Correlating the degree of metal–promoter interaction to ethanol selectivity over MnRh/CNTs CO hydrogenation 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.

Identifying Descriptors for Promoted Rhodium-Based Catalysts for Higher Alcohol Synthesis via Machine Learning

Rhodium-based catalysts offer remarkable selectivities toward higher alcohols, specifically ethanol, via syngas conversion. However, the addition of metal promoters is required to increase reactivity, augmenting the complexity of the system. Herein, we present an interpretable machine learning (ML) approach to predict and rationalize the performance of Rh-Mn-P/SiO2 catalysts (P = 19 promoters) using the open-source dataset on Rh-catalyzed higher alcohol synthesis (HAS) from Pacific Northwest National Laboratory (PNNL). A random forest model trained on this dataset comprising 19 alkali, transition, post-transition metals, and metalloid promoters, using catalytic descriptors and reaction conditions, predicts the higher alcohols space-time yield (STYHA) with an accuracy of R 2 = 0.76. The promoter's cohesive energy and alloy formation energy with Rh are revealed as significant descriptors during posterior feature-importance analysis. Their interplay is captured as a dimensionless property, coined promoter affinity index (PAI), which exhibits volcano correlations for space-time yield. Based on this descriptor, we develop guidelines for the rational selection of promoters in designing improved Rh-Mn-P/SiO2 catalysts. This study highlights ML as a tool for computational screening and performance prediction of unseen catalysts and simultaneously draws insights into the property-performance relations of complex catalytic systems.

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.

Functionalized Carbon Materials in Syngas Conversion

Functionalized carbon materials are widely used in heterogeneous catalysis due to their unique properties such as adjustable surface properties, excellent thermal conductivity, high surface areas, tunable porosity, and moderate interactions with guest metals. The transformation of syngas into hydrocarbons (known as the Fischer-Tropsch synthesis) or oxygenates is an exothermic reaction and is typically catalyzed by transition metals dispersed on functionalized supports. Various carbon materials have been employed in syngas conversions not only for improving the performance or decreasing the dosage of expensive active metals but also for building model catalysts for fundamental research. This article provides a critical review on recent advances in the utilization of carbon materials, in particular the recently developed functionalized nanocarbon materials, for syngas conversions to either hydrocarbons or oxygenates. The unique features of carbon materials in dispersing metal nanoparticles, heteroatom doping, surface modification, and building special nanoarchitectures are highlighted. The key factors that control the reaction course and the reaction mechanism are discussed to gain insights for the rational design of efficient carbon-supported catalysts for syngas conversions. The challenges and future opportunities in developing functionalized carbon materials for syngas conversions are briefly analyzed.

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.

Ultrastable Magnetic Nanoparticles Encapsulated in Carbon for Magnetically Induced Catalysis

Magnetically induced catalysis using magnetic nanoparticles (MagNPs) as heating agents is a new efficient method to perform reactions at high temperatures. However, the main limitation is the lack of stability of the catalysts operating in such harsh conditions. Normally, above 500 °C, significant sintering of MagNPs takes place. Here we present encapsulated magnetic FeCo and Co NPs in carbon (Co@C and FeCo@C) as an ultrastable heating material suitable for high-temperature magnetic catalysis. Indeed, FeCo@C or a mixture of FeCo@C:Co@C (2:1) decorated with Ni or Pt-Sn showed good stability in terms of temperature and catalytic performances. In addition, consistent conversions and selectivities regarding conventional heating were observed for CO₂ methanation (Sabatier reaction), propane dehydrogenation (PDH), and propane dry reforming (PDR). Thus, the encapsulation of MagNPs in carbon constitutes a major advance in the development of stable catalysts for high-temperature magnetically induced catalysis.

