Effect of potassium on the active phases of Fe catalysts for carbon dioxide conversion to liquid fuels through hydrogenation

Synthesis of Liquid Hydrocarbon via Direct Hydrogenation of CO2 over FeCu-Based Bifunctional Catalyst Derived from Layered Double Hydroxides

Here, we report a Na-promoted FeCu-based catalyst with excellent liquid hydrocarbon selectivity and catalytic activity. The physiochemical properties of the catalysts were comprehensively characterized by various characterization techniques. The characterization results indicate that the catalytic performance of the catalysts was closely related to the nature of the metal promoters. The Na-AlFeCu possessed the highest CO2 conversion due to enhanced CO2 adsorption of the catalysts by the introduction of Al species. The introduction of excess Mg promoter led to a strong methanation activity of the catalyst. Mn and Ga promoters exhibited high selectivity for light hydrocarbons due to their inhibition of iron carbides generation, resulting in a lack of chain growth capacity. The Na-ZnFeCu catalyst exhibited the optimal C5+ yield, owing to the fact that the Zn promoter improved the catalytic activity and liquid hydrocarbon selectivity by modulating the surface CO2 adsorption and carbide content. Carbon dioxide (CO2) hydrogenation to liquid fuel is considered a method for the utilization and conversion of CO2, whereas satisfactory activity and selectivity remains a challenge. This method provides a new idea for the catalytic hydrogenation of CO2 and from there the preparation of high-value-added products.

Autothermal Reforming of Volatile Organic Compounds to Hydrogen-Rich Gas

Industrial emissions of volatile organic compounds are urgently addressed for their toxicity and carcinogenicity to humans. Developing efficient and eco-friendly reforming technology of volatile organic compounds is important but still a great challenge. A promising strategy is to generate hydrogen-rich gas for solid oxide fuel cells by autothermal reforming of VOCs. In this study, we found a more desirable commercial catalyst (NiO/K₂O-γ-Al₂O₃) for the autothermal reforming of VOCs. The performance of autothermal reforming of toluene as a model compound over a NiO/K₂O-γ-Al₂O₃ catalyst fitted well with the simulation results at the optimum operating conditions calculated based on a simulation using Aspen PlusV11.0 software. Furthermore, the axial temperature distribution of the catalyst bed was monitored during the reaction, which demonstrated that the reaction system was self-sustaining. Eventually, actual volatile organic compounds from the chemical factory (C₉, C₁₀, toluene, paraxylene, diesel, benzene, kerosene, raffinate oil) were completely reformed over NiO/K₂O-γ-Al₂O₃. Reducing emissions of VOCs and generating hydrogen-rich gas as a fuel from the autothermal reforming of VOCs is a promising strategy.

The Conversion of Waste Biomass into Carbon-Supported Iron Catalyst for Syngas to Clean Liquid Fuel Production

Syngas has been utilized in the production of chemicals and fuels, as well as in the creation of electricity. Feedstock impurities, such as nitrogen, sulfur, chlorine, and ash, in syngas have a negative impact on downstream processes. Fischer–Tropsch synthesis is a process that relies heavily on temperature to increase the production of liquid fuels (FTS). In this study, waste biomass converted into activated carbon and then a carbon-supported iron-based catalyst was prepared. The catalyst at 200 °C and 350 °C was used to investigate the influence of temperature on the subsequent application of syngas to liquid fuels. Potassium (K) was used as a structural promoter in the Fe-C catalyst to boost catalyst activity and structural stability (Fe-C-K). Low temperatures (200 °C) cause 60% and 80% of diesel generation, respectively, without and with potassium promoter. At high temperatures (350 °C), the amount of gasoline produced is 36% without potassium promoter, and 72% with promoter. Iron carbon-supported catalysts with potassium promoter increase gasoline conversion from 36.4% (Fe-C) to 72.5% (Fe-C-K), and diesel conversion from 60.8% (Fe-C) to 80.0% (Fe-C-K). As seen by SEM pictures, iron particles with potassium promoter were found to be equally distributed on the surface of activated carbon.

