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

Selectivity Control by Relay Catalysis in CO and CO2 Hydrogenation to Multicarbon Compounds

ConspectusThe hydrogenative conversion of both CO and CO2 into high-value multicarbon (C2+) compounds, such as olefins, aromatic hydrocarbons, ethanol, and liquid fuels, has attracted much recent attention. The hydrogenation of CO is related to the chemical utilization of various carbon resources including shale gas, biomass, coal, and carbon-containing wastes via syngas (a mixture of H2 and CO), while the hydrogenation of CO2 by green H2 to chemicals and liquid fuels would contribute to recycling CO2 for carbon neutrality. The state-of-the-art technologies for the hydrogenation of CO/CO2 to C2+ compounds primarily rely on a direct route via Fischer-Tropsch (FT) synthesis and an indirect route via two methanol-mediated processes, i.e., methanol synthesis from CO/CO2 and methanol to C2+ compounds. The direct route would be more energy- and cost-efficient owing to the reduced operation units, but the product selectivity of the direct route via FT synthesis is limited by the Anderson-Schulz-Flory (ASF) distribution. Selectivity control for the direct hydrogenation of CO/CO2 to a high-value C2+ compound is one of the most challenging goals in the field of C1 chemistry, i.e., chemistry for the transformation of one-carbon (C1) molecules.We have developed a relay-catalysis strategy to solve the selectivity challenge arising from the complicated reaction network in the hydrogenation of CO/CO2 to C2+ compounds involving multiple intermediates and reaction channels, which inevitably lead to side reactions and byproducts over a conventional heterogeneous catalyst. The core of relay catalysis is to design a single tandem-reaction channel, which can direct the reaction to the target product controllably, by choosing appropriate intermediates (or intermediate products) and reaction steps connecting these intermediates, and arranging optimized yet matched catalysts to implement these steps like a relay. This Account showcases representative relay-catalysis systems developed by our group in the past decade for the synthesis of liquid fuels, lower (C2-C4) olefins, aromatics, and C2+ oxygenates from CO/CO2 with selectivity breaking the limitation of conventional catalysts. These relay systems are typically composed of a metal or metal oxide for CO/CO2/H2 activation and a zeolite for C-C coupling or reconstruction, as well as a third or even a fourth catalyst component with other functions if necessary. The mechanisms for the activation of H2 and CO/CO2 on metal oxides, which are distinct from that on the conventional transition or noble metal surfaces, are discussed with emphasis on the role of oxygen vacancies. Zeolites catalyze the conversion of intermediates (including hydrocracking/isomerization of heavier hydrocarbons, methanol-to-hydrocarbon reactions, and carbonylation of methanol/dimethyl ether) in the relay system, and the selectivity is mainly controlled by the Brønsted acidity and the shape-selectivity or the confinement effect of zeolites. We demonstrate that the thermodynamic/kinetic matching of the relay steps, the proximity and spatial arrangement of the catalyst components, and the transportation of intermediates/products in sequence are the key issues guiding the selection of each catalyst component and the construction of an efficient relay-catalysis system. Our methodology would also be useful for the transformation of other C1 molecules via controlled C-C coupling, inspiring more efforts toward precision catalysis.

Steering interface effect of H-ZSM-5 zeolites with tailored surface barriers to improve their catalytic performances

An efficient zeolite interface with optimized surface barriers was tailored by passivating the hydroxyl-group defects at surfaces or near pore mouths. The surface permeability of the modified zeolite was almost 90% greater than that of the pristine one, leading to remarkable improvements in C=2-3 selectivity and an anti-inactivation rate of 75% for the catalytic cracking reaction.

