Multiple-Functional Capsule Catalysts: A Tailor-Made Confined Reaction Environment for the Direct Synthesis of Middle Isoparaffins from Syngas

Oxide-Zeolite-Based Composite Catalyst Concept That Enables Syngas Chemistry beyond Fischer-Tropsch Synthesis

Syngas chemistry has been under study since Fischer-Tropsch synthesis (FTS) was invented in the 1920s. Despite the successful applications of FTS as the core technology of coal-to-liquid and gas-to-liquid processes in industry, the product selectivity control of syngas conversion still remains a great challenge, particularly for value-added chemicals such as light olefins. Recent studies show that the catalyst design concept of OXZEO (oxide-zeolite-based composite) enables direct syngas conversion to mixed light olefins with a selectivity reaching 80% and to ethylene with a selectivity of 83% among hydrocarbons. They both well-surpass the limits predicated by the Anderson-Schultz-Flory model via the conventional FTS route (58% and 30%, respectively). Furthermore, this catalyst concept allows one-step synthesis of gasoline-range isoparaffins and aromatic compounds, which is otherwise not possible in conventional FTS. A rapidly growing number of studies demonstrate the versatility of this concept and may form a technology platform for utilization of carbon resources including coal, natural gas, and biomass via syngas to a variety of basic chemicals and fuels. However, the selectivity control mechanism is far from being understood. Therefore, we focus mainly on the catalytic roles of the bifunctionalities of OXZEO while reviewing the development of bifunctional catalysts for selective syngas conversion by taking syngas-to-light olefins as an example. With this, we intend to provide insights into the selectivity control mechanism of the OXZEO concept in order to understand the challenges and prospects for future development of much more active and more selective catalysts.

Facile Synthesis of Proton-Type ZSM-5 by Using Quasi-Solid-Phase (QSP) Method

Herein, a simple and green quasi-solid-phase (QSP) method for facile synthesis of proton-type ZSM-5 avoiding use of excessive water, dry gel, Na⁺ cation and fluoride is reported. Crystallization by using the stoichiometric amount of TPAOH (tetrapropylammonium hydroxide) at 180 °C for only 12 h gave well-structured HZSM-5 crystals with high specific surface area of 429 m²  g^-1 and high thermal stability. 5MRs was observed to closely relate the formation of MFI structure and QSP method exhibits shorter induction period (t₀ ), higher nucleation rate (V_n ), and faster growth rate (V_g ). Moreover, HZ-12-180 showed extremely better and rather stable catalytic activity for methanol-to-propylene reaction by comparison with commercial HZSM-5.

Cobalt hybrid catalysts in Fischer-Tropsch synthesis

Currently, cobalt and zeolites are used in Fischer-Tropsch synthesis (FTS) to produce gasoline-range hydrocarbons (GRHs) that constitute clean and environmentally friendly fuels. This technology has earned a great deal of attention from researchers across the world, as it provides a substitute for fuel derived from fossil crudes, which have hitherto been the sole source of the petrol and diesel required by the industry. However, owing to the depletion of the earth’s oil and coal reserves and the unfavourable environmental impact of conventional fuel production, an alternative source of fuel is needed. This article provides a critical review of the technological challenges involved in producing middle isoparaffins and olefins (gasoline hydrocarbons) by FTS. These involve combining cobalt-based catalysts and zeolites to form hybrid catalysts. In this review, we address most of these by setting out each method of creating cobalt and zeolite hybrid catalysts in turn, so that researchers can identify which applications are most effective for producing GRHs.

Design of a core-shell catalyst: an effective strategy for suppressing side reactions in syngas for direct selective conversion to light olefins

An elegant catalyst is designed via the encapsulation of metallic oxide Zn-Cr inside of zeolite SAPO34 as a core-shell structure (Zn-Cr@SAPO) to realize the coupling of methanol-synthesis and methanol-to-olefin reactions. It can not only break through the limitation of the Anderson-Schulz-Flory distribution but can also overcome the disadvantages of physical mixture catalysts, such as excessive CO2 formation. The confinement effect, hierarchical structure and extremely short distance between the two active components result in the Zn-Cr@SAPO capsule catalyst having better mass transfer and diffusion with a boosted synergistic effect. Due to the difference between the adsorption energies of the Zn-Cr metallic oxide/SAPO zeolite physical mixture and capsule catalysts, the produced water and light olefins are easily removed from the Zn-Cr@SAPO capsule catalyst after formation, suppressing the side reactions. The light olefin space time yield (STY) of the capsule catalyst is more than twice that of the typical physical mixture catalyst. The designed capsule catalyst has superior potential for scale-up in industrial applications while simultaneously extending the capabilities of hybrid catalysts for other tandem catalysis reactions through this strategy.

