Conversion of CO2, CO, and H2 in CO2 Hydrogenation to Fungible Liquid Fuels on Fe-Based Catalysts

Recent Advances Hydrogenation of Carbon Dioxide to Light Olefins over Iron-Based Catalysts via the Fischer-Tropsch Synthesis

The massive burning of fossil fuels has been important for economic and social development, but the increase in the CO2 concentration has seriously affected environmental sustainability. In industrial and agricultural production, light olefins are one of the most important feedstocks. Therefore, the preparation of light olefins by CO2 hydrogenation has been intensively studied, especially for the development of efficient catalysts and for the application in industrial production. Fe-based catalysts are widely used in Fischer-Tropsch synthesis due to their high stability and activity, and they also exhibit excellent catalytic CO2 hydrogenation to light olefins. This paper systematically summarizes and analyzes the reaction mechanism of Fe-based catalysts, alkali and transition metal modifications, interactions between active sites and carriers, the synthesis process, and the effect of the byproduct H2O on catalyst performance. Meanwhile, the challenges to the development of CO2 hydrogenation for light olefin synthesis are presented, and future development opportunities are envisioned.

Novel heterogeneous Fe-based catalysts for carbon dioxide hydrogenation to long chain α-olefins-A review

The thermocatalytic conversion of carbon dioxide (CO2) into high value-added chemicals provides a strategy to address the environmental problems caused by excessive carbon emissions and the sustainable production of chemicals. Significant progress has been made in the CO2 hydrogenation to long chain α-olefins, but controlling C-O activation and C-C coupling remains a great challenge. This review focuses on the recent advances in catalyst design concepts for the synthesis of long chain α-olefins from CO2 hydrogenation. We have systematically summarized and analyzed the ingenious design of catalysts, reaction mechanisms, the interaction between active sites and supports, structure-activity relationship, influence of reaction process parameters on catalyst performance, and catalyst stability, as well as the regeneration methods. Meanwhile, the challenges in the development of the long chain α-olefins synthesis from CO2 hydrogenation are proposed, and the future development opportunities are prospected. The aim of this review is to provide a comprehensive perspective on long chain α-olefins synthesis from CO2 hydrogenation to inspire the invention of novel catalysts and accelerate the development of this process.

MIL-100(Fe)-derived catalysts for CO2 conversion via low- and high-temperature reverse water-gas shift reaction

Fe-derived catalysts were synthesized by the pyrolysis of MIL-100 (Fe) metal-organic framework (MOF) and evaluated in the reverse water-gas shift (RWGS) reaction. The addition of Rh as a dopant by in-situ incorporation during the synthesis and wet impregnation was also considered. Our characterization data showed that the main active phase was a mixture of α-Fe, Fe₃C, and Fe₃O₄ in all the catalysts evaluated. Additionally, small Rh loading leads to a decrease in the particle size in the active phase. Despite all three catalysts showing commendable CO selectivity levels, the C@Fe* catalyst showed the most promising performance at a temperature below 500 °C, attributed to the in-situ incorporation of Rh during the synthesis. Overall, this work showcases a strategy for designing novel Fe MOF-derived catalysts for RWGS reaction, opening new research opportunities for CO₂ utilization schemes.

CeFeO3-CeO2-Fe2O3 Systems: Synthesis by Solution Combustion Method and Catalytic Performance in CO2 Hydrogenation

Rare-earth orthoferrites have found wide application in thermocatalytic reduction-oxidation processes. Much less attention has been paid, however, to the production of CeFeO₃, as well as to the study of its physicochemical and catalytic properties, in particular, in the promising process of CO₂ utilization by hydrogenation to CO and hydrocarbons. This study presents the results of a study on the synthesis of CeFeO₃ by solution combustion synthesis (SCS) using various fuels, fuel-to-oxidizer ratios, and additives. The SCS products were characterized by XRD, FTIR, N₂-physisorption, SEM, DTA-TGA, and H₂-TPR. It has been established that glycine provides the best yield of CeFeO₃, while the addition of NH₄NO₃ promotes an increase in the amount of CeFeO₃ by 7-12 wt%. In addition, the synthesis of CeFeO₃ with the participation of NH₄NO₃ makes it possible to surpass the activity of the CeO₂-Fe₂O₃ system at low temperatures (300-400 °C), as well as to increase selectivity to hydrocarbons. The observed effects are due to the increased gas evolution and ejection of reactive FeO_x nanoparticles on the surface of crystallites, and an increase in the surface defects. CeFeO₃ obtained in this study allows for achieving higher CO₂ conversion compared to LaFeO₃ at 600 °C.

Modified fischer-tropsch synthesis: A review of highly selective catalysts for yielding olefins and higher hydrocarbons

Global warming, fossil fuel depletion, climate change, as well as a sudden increase in fuel price have motivated scientists to search for methods of storage and reduction of greenhouse gases, especially CO2. Therefore, the conversion of CO2 by hydrogenation into higher hydrocarbons through the modified Fischer–Tropsch Synthesis (FTS) has become an important topic of current research and will be discussed in this review. In this process, CO2 is converted into carbon monoxide by the reverse water-gas-shift reaction, which subsequently follows the regular FTS pathway for hydrocarbon formation. Generally, the nature of the catalyst is the main factor significantly influencing product selectivity and activity. Thus, a detailed discussion will focus on recent developments in Fe-based, Co-based, and bimetallic catalysts in this review. Moreover, the effects of adding promoters such as K, Na, or Mn on the performance of catalysts concerning the selectivity of olefins and higher hydrocarbons are assessed.