In Situ Removal of Benzene as a Biomass Tar Model Compound Employing Hematite Oxygen Carrier

Tar is an unavoidable biomass gasification byproduct. Tar formation reduces gasification efficiency and limits the further application of biomass gasification technology. Hence, efficient tar removal is a major problem to be solved in the formation and application of biomass gasification technology. Chemical looping gasification (CLG), a novel and promising gasification technology has attracted extensive attention owing to its low tar generation. Active oxygen carriers (OCs), the reduced OC in CLG, are considered to be excellent catalysts for tar cracking. In this study, the use of benzene as a typical tar model compound for tar removal using the iron ore OC is investigated. In the blank experiment, where an inert material (SiO2) is used as the carrier, the benzene cracking is relatively low, and the benzene conversion, H2 yield, and carbon conversion are 53.65%, 6.33%, and 1.24%, respectively. The addition of hematite promotes benzene cracking. A large amount of oxygen-containing gases (CO and CO2) are generated. Additionally, the conversion degrees for benzene, H2 and carbon are about 67.75%, 21.55%, and 38.39%, respectively. These results indicate that hematite performs both oxidation and catalysis during benzene cracking. The extension of the residence time facilitates benzene removal, owing to the good interaction between the gas phase and solid phase. The addition of water vapor inhibits the benzene conversion and promotes the conversion of carbon deposition. The lattice oxygen reactivity of hematite OC shows an uptrend as the cycle number is increased during the benzene conversion cycle. The experimental results confirm that CLG has a low-tar advantage and that hematite is an effective OC for benzene removal.

Effect of crystal size on the acidity of nanometric Y zeolite: number of sites, strength, acid nature, and dehydration of 2-propanol

Crystallinity damage in acid Y zeolite affects the direct relationship between the number of acid sites or conversion of 2-propanol and the zeolite size and the selectivity of 2-propene in nanosized Y zeolite.

Boosting propane dehydroaromatization by confining PtZn alloy nanoparticles within H-ZSM-5 crystals

A Pt–Zn@H-ZSM-5 catalyst with Pt–Zn alloy nanoparticles confined in H-ZSM-5 crystals exhibits a significantly improved performance in the propane dehydroaromatization reaction.

The effect of the particle size on Fischer-Tropsch synthesis for ZSM-5 zeolite supported cobalt-based catalysts

A series of mesoporous ZSM-5 zeolite supported cobalt-based catalysts with the cobalt crystal sizes in the range of 4.5-18.1 nm were prepared for syngas conversion. The highly selective synthesis of various liquid fuels including gasoline, jet fuel and diesel range hydrocarbons is achieved with different cobalt nanoparticle sizes.

Advances in Catalytic Applications of Zeolite-Supported Metal Catalysts

Zeolites possessing large specific surface areas, ordered micropores, and adjustable acidity/basicity have emerged as ideal supports to immobilize metal species with small sizes and high dispersities. In recent years, the zeolite-supported metal catalysts have been widely used in diverse catalytic processes, showing excellent activity, superior thermal/hydrothermal stability, and unique shape-selectivity. In this review, a comprehensive summary of the state-of-the-art achievements in catalytic applications of zeolite-supported metal catalysts are presented for important heterogeneous catalytic processes in the last five years, mainly including 1) the hydrogenation reactions (e.g., CO/CO₂ hydrogenation, hydrogenation of unsaturated compounds, and hydrogenation of nitrogenous compounds); 2) dehydrogenation reactions (e.g., alkane dehydrogenation and dehydrogenation of chemical hydrogen storage materials); 3) oxidation reactions (e.g., CO oxidation, methane oxidation, and alkene epoxidation); and 4) other reactions (e.g., hydroisomerization reaction and selective catalytic reduction of NO_x with ammonia reaction). Finally, some current limitations and future perspectives on the challenge and opportunity for this subject are pointed out. It is believed that this review will inspire more innovative research on the synthesis and catalysis of zeolite-supported metal catalysts and promote their future developments to meet the emerging demands for practical applications.