A review of catalytic hydrogenation of carbon dioxide: From waste to hydrocarbons

With the rapid development of industrial society and humankind’s prosperity, the growing demands of global energy, mainly based on the combustion of hydrocarbon fossil fuels, has become one of the most severe challenges all over the world. It is estimated that fossil fuel consumption continues to grow with an annual increase rate of 1.3%, which has seriously affected the natural environment through the emission of greenhouse gases, most notably carbon dioxide (CO₂). Given these recognized environmental concerns, it is imperative to develop clean technologies for converting captured CO₂ to high-valued chemicals, one of which is value-added hydrocarbons. In this article, environmental effects due to CO₂ emission are discussed and various routes for CO₂ hydrogenation to hydrocarbons including light olefins, fuel oils (gasoline and jet fuel), and aromatics are comprehensively elaborated. Our emphasis is on catalyst development. In addition, we present an outlook that summarizes the research challenges and opportunities associated with the hydrogenation of CO₂ to hydrocarbon products.

Mechanistic Insight into Hydrocarbon Synthesis via CO2 Hydrogenation on χ-Fe5C2 Catalysts

Converting CO₂ into value-added chemicals and fuels is one of the promising approaches to alleviate CO₂ emissions, reduce the dependence on nonrenewable energy resources, and minimize the negative environmental effect of fossil fuels. This work used density functional theory (DFT) calculations combined with microkinetic modeling to provide fundamental insight into the mechanisms of CO₂ hydrogenation to hydrocarbons over the iron carbide catalyst, with a focus on understanding the energetically favorable pathways and kinetic controlling factors for selective hydrocarbon production. The crystal orbital Hamiltonian population analysis demonstrated that the transition states associated with O-H bond formation steps within the path are less stable than those of C-H bond formation, accounting for the observed higher barriers in O-H bond formation from DFT. Energetically favorable pathways for CO₂ hydrogenation to CH₄ and C₂H₄ products were identified which go through an HCOO intermediate, while the CH* species was found to be the key C₁ intermediate over χ-Fe₅C₂(510). The microkinetic modeling results showed that the relative selectivity to CH₄ is higher than C₂H₄ in CO₂ hydrogenation, but the trend is opposite under CO hydrogenation conditions. The major impact on C₂ hydrocarbon production is attributed to the high surface coverage of O* from CO₂ conversion, which occupies crucial active sites and impedes C-C couplings to C₂ species over χ-Fe₅C₂(510). The coexistence of iron oxide and carbide phases was proposed and the interfacial sites created between the two phases impact CO₂ surface chemistry. Adding potassium into the Fe₅C₂ catalyst accelerates O* removal from the carbide surface, enhances the stability of the iron carbide catalyst, thus, promotes C-C couplings to hydrocarbons.

Hydrogenation of Carbon Dioxide to Value-Added Liquid Fuels and Aromatics over Fe-Based Catalysts Based on the Fischer–Tropsch Synthesis Route

Hydrogenation of CO2 to value-added chemicals and fuels not only effectively alleviates climate change but also reduces over-dependence on fossil fuels. Therefore, much attention has been paid to the chemical conversion of CO2 to value-added products, such as liquid fuels and aromatics. Recently, efficient catalysts have been developed to face the challenge of the chemical inertness of CO2 and the difficulty of C–C coupling. Considering the lack of a detailed summary on hydrogenation of CO2 to liquid fuels and aromatics via the Fischer–Tropsch synthesis (FTS) route, we conducted a comprehensive and systematic review of the research progress on the development of efficient catalysts for hydrogenation of CO2 to liquid fuels and aromatics. In this work, we summarized the factors influencing the catalytic activity and stability of various catalysts, the strategies for optimizing catalytic performance and product distribution, the effects of reaction conditions on catalytic performance, and possible reaction mechanisms for CO2 hydrogenation via the FTS route. Furthermore, we also provided an overview of the challenges and opportunities for future research associated with hydrogenation of CO2 to liquid fuels and aromatics.