New horizon in C1 chemistry: breaking the selectivity limitation in transformation of syngas and hydrogenation of CO2 into hydrocarbon chemicals and fuels

Recent advances in bifunctional catalysis for conversion of syngas and hydrogenation of CO₂ into chemicals and fuels have been highlighted.

Synthesis of Engineered Zeolitic Materials: From Classical Zeolites to Hierarchical Core-Shell Materials

The term "engineered zeolitic materials" refers to a class of materials with a rationally designed pore system and active-sites distribution. They are primarily made of crystalline microporous zeolites as the main building blocks, which can be accompanied by other secondary components to form composite materials. These materials are of potential importance in many industrial fields like catalysis or selective adsorption. Herein, critical aspects related to the synthesis and modification of such materials are discussed. The first section provides a short introduction on classical zeolite structures and properties, and their conventional synthesis methods. Then, the motivating rationale behind the growing demand for structural alteration of these zeolitic materials is discussed, with an emphasis on the ongoing struggles regarding mass-transfer issues. The state-of-the-art techniques that are currently available for overcoming these hurdles are reviewed. Following this, the focus is set on core-shell composites as one of the promising pathways toward the creation of a new generation of highly versatile and efficient engineered zeolitic substances. The synthesis approaches developed thus far to make zeolitic core-shell materials and their analogues, yolk-shell, and hollow materials, are also examined and summarized. Finally, the last section concisely reviews the performance of novel core-shell, yolk-shell, and hollow zeolitic materials for some important industrial applications.

Role of mesopores in Co/ZSM-5 for the direct synthesis of liquid fuel by Fischer–Tropsch synthesis

In a complex reaction system, in which gas, liquid, and solid catalysts work together, understanding the impact of mass transfer that varies with the catalyst pore structure is very challenging but also essential to designing selective catalysts.

Design and Synthesis of Powerful Capsule Catalysts Aimed at Applications in C1 Chemistry and Biomass Conversion

Tandem catalytic reaction is a promising strategy to improve the utilization efficiency of energy and resources. The conventional hybrid catalysts cannot readily realize the precisely controlled synthesis of target products due to the unrestricted, open reaction environment. Assembling the hybrid catalyst with multiple active sites into core-shell structured capsule catalyst is one of the most effective ways to enhance the selectivity of desired products during a tandem catalysis process, because the core-shell structure offers a space-confined reaction field and synergistic effect. This review describes our recent progresses on the design and synthesis of core-shell structured zeolite capsule catalysts developed for C1 chemistry and biomass conversion. The various synthesis methods for constructing the well-defined zeolite capsule catalysts are described in detail. The applications of the capsule catalysts in catalysis, including the middle isoparaffins synthesis from syngas, one-step synthesis of dimethyl ether, and liquid-phase tandem reaction of glycerol conversion, are discussed, respectively. Our perspectives regarding the challenges and opportunities for future research in the field are also provided.

Design of nanocomposites with cobalt encapsulated in the zeolite micropores for selective synthesis of isoparaffins in Fischer–Tropsch reaction

A new strategy for the synthesis of metal–zeolite nanocomposite materials containing metal nanoparticles only in the zeolite pores is proposed.

Building premium secondary reaction field with a miniaturized capsule catalyst to realize efficient synthesis of a liquid fuel directly from syngas

A premium secondary reaction field is built by miniaturized core–shell catalyst for synthesis of liquid fuel from syngas.

Perspectives on zeolite-encapsulated metal nanoparticles and their applications in catalysis

Recent strategies for the design of zeolites with unusual architectures and porosities offer many opportunities for the encapsulation of catalysts.

Polymeric nanocapsules templated on liquid cores as efficient photoreactors

Polymeric nanocapsules templated on liquid core, stabilized by graft amphiphilic polyelectrolytes were fabricated and applied as photochemical reactors.

Structuring catalyst and reactor – an inviting avenue to process intensification

Multiphase catalytic processes involve the combination of scale-dependent and scale-independent phenomena, often resulting in a compromised, sub-optimal performance.

Selective transformation of syngas into gasoline-range hydrocarbons over mesoporous H-ZSM-5-supported cobalt nanoparticles

Bifunctional Fischer-Tropsch (FT) catalysts that couple uniform-sized Co nanoparticles for CO hydrogenation and mesoporous zeolites for hydrocracking/isomerization reactions were found to be promising for the direct production of gasoline-range (C5-11 ) hydrocarbons from syngas. The Brønsted acidity results in hydrocracking/isomerization of the heavier hydrocarbons formed on Co nanoparticles, while the mesoporosity contributes to suppressing the formation of lighter (C1-4 ) hydrocarbons. The selectivity for C5-11 hydrocarbons could reach about 70 % with a ratio of isoparaffins to n-paraffins of approximately 2.3 over this catalyst, and the former is markedly higher than the maximum value (ca. 45 %) expected from the Anderson-Schulz-Flory distribution. By using n-hexadecane as a model compound, it was clarified that both the acidity and mesoporosity play key roles in controlling the hydrocracking reactions and thus contribute to the improved product selectivity in FT synthesis.