Spontaneous Pillaring of Pentasil Zeolites

Conventional methods to prepare hierarchical zeolites depend upon the use of organic structure-directing agents and often require multiple synthesis steps with limited product yield and Brønsted acid concentration. Here, it is shown that the use of MEL- or MFI-type zeolites as crystalline seeds induces the spontaneous formation of self-pillared pentasil zeolites, thus avoiding the use of any organic or branching template for the crystallization of these hierarchical structures. The mechanism of formation is evaluated by time-resolved electron microscopy to provide evidence for the heterogeneous nucleation and growth of sequentially branched nanosheets from amorphous precursors. The resulting hierarchical zeolites have large external surface area and high percentages of external acid sites, which markedly improves their catalytic performance in the Friedel-Crafts alkylation and methanol to hydrocarbons reactions. These findings highlight a facile, commercially viable synthesis method to reduce mass-transport limitations and improve the performance of zeolite catalysts.

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.

Applications of Zeolites to C1 Chemistry: Recent Advances, Challenges, and Opportunities

C1 chemistry, which is the catalytic transformation of C1 molecules including CO, CO₂ , CH₄ , CH₃ OH, and HCOOH, plays an important role in providing energy and chemical supplies while meeting environmental requirements. Zeolites are highly efficient solid catalysts used in the chemical industry. The design and development of zeolite-based mono-, bi-, and multifunctional catalysts has led to a booming application of zeolite-based catalysts to C1 chemistry. Combining the advantages of zeolites and metallic catalytic species has promoted the catalytic production of various hydrocarbons (e.g., methane, light olefins, aromatics, and liquid fuels) and oxygenates (e.g., methanol, dimethyl ether, formic acid, and higher alcohols) from C1 molecules. The key zeolite descriptors that influence catalytic performance, such as framework topologies, nanoconfinement effects, Brønsted acidities, secondary-pore systems, particle sizes, extraframework cations and atoms, hydrophobicity and hydrophilicity, and proximity between acid and metallic sites are discussed to provide a deep understanding of the significance of zeolites to C1 chemistry. An outlook regarding challenges and opportunities for the conversion of C1 resources using zeolite-based catalysts to meet emerging energy and environmental demands is also presented.

Metal@Zeolite Hybrid Materials for Catalysis

The fixation of metal nanoparticles into zeolite crystals has emerged as a new series of heterogeneous catalysts, giving performances that steadily outperform the generally supported catalysts in many important reactions. In this outlook, we define different noble metal-in-zeolite structures (metal@zeolite) according to the size of the nanoparticles and their relative location to the micropores. The metal species within the micropores and those larger than the micropores are denoted as encapsulated and fixed structures, respectively. The development in the strategies for the construction of metal@zeolite hybrid materials is briefly summarized in this work, where the rational preparation and improved thermal stability of the metal nanostructures are particularly mentioned. More importantly, these metal@zeolite hybrid materials as catalysts exhibit excellent shape selectivity. Finally, we review the current challenges and future perspectives for these metal@zeolite catalysts.

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.

Syngas to light olefins conversion with high olefin/paraffin ratio using ZnCrOx/AlPO-18 bifunctional catalysts

Direct synthesis of light olefins from syngas (STO) using a bifunctional catalyst composed of oxide and zeolite has attracted extensive attention in both academia and industry. It is highly desirable to develop robust catalysts that could enhance the CO conversion while simultaneously maintain high selectivity to C2-C4 olefins. Herein, we report a bifunctional catalyst consisting of ZnCr binary oxide (ZnCrO_x) and low-Si AlPO-18 zeolite, showing both satisfying selectivity to C2-C4 olefins of 45.0% (86.7%, CO₂ free) and high olefin/paraffin ratio of 29.9 at the CO conversion of 25.2% under mild reaction conditions (4.0 MPa, 390 °C). By optimizing the reaction conditions, the CO conversion could be markedly increased to 49.3% with a slight drop in selectivity. CD₃CN/CO-FTIR characterizations and theoretical calculations demonstrate that low-Si AlPO-18 zeolite has lower acid strength, and is therefore less reactive toward the hydride transfer in the STO reaction, leading to a higher olefin/paraffin ratio.