Identifying Performance Descriptors in CO2 Hydrogenation over Iron-Based Catalysts Promoted with Alkali Metals

Alkali metal promoters have been widely employed for preparation of heterogeneous catalysts used in many industrially important reactions. However, the fundamentals of their effects are usually difficult to access. Herein, we unravel mechanistic and kinetic aspects of the role of alkali metals in CO₂ hydrogenation over Fe-based catalysts through state-of-the-art characterization techniques, spatially resolved steady-state and transient kinetic analyses. The promoters affect electronic properties of iron in iron carbides. These carbide characteristics determine catalyst ability to activate H₂ , CO and CO₂ . The Allen scale electronegativity of alkali metal promoter was successfully correlated with the rates of CO₂ hydrogenation to higher hydrocarbons and CH₄ as well as with the rate constants of individual steps of CO or CO₂ activation. The derived knowledge can be valuable for designing and preparing catalysts applied in other reactions where such promoters are also used.

Direct Construction of K-Fe3C@C Nanohybrids Utilizing Waste Biomass of Pomelo Peel as High-Performance Fischer–Tropsch Catalysts

As the only renewable organic carbon source, abundant biomass has long been established and developed to mass-produce functionalized carbon materials. Herein, an extremely facile and green strategy was executed for the first time to in situ construct K-Fe3C@C nanohybrids directly by one-pot carbonizing the pomelo peel impregnated with Fe(NO3)3 solutions. The pyrolytically self-assembled nanohybrids were successfully applied in Fischer–Tropsch synthesis (FTS) and demonstrated high catalytic performance. Accordingly, the optimized K-Fe3C@C catalysts revealed excellent FTS activity (92.6% CO conversion) with highlighted C5+ hydrocarbon selectivity of 61.3% and light olefin (C2-4=) selectivity of 26.0% (olefin/paraffin (O/P) ratio of 6.2). Characterization results further manifest that the high performance was correlated with the in situ formation of the core-shell nanostructure consisting of Fe3C nanoparticles enwrapped by graphitized carbon shells and the intrinsic potassium promoter originated in pomelo peel during high-temperature carbonization. This work provided a facile approach for the low-cost mass-fabrication of high-performance FTS catalysts directly utilizing waste biomass without any chemical pre-treatment or purification.

Dynamic structural evolution of iron catalysts involving competitive oxidation and carburization during CO2 hydrogenation

Identifying the dynamic structure of heterogeneous catalysts is crucial for the rational design of new ones. In this contribution, the structural evolution of Fe(0) catalysts during CO₂ hydrogenation to hydrocarbons has been investigated by using several (quasi) in situ techniques. Upon initial reduction, Fe species are carburized to Fe₃C and then to Fe₅C₂. The by-product of CO₂ hydrogenation, H₂O, oxidizes the iron carbide to Fe₃O₄. The formation of Fe₃O₄@(Fe₅C₂+Fe₃O₄) core-shell structure was observed at steady state, and the surface composition depends on the balance of oxidation and carburization, where water plays a key role in the oxidation. The performance of CO₂ hydrogenation was also correlated with the dynamic surface structure. Theoretical calculations and controll experiments reveal the interdependence between the phase transition and reactive environment. We also suggest a practical way to tune the competitive reactions to maintain an Fe₅C₂-rich surface for a desired C₂₊ productivity.

CO2 Hydrogenation to Olefin-Rich Hydrocarbons Over Fe-Cu Bimetallic Catalysts: An Investigation of Fe-Cu Interaction and Surface Species

Previously, we reported a strong Fe-Cu synergy in CO2 hydrogenation to olefin-rich C2+ hydrocarbons over the γ-Al2O3 supported bimetallic Fe-Cu catalysts. In this work, we aimed to clarify such a synergy by investigating the catalyst structure, Fe-Cu interaction, and catalyst surface properties through a series of characterizations. H2-TPR results showed that the addition of Cu made both Fe and Cu easier to reduce via the strong interaction between Fe and Cu. It was further confirmed by X-ray absorption spectroscopy (XAS) and TEM, which showed the presence of metallic Fe and Fe-Cu alloy phases in the reduced Fe-Cu(0.17) catalyst induced by Cu addition. By correlating TPD results with the reaction performance, we found that the addition of Cu enhanced both the moderately and strongly adsorbed H2 and CO2 species, consequently enhanced CO2 conversion and C2+ selectivity. Adding K increased the adsorbed-CO2/adsorbed-H2 ratio by greatly enhancing the moderately and strongly adsorbed CO2 and slightly suppressing the moderately and strongly adsorbed H2, resulting in a significantly increased O/P ratio in the produced hydrocarbons. The product distribution analysis and in situ DRIFTS suggested that CO2 hydrogenation over the Fe-Cu catalyst involved both an indirect route with CO as the primary product and a direct route to higher hydrocarbons.

