Olefins from Natural Gas by Oxychlorination

Europium–Magnesium–Aluminum-Based Mixed-Metal Oxides as Highly Active Methane Oxychlorination Catalysts

Methane oxychlorination (MOC) is a promising reaction for the production of liquefied methane derivatives. Even though catalyst design is still in its early stages, the general trend is that benchmark catalyst materials have a redox-active site, with, e.g., Cu²⁺, Ce⁴⁺, and Pd²⁺ as prominent showcase examples. However, with the identification of nonreducible LaOCl moiety as an active center for MOC, it was demonstrated that a redox-active couple is not a requirement to establish a high activity. In this work, we show that Mg²⁺-Al³⁺-based mixed-metal oxide (MMO) materials are highly active and stable MOC catalysts. The synergistic interaction between Mg²⁺ and Al³⁺ could be exploited due to the fact that a homogeneous distribution of the chemical elements was achieved. This interaction was found to be crucial for the unexpectedly high MOC activity, as reference MgO and γ-Al₂O₃ materials did not show any significant activity. Operando Raman spectroscopy revealed that Mg²⁺ acted as a chlorine buffer and subsequently as a chlorinating agent for Al³⁺, which was the active metal center in the methane activation step. The addition of the redox-active Eu³⁺ to the nonreducible Mg²⁺-Al³⁺ MMO catalyst enabled further tuning of the catalytic performance and made the EuMg₃Al MMO catalyst one of the most active MOC catalyst materials reported so far. Combined operando Raman/luminescence spectroscopy revealed that the chlorination behavior of Mg²⁺ and Eu³⁺ was correlated, suggesting that Mg²⁺ also acted as a chlorinating agent for Eu³⁺. These results indicate that both redox activity and synergistic effects between Eu, Mg, and Al are required to obtain high catalytic performance. The importance of elemental synergy and redox properties is expected to be translatable to the oxychlorination of other hydrocarbons, such as light alkanes, due to large similarities in catalytic chemistry.

Engineering the catalytic properties of CeO2 catalyst in HCl-assisted propane dehydrogenation by effective doping: A first-principles-based microkinetic simulation

HCl-assisted propane dehydrogenation (PDH) is an attractive route for propene production with good selectivity. In this study, the doping of CeO2 with different transition metals, including V, Mn, Fe, Co, Ni, Pd, Pt, and Cu, in the presence of HCl was investigated for PDH. The dopants have a pronounced effect on the electronic structure of pristine ceria that significantly alters the catalytic capabilities. The calculations indicate the spontaneous dissociation of HCl on all surfaces with a facile abstraction of the first hydrogen atom except on V- and Mn-doped surfaces. The lowest energy barrier of 0.50 and 0.51eV was found for Pd- and Ni-doped CeO2 surfaces. The surface oxygen is responsible for hydrogen abstraction, and its activity is described by the p-band center. Microkinetics simulation is performed on all doped surfaces. The increase in the turnover frequency (TOF) is directly linked with the partial pressure of propane. The adsorption energy of reactants aligned with the observed performance. The reaction follows first-order kinetics to C3H8. Furthermore, on all surfaces, the formation of C3H7 is found as the rate-determining step confirmed by the degree of rate control (DRC) analysis. This study provides a decisive description of catalyst modification for HCl-assisted PDH.

Bifunctional Europium for Operando Catalyst Thermometry in an Exothermic Chemical Reaction

Often the reactor or the reaction medium temperature is reported in the field of heterogeneous catalysis, even though it could vary significantly from the reactive catalyst temperature. The influence of the catalyst temperature on the catalytic performance and vice versa is therefore not always accurately known. We here apply EuOCl as both solid catalyst and thermometer, allowing for operando temperature determination. The interplay between reaction conditions and the catalyst temperature dynamics is studied. A maximum temperature difference between the catalyst and oven of +16 °C was observed due to the exothermicity of the methane oxychlorination reaction. Heat dissipation by radiation appears dominating compared to convection in this set-up, explaining the observed uniform catalyst bed temperature. Application of operando catalyst thermometry could provide a deeper mechanistic understanding of catalyst performances and allow for safer process operation in chemical industries.

