Size and Promoter Effects on Stability of Carbon-Nanofiber-Supported Iron-Based Fischer-Tropsch Catalysts

Recent advances in Co2C-based nanocatalysts for direct production of olefins from syngas conversion

Syngas conversion provides an important platform for efficient utilization of various carbon-containing resources such as coal, natural gas, biomass, solid waste and even CO₂. Various value-added fuels and chemicals including paraffins, olefins and alcohols can be directly obtained from syngas conversion via the Fischer-Tropsch Synthesis (FTS) route. However, the product selectivity control still remains a grand challenge for FTS due to the limitation of Anderson-Schulz-Flory (ASF) distribution. Our previous works showed that, under moderate reaction conditions, Co₂C nanoprisms with exposed (101) and (020) facets can directly convert syngas to olefins with low methane and high olefin selectivity, breaking the limitation of ASF. The application of Co₂C-based nanocatalysts unlocks the potential of the Fischer-Tropsch process for producing olefins. In this feature article, we summarized the recent advances in developing highly efficient Co₂C-based nanocatalysts and reaction pathways for direct syngas conversion to olefins via the Fischer-Tropsch to olefin (FTO) reaction. We mainly focused on the following aspects: the formation mechanism of Co₂C, nanoeffects of Co₂C-based FTO catalysts, morphology control of Co₂C nanostructures, and the effects of promoters, supports and reactors on the catalytic performance. From the viewpoint of carbon utilization efficiency, we presented the recent efforts in decreasing the CO₂ selectivity for FTO reactions. In addition, the attempt to expand the target products to aromatics by coupling Co₂C-based FTO catalysts and H-ZSM-5 zeolites was also made. In the end, future prospects for Co₂C-based nanocatalysts for selective syngas conversion were proposed.

Homogeneity of Supported Single-Atom Active Sites Boosting the Selective Catalytic Transformations

Selective conversion of specific functional groups to desired products is highly important but still challenging in industrial catalytic processes. The adsorption state of surface species is the key factor in modulating the conversion of functional groups, which is correspondingly determined by the uniformity of active sites. However, the non-identical number of metal atoms, geometric shape, and morphology of conventional nanometer-sized metal particles/clusters normally lead to the non-uniform active sites with diverse geometric configurations and local coordination environments, which causes the distinct adsorption states of surface species. Hence, it is highly desired to modulate the homogeneity of the active sites so that the catalytic transformations can be better confined to the desired direction. In this review, the construction strategies and characterization techniques of the uniform active sites that are atomically dispersed on various supports are examined. In particular, their unique behavior in boosting the catalytic performance in various chemical transformations is discussed, including selective hydrogenation, selective oxidation, Suzuki coupling, and other catalytic reactions. In addition, the dynamic evolution of the active sites under reaction conditions and the industrial utilization of the single-atom catalysts are highlighted. Finally, the current challenges and frontiers are identified, and the perspectives on this flourishing field is provided.

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.

Fe Nanoparticle Size Control of the Fe-MOF-Derived Catalyst Using a Solvothermal Method: Effect on FTS Activity and Olefin Production

The design of a highly active Fe-supported catalyst with the optimum particle and pore size, dispersion, loading, and stability is essential for obtaining the desired product selectivity. This study employed a solvothermal method to prepare two Fe-MIL-88B metal-organic framework (MOF)-derived catalysts using triethylamine (TEA) or NaOH as deprotonation catalysts. The catalysts were analyzed using X-ray diffraction, N₂-physisorption, Fourier transform infrared spectroscopy, scanning electron microscopy, transmission electron microscopy, H₂ temperature-programed reduction, and thermogravimetric analysis and were evaluated for the Fischer-Tropsch synthesis performance. It was evident that the catalyst preparation in the presence of TEA produces a higher MOF yield and smaller crystal size than those produced using NaOH. The pyrolysis of MOFs yielded catalysts with different Fe particle sizes of 6 and 35 nm for the preparation in the presence of TEA and NaOH, respectively. Also, both types of catalysts exhibited a high Fe loading (50%) and good stability after 100 h reaction time. The smaller particle size TEA catalyst showed higher activity and higher olefin yield, with 94% CO conversion and a higher olefin yield of 24% at a lower reaction temperature of 280 °C and 20 bar at H₂/CO = 1. Moreover, the smaller particle size TEA catalyst exhibited higher Fe time yield and CH₄ selectivity but with lower chain growth probability (α) and C₅₊ selectivity.

Unravelling the metal–support interactions in χ-Fe5C2/MgO catalysts for olefin synthesis directly from syngas

The structural and electronic modifications of χ-Fe5C2 by MgO contribute to the high selectivity towards lower olefins and the high catalyst stability.

C2 weakens the turnover frequency during the melting of FexCy: insights from reactive MD simulations

The carbon accumulation in the form of C2 on the surface at high temperatures blocks the surface catalytic active sites, reducing the activity of melted FexCy nanoparticles.