A Reusable CNT-Supported Single-Atom Iron Catalyst for the Highly Efficient Synthesis of C-N Bonds

C-N bond formation is regarded as a very useful and fundamental reaction for the synthesis of nitrogen-containing molecules in both organic and pharmaceutical chemistry. Noble-metal and homogeneous catalysts have frequently been used for C-N bond formation, however, these catalysts have a number of disadvantages, such as high cost, toxicity, and low atom economy. In this work, a low-toxic and cheap iron complex (iron ethylene-1,2-diamine) has been loaded onto carbon nanotubes (CNTs) to prepare a heterogeneous single-atom catalyst (SAC) named Fe-N_x /CNTs. We employed this SAC in the synthesis of C-N bonds for the first time. It was found that Fe-N_x /CNTs is an efficient catalyst for the synthesis of C-N bonds starting from aromatic amines and ketones. Its catalytic performance was excellent, giving yields of up to 96 %, six-fold higher than the yields obtained with noble-metal catalysts, such as AuCl₃ /CNTs and RhCl₃ /CNTs. The catalyst showed efficacy in the reactions of thirteen aromatic amine substrates, without the need for additives, and seventeen enaminones were obtained. High-angle annular dark-field scanning transmission electron microscopy in combination with X-ray absorption spectroscopy revealed that the iron species were well dispersed in the Fe-N_x /CNTs catalyst as single atoms and that Fe-N_x might be the catalytic active species. This Fe-N_x /CNTs catalyst has potential industrial applications as it could be cycled seven times without any significant loss of activity.

Unveiling the Structure Sensitivity for Direct Conversion of Syngas to C2-Oxygenates with a Multicomponent-Promoted Rh Catalyst

Abstract

Mn and Li promoted Rh catalysts supported on SiO2 with a thin TiO2 layer were synthesized by stepwise incipient wetness impregnation approach. The thin TiO2 layer on the surface of SiO2 was proved to stabilize those small Rh nanoparticles and hinder their agglomeration. The reducibility of Rh on these catalysts depends on Rh particle size as well as the position of manganese oxide, and large Rh nanoparticles with MnO on Rh nanoparticles can be only reduced at an elevated temperature. Catalyst with large Rh particles exhibits a higher CO conversion and higher products selectivity towards long chain hydrocarbons and C2-oxygenates at the expense of decreasing methane formation than a similar catalyst with smaller Rh particles. This was attributed to the synergistic effect of Mn and Li promotion and molar ratio between Rh0 and Rhδ+ sites on the surface of Rh nanoparticles. Moreover, Rh nanoparticles on MnO are proved to be more efficient in promoting hydrogenation of acetaldehyde to ethanol than its counterpart with MnO on Rh nanoparticles. Finally, in order to target high C2-oxygenates selectivity, low reaction temperature together with a low H2/CO ratio in the feed is recommended.

Graphic Abstract

The effects of the nature of TiO2 supports on the catalytic performance of Rh–Mn/TiO2 catalysts in the synthesis of C2 oxygenates from syngas

Four types of TiO₂ with different rutile/anatase crystalline phase compositions were used as supports, and the effect of the TiO₂ phase composition on the catalytic properties of supported Rh catalysts in the synthesis of C₂ oxygenates from syngas was studied.

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.

The effects of PVP-modified SiO2 on the catalytic performance of CO hydrogenation over Rh–Mn–Li/SiO2 catalysts

The properties of PVP-modified SiO₂ markedly influence the catalytic performance of Rh–Mn–Li/SiO₂ catalysts on C₂⁺ oxygenates synthesis from CO hydrogenation.

Promotional effects of Cr and Fe on Rh/SiO2 catalyst for the preparation of ethanol from CO hydrogenation

The mode of contact between Rh and Cr is different to that between Rh and Fe.

Complex Nano-objects Displaying Both Magnetic and Catalytic Properties: A Proof of Concept for Magnetically Induced Heterogeneous Catalysis

Addition of Co2(Co)9 and Ru3(CO)12 on preformed monodisperse iron(0) nanoparticles (Fe(0) NPs) at 150 °C under H2 leads to monodisperse core-shell Fe@FeCo NPs and to a thin discontinuous Ru(0) layer supported on the initial Fe(0) NPs. The new complex NPs were studied by state-of-the-art transmission electron microscopy techniques as well as X-ray diffraction, Mössbauer spectroscopy, and magnetic measurements. These particles display large heating powers (SAR) when placed in an alternating magnetic field. The combination of magnetic and surface catalytic properties of these novel objects were used to demonstrate a new concept: the possibility of performing Fischer-Tropsch syntheses by heating the catalytic nanoparticles with an external alternating magnetic field.