Towards the development of the emerging process of CO2 heterogenous hydrogenation into high-value unsaturated heavy hydrocarbons

The emerging process of CO₂ hydrogenation through heterogenous catalysis into important bulk chemicals provides an alternative strategy for sustainable and low-cost production of valuable chemicals, and brings an important chance for mitigating CO₂ emissions. Direct synthesis of the family of unsaturated heavy hydrocarbons such as α-olefins and aromatics via CO₂ hydrogenation is more attractive and challenging than the production of short-chain products to modern society, suffering from the difficult control between C-O activation and C-C coupling towards long-chain hydrocarbons. In the past several years, rapid progress has been achieved in the development of efficient catalysts for the process and understanding of their catalytic mechanisms. In this review, we provide a comprehensive, authoritative and critical overview of the substantial progress in the synthesis of α-olefins and aromatics from CO₂ hydrogenation via direct and indirect routes. The rational fabrication and design of catalysts, proximity effects of multi-active sites, stability and deactivation of catalysts, reaction mechanisms and reactor design are systematically discussed. Finally, current challenges and potential applications in the development of advanced catalysts, as well as opportunities of next-generation CO₂ hydrogenation techniques for carbon neutrality in future are proposed.

Synergistic Effect of Alkali Na and K Promoter on Fe-Co-Cu-Al Catalysts for CO2 Hydrogenation to Light Hydrocarbons

Alkali metal K- and/or Na-promoted FeCoCuAl catalysts were synthesized by precipitation and impregnation, and their physicochemical and catalytic performance for CO2 hydrogenation to light hydrocarbons was also investigated in the present work. The results indicate that Na and/or K introduction leads to the formation of active phase metallic Fe and Fe-Co crystals in the order Na < K < K-Na. The simultaneous introduction of Na and K causes a synergistic effect on increasing the basicity and electron-rich property, promoting the formation of active sites Fe@Cu and Fe-Co@Cu with Cu0 as a crystal core. These effects are advantageous to H2 dissociative adsorption and CO2 activation, giving a high CO2 conversion with hydrogenation. Moreover, electron-rich Fe@Cu (110) and Fe-Co@Cu (200) provide active centers for further H2 dissociative adsorption and O-C-Fe intermediate formation after adsorption of CO produced by RWGS. It is beneficial for carbon chain growth in C2+ hydrocarbons, including olefins and alkanes. FeCoCuAl simultaneously modified by K-Na exhibits the highest CO2 conversion and C2+ selectivity of 52.87 mol% and 89.70 mol%, respectively.

Adjusting the CO2 hydrogenation pathway via the synergic effects of iron carbides and iron oxides

The synergic effects of iron carbides and iron oxides were used to adjust the reaction pathway to form alkenes or ethanol.

Novel Heterogeneous Catalysts for CO2 Hydrogenation to Liquid Fuels

Carbon dioxide (CO₂) hydrogenation to liquid fuels including gasoline, jet fuel, diesel, methanol, ethanol, and other higher alcohols via heterogeneous catalysis, using renewable energy, not only effectively alleviates environmental problems caused by massive CO₂ emissions, but also reduces our excessive dependence on fossil fuels. In this Outlook, we review the latest development in the design of novel and very promising heterogeneous catalysts for direct CO₂ hydrogenation to methanol, liquid hydrocarbons, and higher alcohols. Compared with methanol production, the synthesis of products with two or more carbons (C₂₊) faces greater challenges. Highly efficient synthesis of C₂₊ products from CO₂ hydrogenation can be achieved by a reaction coupling strategy that first converts CO₂ to carbon monoxide or methanol and then conducts a C-C coupling reaction over a bifunctional/multifunctional catalyst. Apart from the catalytic performance, unique catalyst design ideas, and structure-performance relationship, we also discuss current challenges in catalyst development and perspectives for industrial applications.

