A mechanistic basis for the effects of Mn loading on C2+ oxygenates synthesis directly from syngas over Rh–MnO /SiO2 catalysts

In Situ Surfaced Mn-Mn Dimeric Sites Dictate CO Hydrogenation Activity and C2 Selectivity over MnRh Binary Catalysts

Massive ethanol production has long been a dream of human society. Despite extensive research in past decades, only a few systems have the potential of industrialization: specifically, Mn-promoted Rh (MnRh) binary heterogeneous catalysts were shown to achieve up to 60% C2 oxygenates selectivity in converting syngas (CO/H2) to ethanol. However, the active site of the binary system has remained poorly characterized. Here, large-scale machine-learning global optimization is utilized to identify the most stable Mn phases on Rh metal surfaces under reaction conditions by exploring millions of likely structures. We demonstrate that Mn prefers the subsurface sites of Rh metal surfaces and is able to emerge onto the surface forming MnRh surface alloy once the oxidative O/OH adsorbates are present. Our machine-learning-based transition state exploration further helps to resolve automatedly the whole reaction network, including 74 elementary reactions on various MnRh surface sites, and reveals that the Mn-Mn dimeric site at the monatomic step edge is the true active site for C2 oxygenate formation. The turnover frequency of the C2 product on the Mn-Mn dimeric site at MnRh steps is at least 107 higher than that on pure Rh steps from our microkinetic simulations, with the selectivity to the C2 product being 52% at 523 K. Our results demonstrate the key catalytic role of Mn-Mn dimeric sites in allowing C-O bond cleavage and facilitating the hydrogenation of O-terminating C2 intermediates, and rule out Rh metal by itself as the active site for CO hydrogenation to C2 oxygenates.

Enhanced Proximity of Rh1,2-Rhn Ensembles Encaged in UiO-67 Boosting Catalytic Conversion of Syngas to Oxygenates

Maintaining high conversion under the premise of high oxygenates selectivity in syngas conversion is important but a formidable challenge in Rh catalysis. Monometallic Rh catalysts provide poor oxygenate conversion efficiency, and efforts have been focused on constructing adjacent polymetallic sites; however, the one-pass yields of C2+ oxygenates over the reported Rh-based catalysts were mostly <20 %. In this study, we constructed a monometallic Rh catalyst encapsulated in UiO-67 (Rh/UiO-67) with enhanced proximity to dual-site Rh1,2-Rhn ensembles. Unexpectedly, this catalyst exhibited high efficacy for oxygenate synthesis from syngas, giving a high oxygenate selectivity of 72.0 % with a remarkable CO conversion of 50.4 %, and the one-pass yield of C2+ oxygenates exceeded 25 %. The state-of-the-art characterizations further revealed the spontaneous formation of an ensemble of Rh single atoms/dimers (Rh1,2) in the proximity of ultrasmall Rh clusters (Rhn) confined within the nanocavity of UiO-67, providing adjacent Rh+-Rh0 dual sites dynamically during the reaction that promote the relay of the undissociated CHO species to the CHx species. Thus, our results open a new route for designing highly efficient Rh catalysts for the conversion of syngas to oxygenates by precisely tuning the ensemble and proximity of the dual active sites in a confined space.

Recent advances in the routes and catalysts for ethanol synthesis from syngas

Ethanol, as one of the important bulk chemicals, is widely used in modern society. It can be produced by fermentation of sugar, petroleum refining, or conversion of syngas (CO/H₂). Among these approaches, conversion of syngas to ethanol (STE) is the most environmentally friendly and economical process. Although considerable progress has been made in STE conversion, control of CO activation and C-C growth remains a great challenge. This review highlights recent advances in the routes and catalysts employed in STE technology. The catalyst designs and pathway designs are summarized and analysed for the direct and indirect STE routes, respectively. In the direct STE routes (i.e., one-step synthesis of ethanol from syngas), modified catalysts of methanol synthesis, modified catalysts of Fischer-Tropsch synthesis, Mo-based catalysts, noble metal catalysts and multifunctional catalysts are systematically reviewed based on their catalyst designs. Further, in the indirect STE routes (i.e., multi-step processes for ethanol synthesis from syngas via methanol/dimethyl ether as intermediates), carbonylation of methanol/dimethyl ether followed by hydrogenation, and coupling of methanol with CO to form dimethyl oxalate followed by hydrogenation, are outlined according to their pathway designs. The goal of this review is to provide a comprehensive perspective on STE technology and inspire the invention of new catalysts and pathway designs in the near future.