Transient Behavior of CO and CO2 Hydrogenation on Fe@SiO2 Core–Shell Model Catalysts—A Stoichiometric Analysis of Experimental Data

The hydrogenation of CO and CO2 from industrial exhaust gases into CH4 represents a promising method for sustainable chemical energy storage. While iron-based catalysts are in principle suitable for that purpose, the active metal Fe undergoes a complex transformation during the chemical reaction process. However, only little is known about the change in catalytically active species under reaction conditions, primarily caused by structural changes in the catalyst material, so far. By using core–shell model materials, factors that alter the catalyst structure can be excluded, making it possible to observe the direct influence of the reactants on the activity in the present work. Furthermore, stoichiometric analysis was used as a key tool for the evaluation of individual key reactions in the complex reaction network purely from experimental data, thus making it possible to draw conclusions about the catalyst state. In the case of CO hydrogenation, the presumed Boudouard reaction and the associated carburization of the catalyst can be quantified and the main reaction (CO methanation) can be determined. The results of the CO2 hydrogenation showed that the reverse water–gas shift reaction mainly took place, but under an ongoing change in the catalytic active iron phase. Due to the systematic exchange between CO and CO2 in the reactant gas stream, a mutual influence could also be observed. The results from the stoichiometric analysis provide the basis for the development of kinetic models for the key reactions in future work.

Detailed Kinetic Modeling of CO2-Based Fischer–Tropsch Synthesis

The direct hydrogenation of CO2 to long-chain hydrocarbons, so called CO2-based Fischer–Tropsch synthesis (FTS), is a viable future production route for various hydrocarbons used in the chemical industry or fuel applications. The detailed modeling of the reactant consumption and product distribution is very important for further process improvements but has gained only limited attention so far. We adapted proven modeling approaches from the traditional FTS and developed a detailed kinetic model for the CO2-FTS based on experiments with an Fe based catalyst in a lab-scale tubular reactor. The model is based on a direct CO2 dissociation mechanism for the reverse water gas shift and the alkyl mechanism with an H-assisted CO dissociation step for the FTS. The model is able to predict the reactant consumption, as well as the hydrocarbon distribution, reliably within the experimental range studied (10 bar, 280–320 °C, 900–120,000 mLN h−1 g−1 and H2/CO2 molar inlet ratios of 2–4) and demonstrates the applicability of traditional FTS models for the CO2-based synthesis. Peculiarities of the fractions of individual hydrocarbon classes (1-alkenes, n-alkanes, and iso-alkenes) are accounted for with chain-length-dependent kinetic parameters for branching and dissociative desorption. However, the reliable modeling of class fractions for high carbon number products (>C12) remains a challenge not only from a modeling perspective but also from product collection and analysis.

Catalysts for the Conversion of CO2 to Low Molecular Weight Olefins-A Review

There is a large worldwide demand for light olefins (C₂⁼-C₄⁼), which are needed for the production of high value-added chemicals and plastics. Light olefins can be produced by petroleum processing, direct/indirect conversion of synthesis gas (CO + H₂) and hydrogenation of CO₂. Among these methods, catalytic hydrogenation of CO₂ is the most recently studied because it could contribute to alleviating CO₂ emissions into the atmosphere. However, due to thermodynamic reasons, the design of catalysts for the selective production of light olefins from CO₂ presents different challenges. In this regard, the recent progress in the synthesis of nanomaterials with well-controlled morphologies and active phase dispersion has opened new perspectives for the production of light olefins. In this review, recent advances in catalyst design are presented, with emphasis on catalysts operating through the modified Fischer-Tropsch pathway. The advantages and disadvantages of olefin production from CO₂ via CO or methanol-mediated reaction routes were analyzed, as well as the prospects for the design of a single catalyst for direct olefin production. Conclusions were drawn on the prospect of a new catalyst design for the production of light olefins from CO₂.

Phase transformation of iron oxide to carbide and Fe3C as an active center for the RWGS reaction

Fe3C was produced from iron oxide and identified as active and stable in the reverse water gas shift reaction.

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.

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.

On the nature of active phases and sites in CO and CO2 hydrogenation catalysts

Advanced characterisation techniques are shedding new light on the identification of active CO_x hydrogenation phases and sites.

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 CO₂via 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.

CO₂ hydrogenation to hydrocarbons over heterogeneous catalysts.

CO2 hydrogenation to higher hydrocarbons on K/Fe–Al–O spinel catalysts promoted with Si, Ti, Zr, Hf, Mn and Ce

Si and Zr species grafted on Fe–Al–O catalysts act as an inhibitor and promoter, respectively, in CO₂ hydrogenation.