Reverse Water Gas Shift by Chemical Looping with Iron-Substituted Hexaaluminate Catalysts

The Fe-substituted Ba-hexaaluminates (BaFeHAl) are active catalysts for reverse water-gas shift (RWGS) reaction conducted in chemical looping mode. Increasing of the degree of substitution of Al3+ for Fe3+ ions in co-precipitated BaHAl from 60% (BaFeHAl) to 100% (BaFe-hexaferrite, BaFeHF), growing its surface area from 5 to 30 m2/g, and promotion with potassium increased the CO capacity in isothermal RWGS-CL runs at 350–450 °C, where the hexaaluminate/hexaferrite structure is stable. Increasing H2-reduction temperature converts BaFeHAl to a thermally stable BaFeHF modification that contains additional Ba-O-Fe bridges in its structure, reinforcing the connection between alternatively stacked spinel blocks. This material displayed the highest CO capacity of 400 µmol/g at isothermal RWGS-CL run conducted at 550 °C due to increased concentration of oxygen vacancies reflected by greater surface Fe2+/Fe3+ ratio detected by XPS. The results demonstrate direct connection between CO capacity measured in RWGS-CL experiments and calculated CO2 conversion.

Inverse iron oxide/metal catalysts from galvanic replacement

Key chemical transformations require metal and redox sites in proximity at interfaces; however, in traditional oxide-supported materials, this requirement is met only at the perimeters of metal nanoparticles. We report that galvanic replacement can produce inverse FeO_x/metal nanostructures in which the concentration of oxide species adjoining metal domains is maximal. The synthesis involves reductive deposition of rhodium or platinum and oxidation of Fe²⁺ from magnetite (Fe₃O₄). We discovered a parallel dissolution and adsorption of Fe²⁺ onto the metal, yielding inverse FeO_x-coated metal nanoparticles. This nanostructure exhibits the intrinsic activity in selective CO₂ reduction that simple metal nanoparticles have only at interfaces with the support. By enabling a simple way to control the surface functionality of metal particles, our approach is not only scalable but also enables a versatile palette for catalyst design.

While typical catalysts involve oxide-supported metals, inverse catalysts of oxides on metal supports offer an attractive alternative. Here, authors prepare FeO_x-coated Rh nanoparticles via galvanic replacement and dissolution-precipitation to form effective CO₂ reduction catalysts.

Electrospun Fe-Al-O Nanobelts for Selective CO2 Hydrogenation to Light Olefins

Ceramic nanobelt catalysts consisting of Fe-Al-O spinel modified with potassium were synthesized for CO₂ hydrogenation into hydrocarbons. Nanobelts and hollow nanofibers were produced utilizing the internal heat released by oxidation of the organic component within the fibers. This extremely fast and short heating facilitated crystallization of the desired phase, while maintaining small grains and a large surface area. We investigated the effects of mat thickness, composition, and heating rate on the final morphology. A general transformation mechanism for electrospun nanofibers that correlates for the first time the mat's thickness and the rate of oxidation during thermal treatment was proposed. The catalytic performance of carburized ceramic K/Fe-Al-O nanobelts was compared to the K/Fe-Al-O spinel powder. The electrospun catalyst showed a superior carbon dioxide conversion of 48% and a selectivity of 52% to light C₂-C₅ olefins, while the powder catalyst produced mainly C₆⁺ hydrocarbons. Characterization of steady state catalytic materials by energy-dispersive X-ray spectroscopy, X-ray diffraction, X-ray photoelectron spectroscopy, high-resolution transmission electron microscopy, and N₂-adsorption methods revealed that high olefin selectivity of the electrospun materials is related to a high extent of reduction of surface iron atoms because of more efficient interaction with the potassium promoter.