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.

Development of an Iron-Based Fischer—Tropsch Catalyst with High Attrition Resistance and Stability for Industrial Application

In order to develop an iron-based catalyst with high attrition resistance and stability for Fischer–Tropsch synthesis (FTS), a series of experiments were carried out to investigate the effects of SiO2 and its hydroxyl content and a boron promoter on the attrition resistance and catalytic behavior of spray-dried precipitated Fe/Cu/K/SiO2 catalysts. The catalysts were characterized by means of N2 physisorption, nuclear magnetic resonance (NMR), X-ray diffraction (XRD), Raman spectrum, X-ray photoelectron spectroscopy (XPS), H2-thermogravimetric analysis (H2-TGA), temperature-programmed reduction and hydrogenation (TPR and TPH), and scanning and transmission electron microscopy (SEM and TEM). The FTS performance of the catalysts was tested in a slurry-phase continuously stirred tank reactor (CSTR), while the attrition resistance study included a physical test with the standard method and a chemical attrition test under simulated reaction conditions. The results indicated that the increase in SiO2 content enhances catalysts’ attrition resistance and FTS stability, but decreases activity due to the suppression of further reduction of the catalysts. Moreover, the attrition resistance of the catalysts with the same silica content was greatly improved with an increase in hydroxyl number within silica sources, as well as the FTS activity and stability to some degree. Furthermore, the boron element was found to show remarkable promotion of FTS stability, and the promotion mechanism was discussed with regard to probable interactions between Fe and B, K and B, and SiO2 and B, etc. An optimized catalyst based on the results of this study was finalized, scaled up, and successfully applied in a megaton industrial slurry bubble FTS unit, exhibiting excellent FTS performance.

Rational design of tandem catalysts using a core-shell structure approach

A facile and rational approach to synthesize bimetallic heterogeneous tandem catalysts is presented. Using core-shell structures, it is possible to create spatially controlled ensembles of different nanoparticles and investigate coupled chemocatalytic reactions. The CO2 hydrogenation to methane and light olefins was tested, achieving a tandem process successfully.

Effects of Structure and Particle Size of Iron, Cobalt and Ruthenium Catalysts on Fischer–Tropsch Synthesis

This review emphasizes the importance of the catalytic conversion techniques in the production of clean liquid and hydrogen fuels (XTF) and chemicals (XTC) from the carbonaceous materials including coal, natural gas, biomass, organic wastes, biogas and CO2. Dependence of the performance of Fischer–Tropsch Synthesis (FTS), a key reaction of the XTF/XTC process, on catalyst structure (crystal and size) is comparatively examined and reviewed. The contribution illustrates the very complicated crystal structure effect, which indicates that not only the particle type, but also the particle shape, facets and orientation that have been evidenced recently, strongly influence the catalyst performance. In addition, the particle size effects over iron, cobalt and ruthenium catalysts were carefully compared and analyzed. For all Fe, Co and Ru catalysts, the metal turnover frequency (TOF) for CO hydrogenation increased with increasing metal particle size in the small size region i.e., less than the size threshold 7–8 nm, but was found to be independent of particle size for the catalysts with large particle sizes greater than the size threshold. There are some inconsistencies in the small particle size region for Fe and Ru catalysts, i.e., an opposite activity trend and an abnormal peak TOF value were observed on a Fe catalyst and a Ru catalyst (2 nm), respectively. Further study from the literature provides deeper insights into the catalyst behaviors. The intrinsic activity of Fe catalysts (10 nm) at 260–300 °C is estimated in the range of 0.046–0.20 s−1, while that of the Co and Ru catalysts (7–70 nm) at 220 °C are 0.1 s−1 and 0.4 s−1, respectively.

Kinetics and Selectivity Study of Fischer–Tropsch Synthesis to C5+ Hydrocarbons: A Review

Fischer–Tropsch synthesis (FTS) is considered as one of the non-oil-based alternatives for liquid fuel production. This gas-to-liquid (GTL) technology converts syngas to a wide range of hydrocarbons using metal (Fe and Co) unsupported and supported catalysts. Effective design of the catalyst plays a significant role in enhancing syngas conversion, selectivity towards C5+ hydrocarbons, and decreasing selectivity towards methane. This work presents a review on catalyst design and the most employed support materials in FTS to synthesize heavier hydrocarbons. Furthermore, in this report, the recent achievements on mechanisms of this reaction will be discussed. Catalyst deactivation is one of the most important challenges during FTS, which will be covered in this work. The selectivity of FTS can be tuned by operational conditions, nature of the catalyst, support, and reactor configuration. The effects of all these parameters will be analyzed within this report. Moreover, zeolites can be employed as a support material of an FTS-based catalyst to direct synthesis of liquid fuels, and the specific character of zeolites will be elaborated further. Furthermore, this paper also includes a review of some of the most employed characterization techniques for Fe- and Co-based FTS catalysts. Kinetic study plays an important role in optimization and simulation of this industrial process. In this review, the recent developed reaction rate models are critically discussed.