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.

Encapsulation of Metal Nanoparticle Catalysts Within Mesoporous Zeolites and Their Enhanced Catalytic Performances: A Review

Metal nanoparticles (NPs) exhibit desired activities in various catalytic reactions. However, the aggregation and sintering of metal NPs usually cause the loss of catalytic performance in practical reaction processes. Encapsulation of catalytically active metal NPs on/within a high-surface-area inorganic support partially resolve such concerns. Microporous zeolites, owing to their rigid frameworks and porous structural features, have been considered as one of ideal inorganic supports. Metal NPs can be easily encapsulated and stabilized within zeolitic frameworks to prevent unwished aggregation during the catalysis. Unfortunately, sole microporous nanochannels (generally <1 nm) in conventional zeolites are not easy to be accessed. The introduction of another set of nanochannel (e.g., mesopore), known as mesoporous zeolites, can greatly improve the mass-transfer efficiency, which is structurally beneficial for most catalytic reactions. The coexistence of micropores and mesopores in inorganic supports provides the synergetic advantages of both fine confinement effect for metal NPs and easy diffusion for organic reactants/intermediates/products. This review focuses on the recent advances in the design and synthesis of mesoporous zeolites-encapsulated metal NP catalysts as well as their desired catalytic performances (activity and stability) in organic reactions. We first discuss the advantages of mesoporous zeolites as the supports and present general strategies for the construction of mesoporous zeolites. Then, the preparation methods on how to encapsulate NP catalysts within both microporous and mesoporous zeolites are clearly demonstrated. Third, some recent important cases on catalytic applications are presented to verify structural advantages of mesoporous zeolite supports. Within the conclusion, the perspectives on future developments in metal NP catalysts encapsulated within mesoporous zeolites are lastly discussed.

Co-Based Catalysts Derived from Layered-Double-Hydroxide Nanosheets for the Photothermal Production of Light Olefins

Solar-driven Fischer-Tropsch synthesis represents an alternative and potentially low-cost route for the direct production of light olefins from syngas (CO and H₂ ). Herein, a series of novel Co-based photothermal catalysts with different chemical compositions are successfully fabricated by H₂ reduction of ZnCoAl-layered double-hydroxide nanosheets at 300-700 °C. Under UV-vis irradiation, the photothermal catalyst prepared at 450 °C demonstrates remarkable CO hydrogenation performance, affording an olefin (C_2-4⁼ ) selectivity of 36.0% and an olefin/paraffin ratio of 6.1 at a CO conversion of 15.4%. Characterization studies using X-ray absorption fine structure and high-resolution transmission electron microscopy reveal that the active catalyst comprises Co and Co₃ O₄ nanoparticles on a ZnO-Al₂ O₃ mixed metal oxide support. Density functional theory calculations further demonstrate that the oxide-decorated metallic Co nanoparticle heterostructure weakens the further hydrogenation ability of the corresponding Co, leading to the high selectivity to light olefins. This study demonstrates a novel solar-driven catalyst platform for the production of light olefins via CO hydrogenation.

Improvement of the Catalytic Efficiency of Butene Oligomerization Using Alkali Metal Hydroxide-Modified Hierarchical ZSM-5 Catalysts