Fischer-Tropsch catalysts for the production of hydrocarbon fuels with high selectivity

Fischer-Tropsch synthesis is a key reaction in the utilization of non-petroleum carbon resources, such as methane (natural gas, shale gas, and biogas), coal, and biomass, for the sustainable production of clean liquid fuels from synthesis gas. Selectivity control is one of the biggest challenges in Fischer-Tropsch synthesis. This Minireview focuses on the development of new catalysts with controllable product selectivities. Recent attempts to increase the selectivity to C5+ hydrocarbons by preparing catalysts with well-defined active phases or with new supports or by optimizing the interaction between the promoter and the active phase are briefly highlighted. Advances in developing bifunctional catalysts capable of catalyzing both CO hydrogenation to heavier hydrocarbons and hydrocracking/isomerization of heavier hydrocarbons are critically reviewed. It is demonstrated that the control of the secondary hydrocracking reactions by using core-shell nanostructures or solid-acid materials, such as mesoporous zeolites and carbon nanotubes with acid functional groups, is an effective strategy to tune the product selectivity of Fischer-Tropsch synthesis. Very promising selectivities to gasoline- and diesel-range hydrocarbons have been attained over some bifunctional catalysts.

Catalysis engineering of bifunctional solids for the one-step synthesis of liquid fuels from syngas: a review

The combination of acidic zeolites and Fischer–Tropsch synthesis (FTS) catalysts for one-step production of liquid fuels from syngas is critically reviewed.

Tuning interactions between zeolite and supported metal by physical-sputtering to achieve higher catalytic performances

To substitute for petroleum, Fischer-Tropsch synthesis (FTS) is an environmentally benign process to produce synthetic diesel (n-paraffin) from syngas. Industrially, the synthetic gasoline (iso-paraffin) can be produced with a FTS process followed by isomerization and hydrocracking processes over solid-acid catalysts. Herein, we demonstrate a cobalt nano-catalyst synthesized by physical-sputtering method that the metallic cobalt nano-particles homogeneously disperse on the H-ZSM5 zeolite support with weak Metal-Support Interactions (MSI). This catalyst performed the high gasoline-range iso-paraffin productivity through the combined FTS, isomerization and hydrocracking reactions. The weak MSI results in the easy reducibility of the cobalt nano-particles; the high cobalt dispersion accelerates n-paraffin diffusion to the neighboring acidic sites on the H-ZSM5 support for isomerization and hydrocracking. Both factors guarantee its high CO conversion and iso-paraffin selectivity. This physical-sputtering technique to synthesize the supported metallic nano-catalyst is a promising way to solve the critical problems caused by strong MSI for various processes.

Towards liquid fuels from biosyngas: effect of zeolite structure in hierarchical-zeolite-supported cobalt catalysts

Wax on, wax off: Bifunctional cobalt-based catalysts on zeolite supports are applied for the valorization of biosyngas through Fischer-Tropsch chemistry. By using these catalysts, waxes can be hydrocracked to shorter-chain hydrocarbons, increasing the selectivity towards the C5 -C11 (gasoline) fraction. The zeolite topology and the amount and strength of acid sites are key parameters to maximize the performance of these bifunctional catalysts, steering Fischer-Tropsch product selectivity towards liquid hydrocarbons.

Exploring iron-based multifunctional catalysts for Fischer-Tropsch synthesis: a review

The continuous increase in oil prices together with an increase in carbon dioxide concentration in the atmosphere has prompted an increased interest in the production of liquid fuels from non-petroleum sources to ensure the continuation of our worldwide demands while maximizing CO(2) utilization. In this sense, the Fischer-Tropsch (FT) technology provides a feasible option to render high value-added hydrocarbons. Alternative sources, such as biomass or coal, offer a real possibility to realize these purposes by making use of H(2)-deficient or CO(2)-rich syngas feeds. The management of such feeds ideally relies on the use of iron catalysts, which exhibit the unique ability to adjust the H(2)/CO molar ratio to an optimum value for hydrocarbon synthesis through the water-gas-shift reaction. Taking advantage of the emerging attention to hybrid FT-synthesis catalysts based on cobalt and their associated benefits, an overview of the current state of literature in the field of iron-based multifunctional catalysts is presented. Of particular interest is the use of zeolites in combination with a FT catalyst in a one-stage operation, herein named multifunctional, which offer key opportunities in the modification of desired product distributions and selectivity, to eventually overcome the quality limitations of the fuels prepared under intrinsic FT conditions. This review focuses on promising research activities addressing the conversion of syngas to liquid fuels mediated by iron-based multifunctional materials, highlights their preparation and properties, and discusses their implication and challenges in the area of carbon utilization through H(2)/CO(+CO(2)) mixtures.