Direct synthesis of lower olefins from syngas via Fischer–Tropsch synthesis catalyzed by a dual-bed catalyst

The pivotal role of bromine in FeMnKBr/YNa catalyst for CO2 hydrogenation to light olefins

Light olefins are key intermediates in the synthesis of petrochemicals, and the conversion of stabilized carbon dioxide to light olefins using catalysts containing halogenated elements such as chlorine is a major challenge. Building on previous reports emphasizing the toxic effects of halogen elements on catalysts, we present the synthesis of FeMnKBr/YNa catalysts. This involved the synthesis of the catalyst by melt permeation using Br-containing potassium salts, other metal nitrates and YNa zeolites. The catalyst performed well in converting syngas (H2/CO2 = 3) to light olefins with a selectivity of 56.2%, CO2 conversion of 34.4%, and CO selectivity of 13.6%. Adding Br aids in reducing the Fe phase, boosts catalyst carburization, and produces more iron carbide species. It also moderately deposits carbon on the active center's surface, enhancing active phase dispersion. Br's electronegativity mitigates the influence of K, reducing catalyst's carbon-carbon coupling ability, leading to more low-carbon olefins generation.

A Review on Green Hydrogen Valorization by Heterogeneous Catalytic Hydrogenation of Captured CO2 into Value-Added Products

The catalytic hydrogenation of captured CO2 by different industrial processes allows obtaining liquid biofuels and some chemical products that not only present the interest of being obtained from a very low-cost raw material (CO2) that indeed constitutes an environmental pollution problem but also constitute an energy vector, which can facilitate the storage and transport of very diverse renewable energies. Thus, the combined use of green H2 and captured CO2 to obtain chemical products and biofuels has become attractive for different processes such as power-to-liquids (P2L) and power-to-gas (P2G), which use any renewable power to convert carbon dioxide and water into value-added, synthetic renewable E-fuels and renewable platform molecules, also contributing in an important way to CO2 mitigation. In this regard, there has been an extraordinary increase in the study of supported metal catalysts capable of converting CO2 into synthetic natural gas, according to the Sabatier reaction, or in dimethyl ether, as in power-to-gas processes, as well as in liquid hydrocarbons by the Fischer-Tropsch process, and especially in producing methanol by P2L processes. As a result, the current review aims to provide an overall picture of the most recent research, focusing on the last five years, when research in this field has increased dramatically.

Light olefin synthesis from a diversity of renewable and fossil feedstocks: state-of the-art and outlook

Light olefins are important feedstocks and platform molecules for the chemical industry. Their synthesis has been a research priority in both academia and industry. There are many different approaches to the synthesis of these compounds, which differ by the choice of raw materials, catalysts and reaction conditions. The goals of this review are to highlight the most recent trends in light olefin synthesis and to perform a comparative analysis of different synthetic routes using several quantitative characteristics: selectivity, productivity, severity of operating conditions, stability, technological maturity and sustainability. Traditionally, on an industrial scale, the cracking of oil fractions has been used to produce light olefins. Methanol-to-olefins, alkane direct or oxidative dehydrogenation technologies have great potential in the short term and have already reached scientific and technological maturities. Major progress should be made in the field of methanol-mediated CO and CO₂ direct hydrogenation to light olefins. The electrocatalytic reduction of CO₂ to light olefins is a very attractive process in the long run due to the low reaction temperature and possible use of sustainable electricity. The application of modern concepts such as electricity-driven process intensification, looping, CO₂ management and nanoscale catalyst design should lead in the near future to more environmentally friendly, energy efficient and selective large-scale technologies for light olefin synthesis.