Oligomerization of light olefin is an effective method to produce plentiful liquid fuels. However, oligomerization processes using microporous zeolites have severe problems due to steric hindrance. In this paper, oligomerization of butene using a series of new types of hierarchical HZSM-5 zeolite catalysts is studied. To obtain the modified HZSM-5 catalysts, HZSM-5 is treated with the same concentration of LiOH, NaOH, KOH, and CsOH aqueous solutions, respectively. It is demonstrated that the alkali treatment can effectively modify the acidity properties and hierarchical structure of the HZSM-5 catalyst, which is confirmed by X-ray Diffraction (XRD), X-ray Fluorescence (XRF), Nitrogen Adsorption-desorption Measurements, Transmission Electron Microscopy Investigations (TEM), Ammonia Temperature-programmed Desorption Method (NH3-TPD), Pyridine FT-IR, and Thermogravimetric Analysis (TGA). The results show that hierarchical catalysts with interconnected open-mesopores, smaller crystal size, and suitable acidity can better prolong the catalyst lifetime during butene oligomerization. Particularly, the HZSM-5 catalysts treated with CsOH aqueous solution (ATHZ5-Cs) proved to be the most effective catalyst, resulting in approximately 99% conversion of butene and exhibiting C8+ selectivity of 85% within 12 h. Thus, an appropriate hierarchical catalyst can satisfy the oligomerization process and has the potential to be used as a substitute for the commercial ZSM-5 catalyst.

A short review of recent advances in CO2 hydrogenation to hydrocarbons over heterogeneous catalysts

CO2 hydrogenation to hydrocarbons is a promising way of making waste to wealth and energy storage, which also solves the environmental and energy issues caused by CO2 emissions. Much efforts and research are aimed at the conversion of CO2 via hydrogenation to various value-added hydrocarbons, such as CH4, lower olefins, gasoline, or long-chain hydrocarbons catalyzed by different catalysts with various mechanisms. This review provides an overview of advances in CO2 hydrogenation to hydrocarbons that have been achieved recently in terms of catalyst design, catalytic performance and reaction mechanism from both experiments and density functional theory calculations. In addition, the factors influencing the performance of catalysts and the first C-C coupling mechanism through different routes are also revealed. The fundamental factor for product selectivity is the surface H/C ratio adjusted by active metals, supports and promoters. Furthermore, the technical and application challenges of CO2 conversion into useful fuels/chemicals are also summarized. To meet these challenges, future research directions are proposed in this review.

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.

Internal defects-oriented dissolution: controllable evolution of hollow ZSM-5 nano-structures

A hollow ZSM-5 nanostructure with a shell thickness of ca. 40 nm is successfully formed in 40 min via ammonia leaching under mild conditions.

One-pass selective conversion of syngas to para-xylene

The finite petroleum resources and environmental crisis compel the development of non-petroleum carbon resources by chemical transformation routes. Syngas (CO + H2) is a crucial junction point that exclusively bridges the non-petroleum carbon resources and other basic chemicals like alcohols, alkane/alkenes, etc. However, the one-pass conversion of syngas to value-added aromatics, especially para-xylene, is still a big challenge. Here we presented a promising hybrid catalyst, named Cr/Zn-Zn/Z5@S1, to effectively realize the one-pass conversion of syngas to para-xylene. This hybrid catalyst exhibited enhanced activity on syngas conversion (CO conversion of 55.0%), good stability of catalyst lifetime and considerable selectivity of para-xylene (27.6% in the total products and 77.3% in xylene). The characterization and catalytic performance evaluation revealed that the well-designed core-shell Zn/Z5@S1 zeolite, as a vital part of this Cr/Zn-Zn/Z5@S1 hybrid catalyst, substantially contributed to its extreme performance for the para-xylene one-pass precise synthesis from syngas. The concerted combination of two components in this hybrid catalyst can effectively depress the formation of unwanted by-products and facilitate the oriented synthesis of para-xylene from syngas with unprecedented efficiency at the same time.

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.

Highly selective production of heavy hydrocarbons over cobalt–graphene–silica nanocomposite catalysts

Cobalt–graphene–silica nanocomposites catalysts were applied in FTS and showed highly selective production of heavy hydrocarbons.

A review of the catalytic hydrogenation of carbon dioxide into value-added hydrocarbons

We review the indirect and direct routes for CO₂ hydrogenation to hydrocarbons and recent developments in catalyst design, performance and mechanism.