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.

Revealing the role of HBr in propane dehydrogenation on CeO2(111) via DFT-based microkinetic simulation

HBr, as a soft oxidant, has been demonstrated to have a good balance between stability and selectivity in catalytic propane dehydrogenation. However, the origin of enhancements induced by HBr (hydrobromic acid) remains elusive. In this study, DFT-based microkinetic simulations were performed to reveal the reaction pathway and performance of propane dehydrogenation catalyzed by CeO₂ in the presence of HBr. Three scenarios were under the investigations, which are pristine, dissociated HBr, and Br assisted surface hydroxyl. The calculations indicated that HBr significantly enhanced the adsorption of propane and provided alternative pathways for propene formation. More significantly, the energy barrier of C-H bond activation in propane was reduced with the assistance of HBr. It was very interesting to find that the reactivity of surface hydroxyl remarkably increased for C-H bond activation in the presence of HBr. The positive role of HBr is clearly evident from the microkinetic simulation. The TOFs of both propane conversion and propene formation increased after the introduction of HBr, which correlates with the apparent decreased activation energy. The reaction rate has a first order dependence on C₃H₈ and zero order dependence on HBr. The current study lays out a solid basis for further optimization of the performance of propane dehydrogenation.

On-purpose design of dual active sites in single V atom anchored C2N nanosheet for propane dehydrogenation catalysis

As an emerging propylene production technology, propane dehydrogenation (PDH) has attracted much attentions from researchers. In this work, we designed the single transition metal atom anchored C2N nanosheets (TM1/C2N) with...

Mechanistic Insights into the Lanthanide-Catalyzed Oxychlorination of Methane as Revealed by Operando Spectroscopy

Commercialization of CH₄ valorization processes is currently hampered by the lack of suitable catalysts, which should be active, selective, and stable. CH₄ oxychlorination is one of the promising routes to directly functionalize CH₄, and lanthanide-based catalysts show great potential for this reaction, although relatively little is known about their functioning. In this work, a set of lanthanide oxychlorides (i.e., LnOCl with Ln = La, Pr, Nd, Sm, Eu, Gd, Tb, Dy, and Ho) and Er- and Yb-based catalysts were synthesized, characterized, and tested. All lanthanide-based catalysts can directly activate CH₄ into chloromethanes, but their catalytic properties differ significantly. EuOCl shows the most promising catalytic activity and selectivity, as very high conversion levels (>30%) and chloromethane selectivity values (>50%) can be reached at moderate reaction temperatures (∼425 °C). Operando Raman spectroscopy revealed that the chlorination of the EuOCl catalyst surface is rate-limiting; hence, increasing the HCl concentration improves the catalytic performance. The CO selectivity could be suppressed from 30 to 15%, while the CH₄ conversion more than doubled from 11 to 24%, solely by increasing the HCl concentration from 10 to 60% at 450 °C. Even though more catalysts reported in this study and in the literature show a negative correlation between the S _CO and HCl concentration, this effect was never as substantial as observed for EuOCl. EuOCl has promising properties to bring the oxychlorination one step closer to an economically viable CH₄ valorization process.

Ethane-Based Catalytic Process for Vinyl Chloride Manufacture

The use of ethane as a platform molecule for the manufacture of polyvinyl chloride (PVC) is a longstanding challenge, which would allow to reduce the raw material costs and CO₂ emissions to produce this plastic. Herein, we discover that rare earth oxychlorides catalyze in a selective (up to 90 %) and stable (>50 h on stream) manner the reaction of ethane and molecular chlorine into 1,2-dichloroethane, which, upon established cracking, will translate into an order of magnitude higher vinyl chloride productivity compared to ethane oxychlorination technologies. In addition, representative europium oxychloride was supported on suitable carriers and was demonstrated to be selective (up to 90 %) and stable (>40 h on stream) in extrudate form. These findings bring the ethane-based production of PVC one step closer to implementation.