Production of Light Olefins via Fischer-Tropsch Process Using Iron-Based Catalysts: A Review

The production of light olefins, as the critical components in chemical industries, is possible via different technologies. The Fischer–Tropsch to olefin (FTO) process aims to convert syngas to light olefins with high selectivity over a proper catalyst, reduce methane formation, and avoid the production of excess CO2. This review describes the production of light olefins through the FTO process using both unsupported and supported iron-based catalysts. The catalytic properties and performances of both the promoted and bimetallic unsupported catalysts are reviewed. The effect of support and its physico-chemical properties on the catalyst activity are also described. The proper catalyst should have high stability to provide long-term performance without reducing the activity and selectivity towards the desired product. The good dispersion of active metals on the surface, proper porosity, optimized metal-support interaction, a high degree of reducibility, and providing a sufficient active phase for the reaction are important parameters affecting the reaction. The selection of the suitable catalyst with enhanced activity and the optimum process conditions can increase the possibility of the FTO reaction for light-olefins production. The production of light olefins via the FTO process over iron-based catalysts is a promising method, as iron is cheap, shows higher resistance to sulfur, and has a higher WGS activity which can be helpful for the feed gas with a low H2/CO ratio, and also has higher selectivity towards light olefins.

Selective Conversion of Syngas to Olefins via Novel Cu-Promoted Fe/RGO and Fe-Mn/RGO Fischer-Tropsch Catalysts: Fixed-Bed Reactor vs Slurry-Bed Reactor

Fischer-Tropsch has become an indispensable choice in the gas-to-liquid conversion reactions to produce a wide range of petrochemicals using recently emerging biomass or other types of feedstock such as coal or natural gas. Herein we report the incorporation of novel Cu nanoparticles with two Fischer-Tropsch synthesis (FTS) catalytic systems, Fe/reduced graphene oxide (rGO) and Fe-Mn/rGO, to evaluate their FTS performance and olefin productivity in two types of reactors: slurry-bed reactor (SBR) and fixed-bed reactor (FBR). Four catalysts were compared and investigated, namely Fe, FeCu7, FeMn10Cu7, and FeMn16, which were highly dispersed over reduced graphene oxide nanosheets. The catalysts were first characterized by transmission electron microscopy (TEM), nitrogen physisorption, X-ray fluorescence (XRF), X-ray diffraction (XRD), and H-TPR techniques. In the SBR, Cu enhanced olefinity only when used alone in FeCu7 without Mn promotion. When used with Mn, the olefin yield was not changed, but light olefins decreased slightly at the expense of heavier olefins. In the FBR system, Cu as a reduction promoter improved the catalyst activity. It increased the olefin yield mainly due to increased activity, even if the CO2 decreased by the action of Cu promoters. The olefinity of the product was improved by Cu promotion but it did not exceed the landmark made by FeMn16 at 320 °C. The paraffinity was also enhanced by Cu promotion especially in the presence of Mn, indicating a strong synergistic effect. Cu was found to be better than Mn in enhancing the paraffin yield, while Mn is a better olefin yield enhancer. Finally, Cu promotion was found to enhance the selectivity towards light olefins C2-4. This study gives a deep insight into the effect of different highly dispersed FTS catalyst systems on the olefin hydrocarbon productivity and selectivity in two major types of FTS reactors.

Fischer–Tropsch Synthesis for Light Olefins from Syngas: A Review of Catalyst Development

Light olefins as one the most important building blocks in chemical industry can be produced via Fischer–Tropsch synthesis (FTS) from syngas. FT synthesis conducted at high temperature would lead to light paraffins, carbon dioxide, methane, and C5+ longer chain hydrocarbons. The present work focuses on providing a critical review on the light olefin production using Fischer–Tropsch synthesis. The effects of metals, promoters and supports as the most influential parameters on the catalytic performance of catalysts are discussed meticulously. Fe and Co as the main active metals in FT catalysts are investigated in terms of pore size, crystal size, and crystal phase for obtaining desirable light olefin selectivity. Larger pore size of Fe-based catalysts is suggested to increase olefin selectivity via suppressing 1-olefin readsorption and secondary reactions. Iron carbide as the most probable phase of Fe-based catalysts is proposed for light olefin generation via FTS. Smaller crystal size of Co active metal leads to higher olefin selectivity. Hexagonal close-packed (HCP) structure of Co has higher FTS activity than face-centered cubic (FCC) structure. Transition from Co to Co3C is mainly proposed for formation of light olefins over Co-based catalysts. Moreover, various catalysts’ deactivation routes are reviewed. Additionally, techno-economic assessment of FTS plants in terms of different costs including capital expenditure and minimum fuel selling price are presented based on the most recent literature. Finally, the potential for global environmental impacts associated with FTS plants including atmospheric and toxicological impacts is considered via lifecycle assessment (LCA).