Highly active carbon nanotube–promoted Rh-Mn-Li/SiO2 catalysts for the synthesis of C2+ oxygenates from syngas

The effect of carbon nanotubes on the catalytic properties of Rh-Mn-Li/SiO2 catalysts was investigated for CO hydrogenation. The catalysts were comprehensively characterized by means of X-ray power diffraction, N2 sorption, transmission electron microscope, H2–temperature-programmed reduction, CO–temperature-programmed desorption, temperature-programmed surface reaction, and X-ray photoelectron spectroscopy. The results showed that an appropriate amount of carbon nanotubes can be attached to the surface of the SiO2 sphere and can improve the Rh dispersion. Moderate Rh-Mn interaction can be obtained by doping with the appropriate amount of carbon nanotubes, which promotes the formation of strongly adsorbed CO and facilitates the progress of CO insertion, resulting in the increase in the selectivity of C2+ oxygenate synthesis.

Formation, dynamics, and long-term stability of Mn- and Fe-promoted Rh/SiO2 catalysts in CO hydrogenation

Fe servers as an electronic modifier on Rh/SiO2 through in situ RhFe nanoalloy formation, whereas Mn is more likely a structural modifier and does not substantially change Rh's intrinsic product spectrum.

Synthesis of C2 oxygenates from syngas over UiO-66 supported Rh–Mn catalysts: the effect of functional groups

UiO-66 and its modified forms were used as supports to prepare Rh–Mn catalysts, and their effects on CO hydrogenation were investigated.

Mechanochemical redox: a calcination-free process to support CoMnOx catalysts

A calcination-free process (mechanochemical redox loading method) to load CoMnO_x onto various supports for efficient and stable CO oxidation.

Understanding Structure-Property Relationships of MoO3-Promoted Rh Catalysts for Syngas Conversion to Alcohols

Rh-based catalysts have shown promise for the direct conversion of syngas to higher oxygenates. Although improvements in higher oxygenate yield have been achieved by combining Rh with metal oxide promoters, details of the structure of the promoted catalyst and the role of the promoter in enhancing catalytic performance are not well understood. In this work, we show that MoO₃-promoted Rh nanoparticles form a novel catalyst structure in which Mo substitutes into the Rh surface, leading to both a 66-fold increase in turnover frequency and an enhancement in oxygenate yield. By applying a combination of atomically controlled synthesis, in situ characterization, and theoretical calculations, we gain an understanding of the promoter-Rh interactions that govern catalytic performance for MoO₃-promoted Rh. We use atomic layer deposition to modify Rh nanoparticles with monolayer-precise amounts of MoO₃, with a high degree of control over the structure of the catalyst. Through in situ X-ray absorption spectroscopy, we find that the atomic structure of the catalytic surface under reaction conditions consists of Mo-OH species substituted into the surface of the Rh nanoparticles. Using density functional theory calculations, we identify two roles of MoO₃: first, the presence of Mo-OH in the catalyst surface enhances CO dissociation and also stabilizes a methanol synthesis pathway not present in the unpromoted catalyst; and second, hydrogen spillover from Mo-OH sites to adsorbed species on the Rh surface enhances hydrogenation rates of reaction intermediates.

Status and prospects in higher alcohols synthesis from syngas

Higher alcohols are important compounds with widespread applications in the chemical, pharmaceutical and energy sectors. Currently, they are mainly produced by sugar fermentation (ethanol and isobutanol) or hydration of petroleum-derived alkenes (heavier alcohols), but their direct synthesis from syngas (CO + H₂) would comprise a more environmentally-friendly, versatile and economical alternative. Research efforts in this reaction, initiated in the 1930s, have fluctuated along with the oil price and have considerably increased in the last decade due to the interest to exploit shale gas and renewable resources to obtain the gaseous feedstock. Nevertheless, no catalytic system reported to date has performed sufficiently well to justify an industrial implementation. Since the design of an efficient catalyst would strongly benefit from the establishment of synthesis-structure-function relationships and a deeper understanding of the reaction mechanism, this review comprehensively overviews syngas-based higher alcohols synthesis in three main sections, highlighting the advances recently made and the challenges that remain open and stimulate upcoming research activities. The first part critically summarises the formulations and methods applied in the preparation of the four main classes of materials, i.e., Rh-based, Mo-based, modified Fischer-Tropsch and modified methanol synthesis catalysts. The second overviews the molecular-level insights derived from microkinetic and theoretical studies, drawing links to the mechanisms of Fischer-Tropsch and methanol syntheses. Finally, concepts proposed to improve the efficiency of reactors and separation units as well as to utilise CO₂ and recycle side-products in the process are described in the third section.

Insights into structure and dynamics of (Mn,Fe)Ox-promoted Rh nanoparticles

The mutual interaction between Rh nanoparticles and manganese/iron oxide promoters in silica-supported Rh catalysts for the hydrogenation of CO to higher alcohols was analyzed by applying a combination of spectroscopy and microscopy.