Process modelling and life cycle assessment coupled with experimental work to shape the future sustainable production of chemicals and fuels

Meeting the sustainable development goals and carbon neutrality targets requires transitioning to cleaner products, which poses significant challenges to the future chemical industry. Identifying alternative pathways to cover the growing demand for chemicals and fuels in a more sustainable manner calls for close collaborative programs between experimental and computational groups as well as new tools to support these joint endeavours. In this broad context, we here review the role of process systems engineering tools in assessing and optimising alternative chemical production patterns based on renewable resources, including renewable carbon and energy. The focus is on the use of process modelling and optimisation combined with life cycle assessment methodologies and network analysis to underpin experiments and generate insight into how the chemical industry could optimally deliver chemicals and fuels with a lower environmental footprint. We identify the main gaps in the literature and provide directions for future work, highlighting the role of PSE concepts and tools in guiding the future transition and complementing experimental studies more effectively.

2D Rare Earth Material (EuOCl) with Ultra-Narrow Photoluminescence at Room Temperature

High color purity and color rendition of 2D luminescent materials have long been pursued for applications in low-dimensional lighting, display, biolabeling, and laser. However, the reported photoluminescence (PL) linewidth of most 2D luminescent materials is about dozens of meV. Herein, a brand-new luminescent system of 2D rare earth (RE) material EuOCl (1.1 nm) with ultra-narrow linewidth (1.2 meV) at room temperature is successfully synthesized via chemical vapor deposition (CVD). The linewidth of EuOCl flakes at room temperature is even narrower than most 2D luminescent materials and heterostructures detected at below 10 K. Impressively, the as-synthesized EuOCl flakes show abnormal temperature-dependent photoluminescent properties, which is absolutely different from the relatively stable 4f-4f transitions in RE owing to shielding from outer shell electrons. J-mixing effect has been successfully applied for this phenomenon. Undoubtedly, luminescent 2D EuOCl flakes will open new territory for the applications of 2D RE materials in the 2D luminescent areas, especially for the applications at room temperature.

Physico-Chemical Changes in the KCl-MgCl2/La-FAU Composite Catalyst Induced by Oxidative Dehydrogenation of Ethane

In this research, a binary eutectic composition of KCl and MgCl2 supported over lanthanum exchanged FAU (faujasite) zeolite has been investigated for the oxidative dehydrogenation (ODH) of ethane. The catalyst was prepared by the thermal treatment of La-FAU with a mechanical mixture of alkali chlorides under a flow of helium at 500 °C. The eutectic mixture of alkali chlorides formed at this temperature and a molten layer were spread over the support. Synthesized fresh and spent catalysts were characterized to obtain information about changes in crystallinity, textural properties, phase content, chemical composition, and morphology of the catalyst over the reaction time. The initial conversion of ethane was 80% with ethene as the main product (65% yield). The catalyst deactivation has been demonstrated over time on the stream (TOS). The characterization methods confirmed that the chlorine was being removed from the catalyst. The side products detected by mass spectroscopy, including chlorinated hydrocarbons, have been found as a key pathway of chlorine removal from the catalyst. The exchange of chlorine for oxygen in the catalyst led to a significant decrease in the activity and production of higher hydrocarbons and their oxygenates as side products of the ODH reaction.

Quantification of Redox Sites during Catalytic Propane Oxychlorination by Operando EPR Spectroscopy

Identification and quantification of redox-active centers at relevant conditions for catalysis is pivotal to understand reaction mechanisms and requires development of advanced operando methods. Herein, we demonstrate operando EPR spectroscopy as an important technique to quantify the oxidation state of representative CrPO₄ and EuOCl catalysts during propane oxychlorination, an attractive route for propylene production. In particular, we show that the space-time-yield of C₃ H₆ correlates with the amount of Cr²⁺ and Eu²⁺ ions generated over the catalysts during reaction. These results provide a powerful strategy to gather quantitative understanding of selective alkane oxidation, which could potentially be extrapolated to other functionalization approaches and operating conditions.

