of CO activation.

Hydrogenation of CO to olefins over a supported iron catalyst on MgAl2O4 spinel: effects of the spinel synthesis method

In the process of CO hydrogenation to olefins by the Fischer–Tropsch synthesis (FTO), the support is a key factor in the activity, selectivity, and thermal and chemical stability of the catalysts, and magnesium aluminate spinel (MgAl₂O₄) has recently been reported to be very effective. In this work, three methods, namely, citric acid solution combustion (MAC), EDTA sol–gel (MAG) and NH₃-coprecipitation (MAP) have been employed to prepare the spinel with detailed characterization of the structure, specific surface area, porosity, and alkalinity properties of both the as-synthesized spinel and the supported catalysts. The results showed that MAC and MAG possessed stronger basicity with more homogeneous particle sizes and narrower distribution of the pore size due to the formation of the metal-nitrate–chelate-complex. This led to a large quantity of gas being released during calcination, however, stronger interactions between the active phase and MAC resulted in lower CO conversion. The catalyst supported on MAP (CMAP) exhibited the highest CO conversion, the highest selectivity of lower olefins, the shortest induction period of reaction, and the lowest AFS chain growth probability; thus, MAP was suggested as an applicable synthetic method. Based on the CMAP catalyst, the effects of the operational conditions were investigated and a 200 hour stability test was carried out with satisfactory performance.

In the process of CO hydrogenation to olefins by the Fischer–Tropsch synthesis, the support is a key factor in the activity, selectivity, and thermal and chemical stability of the catalysts, and magnesium aluminate spinel has recently been reported to be very effective.

Magnetic Heterostructures: Interface Control to Optimize Magnetic Property and Multifunctionality

Generally, magnetic heterostructures are obtained by the growth of another component on the surface of seed nanoparticles. The direct electrical and magnetic interactions between the solid-state interfaces would endow the heterostructures with properties beyond the individual components. We have devoted the past few years to magnetic-optical, magnetic-catalytic, and exchange-coupled heterostructures, where the interface effects regulate and optimize the optical, catalytic, and magnetic properties, respectively. In this Spotlight on Applications, we describe our recent progress on magnetic heterostructures. Upon the understanding on the interface control, we then discuss our recent efforts to synthesize core-shell, dimer, and nanocomposite structures, while the regulation of their magnetic, optical, and catalytic properties is addressed in turn. Finally, we give the perspectives of magnetic heterostructures.

A DFT Insight into the Tuning Effect of Potassium Promoter on the Formation of Carbon Atoms via Carburization Gases Dissociation on Iron-Based Catalysts

The research of the formation mechanism of iron carbides is significant to design the high-performance catalysts for the Fischer–Tropsch synthesis (FTS) process. In this paper, the effect of potassium promoter on the formation of atomic carbon via carburization gases dissociation on the iron-based catalyst, the C2H4, C2H2 and CO/H2 adsorption energies and dissociation paths as well as the rate constants of the corresponding elementary steps are investigated by DFT on the Fe(110), Fe(110)-K2O, Fe(211) and Fe(211)-K2O surfaces. The calculation results demonstrated that the K2O promoter can modify the capabilities of surface C formation via the thermodynamic method as well as the kinetical method. The K2O promoter can increase the CO adsorption energy while decreasing the C2H4 adsorption energy both on Fe(110) and Fe(211) surfaces. Kinetically, via tuning the catalyst surfaces from Fe(110) to Fe(211), the K2O promoter can inhibit the ability of C2H4/C2H2 dissociation to atomic carbon, while enhancing the ability of CO/H2 decomposition to atomic carbon. The C2H4/C2H2 dissociation rate constants on Fe(211) and Fe(211)-K2O are about 107 times slower than that on Fe(110) and Fe(110)-K2O, whereas the dissociation rate constants of CO/H2 on Fe(211) are about 106 times faster than that on Fe(110), and about 107 times faster on Fe(211)-K2O than on Fe(110)-K2O.

Facile fabrication of porous Fe@C nanohybrids from natural magnetite as excellent Fischer-Tropsch catalysts

Fe-Based catalysts play crucial roles in Fischer-Tropsch synthesis (FTS). Herein, we for the first time demonstrate a facile sol-gel approach using natural magnetite and citric acid to fabricate porous Fe@C nanohybrids as FTS catalysts. Excellent FTS activity and stability were revealed and attributed to the formation of an Fe3C active phase and a core-shell structure. This flexible synthesis strategy clearly highlights the promising application of such materials in FTS.

The Application of Quasi-Elastic Neutron Scattering to Investigate Hydrogen Diffusion in an Iron-Based Fischer–Tropsch Synthesis Catalyst

Iron-based Fischer–Tropsch synthesis (FTS) catalysts evolve in situ on exposure to synthesis gas (CO & H2) forming a mixture of iron oxides, iron carbides and carbonaceous deposits. Recently, the application of inelastic neutron scattering has shown the progressive formation of a hydrocarbonaceous overlayer during this catalyst conditioning period. The evolving nature of the catalyst alters the proportion of phases present within the catalyst, which may influence the transport of hydrogen within the reaction system. Preliminary quasi-elastic neutron scattering (QENS) measurements are used to investigate hydrogen diffusion within an un-promoted iron FTS catalyst that has experienced varying levels of time-on-stream (0, 12 and 24 h) of ambient pressure CO hydrogenation at 623 K. Measurements on the catalyst samples in the absence of hydrogen show the unreacted sample (t = 0 h) to exhibit little increase in motion over the temperature range studied, whereas the t = 12 and 24 h samples exhibit a pronounced change in motion with temperature. The contrast is attributed to the presence of the afore-mentioned hydrocarbonaceous overlayer. Measurements on the samples in the presence of liquid hydrogen show hydrogen diffusional characteristics to be modified as a function of the catalyst conditioning process but, due to the complexity of the evolving catalyst matrix, the hydrogen motion cannot be attributed to a particular phase or component of the catalyst. Problems in the use of hydrogen as a probe molecule in this instance are briefly considered. Coincident neutron diffraction studies undertaken alongside the QENS measurements confirm the transition from hematite pre-catalyst to that of Hägg carbide during the course of extended times-on-stream.

Interfacial Fe5C2-Cu catalysts toward low-pressure syngas conversion to long-chain alcohols

Long-chain alcohols synthesis (LAS, C₅₊OH) from syngas provides a promising route for the conversion of coal/biomass/natural gas into high-value chemicals. Cu-Fe binary catalysts, with the merits of cost effectiveness and high CO conversion, have attracted considerable attention. Here we report a nano-construct of a Fe₅C₂-Cu interfacial catalyst derived from Cu₄Fe₁Mg₄-layered double hydroxide (Cu₄Fe₁Mg₄-LDH) precursor, i.e., Fe₅C₂ clusters (~2 nm) are immobilized onto the surface of Cu nanoparticles (~25 nm). The interfacial catalyst exhibits a CO conversion of 53.2%, a selectivity of 14.8 mol% and a space time yield of 0.101 g g_cat⁻¹ h⁻¹ for long-chain alcohols, with a surprisingly benign reaction pressure of 1 MPa. This catalytic performance, to the best of our knowledge, is comparable to the optimal level of Cu-Fe catalysts operated at much higher pressure (normally above 3 MPa).

Long-chain alcohols synthesis from syngas conversion is a promising route for the production of high-value chemicals. Here the authors show that a heterogeneous Fe₅C₂/Cu catalyst derived from layered double hydroxides precursor exhibits excellent performance with a space time yield of 0.101 g g_cat⁻¹ h⁻¹ at a low pressure of 1 MPa.

Iron Carbides: Control Synthesis and Catalytic Applications in COx Hydrogenation and Electrochemical HER

Catalytic transformation of CO_x (x = 1, 2) with renewable H₂ into valuable fuels and chemicals provides practical processes to mitigate the worldwide energy crisis. Fe-based catalytic materials are widely used for those reactions due to their abundance and low cost. Novel iron carbides are particularly promising catalytic materials among the reported ferrous catalysts. Recently, a series of strategies has been developed for the preparation of iron carbide nanoparticles and their nanocomposites. Control synthesis of FeC_x -based nanomaterials and their catalytic applications in CO_x hydrogenation and electrochemical hydrogen evolution reaction (HER) are reviewed. The discussion is focused on the unique catalytic activities of iron carbides in CO_x hydrogenation and HER and the correlation between structure and catalytic performance. Future synthesis and potential catalytic applications of iron carbides are also summarized.