Oxidative dehydrogenation of light alkanes to olefins on metal-free catalysts

Metal-free boron- and carbon-based catalysts have shown both great fundamental and practical value in oxidative dehydrogenation (ODH) of light alkanes. In particular, boron-based catalysts show a superior selectivity toward olefins, excellent stability and atom-economy to valuable carbon-based products by minimizing CO2 emission, which are highly promising in future industrialization. The carbonaceous catalysts also exhibited impressive behavior in the ODH of light alkanes helped along by surface oxygen-containing functional groups. This review surveyed and compared the preparation methods of the boron- and carbon-based catalysts and their characterization, their performance in the ODH of light alkanes, and the mechanistic issues of the ODH including the identification of the possible active sites and the exploration of the underlying mechanisms. We discussed different boron-based materials and established versatile methodologies for the investigation of active sites and reaction mechanisms. We also elaborated on the similarities and differences in catalytic and kinetic behaviors, and reaction mechanisms between boron- and carbon-based metal-free materials. A perspective of the potential issues of metal-free ODH catalytic systems in terms of their rational design and their synergy with reactor engineering was sketched.

Status and prospects of the decentralised valorisation of natural gas into energy and energy carriers

We critically review the recent advances in process, reactor, and catalyst design that enable process miniaturisation for decentralised natural gas upgrading into electricity, liquefied natural gas, fuels and chemicals.

Promoting Light Hydrocarbons Yield by Catalytic Hydrodechlorination of Residual Chloromethanes Using Palladium Supported on Zeolite Catalysts

Gas catalytic hydrodechlorination (HDC) of trichloromethane (TCM) and dichloromethane (DCM) was analyzed using Pd (1 wt.%) on different zeolites as catalysts. The aim of this study was to know the surface properties of the catalysts and reaction conditions that promote the yield to light hydrocarbons in this reaction. Five different zeolite supports were used from three commercial zeolites (KL, L-type; NaY, Faujasite; H-MOR, Mordenite). KL and NaY were submitted to ionic exchange treatments in order to increase their acidity and analyze the effect of the acidity in the activity and selectivity of the HDC reaction. Exchanged zeolites (HL and HY) showed the highest Pd dispersion due to their higher surface acidity. The best TCM/DCM conversion and selectivity to light hydrocarbons was obtained using the two non-exchanged zeolite-catalysts, KL and NaY. Low surface acidity seems to be the key aspect to promote the formation of light hydrocarbons. The formation of these products is favored at high reaction temperatures and low H2: chloromethane ratios. KL showed the highest selectivity to olefins (60%), although with a lower dechlorination degree. Non-exchanged NaY catalyst showed high selectivity to paraffins (70% and 95% for the HDC of DCM and TCM, respectively).

Operando Photoelectron Photoion Coincidence Spectroscopy Unravels Mechanistic Fingerprints of Propane Activation by Catalytic Oxyhalogenation

Herein, we demonstrate operando photoelectron photoion coincidence (PEPICO) spectroscopy as a pivotal technique for evidencing unprecedented mechanistic insights by isomer-selective radical detection within complex hydrocarbon-functionalization reaction networks, such as those of catalyzed propane oxychlorination and oxybromination. In particular, while the oxychlorination is surface-confined, we show that in oxybromination alkane activation follows a gas-phase reaction mechanism with evolved bromine and bromine radicals, favoring 2-propyl over 1-propyl radical formation, as evidenced by isomer-selective threshold photoelectron analysis. Furthermore, we provide new mechanistic insights into the cracking and coking pathways that are observed in oxybromination. The first entails propargyl radical formation from consecutive hydrogen abstraction of propyl radicals, ultimately yielding benzene. The second originates from C-C bond cleavage in propane to ethyl and methyl radicals, which produce CH₄ and C₂H₄, or undergo chain-growth reactions, forming C₄-C₆ species.

Halogen type as a selectivity switch in catalysed alkane oxyhalogenation

The type of halogen enables a powerful selectivity control ranging from olefins in oxychlorination to alkyl bromides in oxybromination over europium oxyhalide catalysts.