Mn-Decorated CeO2 nanorod supported iron-based catalyst for high-temperature Fischer–Tropsch synthesis of light olefins

The synergistic effect between Mn and Ce can improve electrons transfer from Ce to Fe and the oxygen migration. The remarkable properties promote the dissociation of CO, suppress the hydrogenation, and improve the selectivity of light olefins.

Stabilization of ε-iron carbide as high-temperature catalyst under realistic Fischer-Tropsch synthesis conditions

The development of efficient catalysts for Fischer–Tropsch (FT) synthesis, a core reaction in the utilization of non-petroleum carbon resources to supply energy and chemicals, has attracted much recent attention. ε-Iron carbide (ε-Fe₂C) was proposed as the most active iron phase for FT synthesis, but this phase is generally unstable under realistic FT reaction conditions (> 523 K). Here, we succeed in stabilizing pure-phase ε-Fe₂C nanocrystals by confining them into graphene layers and obtain an iron-time yield of 1258 μmol_CO g_Fe⁻¹s⁻¹ under realistic FT synthesis conditions, one order of magnitude higher than that of the conventional carbon-supported Fe catalyst. The ε-Fe₂C@graphene catalyst is stable at least for 400 h under high-temperature conditions. Density functional theory (DFT) calculations reveal the feasible formation of ε-Fe₂C by carburization of α-Fe precursor through interfacial interactions of ε-Fe₂C@graphene. This work provides a promising strategy to design highly active and stable Fe-based FT catalysts.

ε-Fe₂C has been identified as the highly active phase for Fischer-Tropsch synthesis (FTS), but is stable only at low-temperature. Here, the authors show that ε-Fe₂C phase can be stabilized even at ~ 573 K by being encapsulated inside graphene layers, and retains high activity in FTS.

Designing Nanoparticles and Nanoalloys for Gas-Phase Catalysis with Controlled Surface Reactivity Using Colloidal Synthesis and Atomic Layer Deposition

Supported nanoparticles are commonly applied in heterogeneous catalysis. The catalytic performance of these solid catalysts is, for a given support, dependent on the nanoparticle size, shape, and composition, thus necessitating synthesis techniques that allow for preparing these materials with fine control over those properties. Such control can be exploited to deconvolute their effects on the catalyst's performance, which is the basis for knowledge-driven catalyst design. In this regard, bottom-up synthesis procedures based on colloidal chemistry or atomic layer deposition (ALD) have proven successful in achieving the desired level of control for a variety of fundamental studies. This review aims to give an account of recent progress made in the two aforementioned synthesis techniques for the application of controlled catalytic materials in gas-phase catalysis. For each technique, the focus goes to mono- and bimetallic materials, as well as to recent efforts in enhancing their performance by embedding colloidal templates in porous oxide phases or by the deposition of oxide overlayers via ALD. As a recent extension to the latter, the concept of area-selective ALD for advanced atomic-scale catalyst design is discussed.

Influence of Promotion on the Growth of Anchored Colloidal Iron Oxide Nanoparticles during Synthesis Gas Conversion

Using colloidal iron oxide nanoparticles with organic ligands, anchored in a separate step from the supports, has been shown to be beneficial to obtain homogeneously distributed metal particles with a narrow size distribution. Literature indicates that promoting these particles with sodium and sulfur creates an active Fischer–Tropsch catalyst to produce olefins, while further adding an H-ZSM-5 zeolite is an effective way to obtain aromatics. This research focused on the promotion of iron oxide colloids with sodium and sulfur using an inorganic ligand exchange followed by the attachment to H-ZSM-5 zeolite crystals. The catalyst referred to as FeP/Z, which consists of iron particles with inorganic ligands attached to a H-ZSM-5 catalyst, was compared to an unpromoted Fe/Z catalyst and an Fe/Z-P catalyst, containing the colloidal nanoparticles with organic ligands, promoted after attachment. A low CO conversion was observed on both FeP/Z and Fe/Z-P, originating from an overpromotion effect for both catalysts. However, when both promoted catalysts were washed (FeP/Z-W and Fe/Z–P-W) to remove the excess of promoters, the activity was much higher. Fe/Z-P-W simultaneously achieved low selectivity toward methane as part of the promoters were still present after washing, whereas for FeP/Z-W the majority of promoters was removed upon washing, which increased the methane selectivity. Moreover, due to the addition of Na+S promoters, the iron nanoparticles in the FeP/Z(-W) catalysts had grown considerably during catalysis, while those in Fe/Z-P(-W) and Fe/Z(-W) remained relatively stable. Lastly, as a large broadening of particle sizes for the used FeP/Z-W was found, where particle sizes had both increased and decreased, Ostwald ripening is suggested for particle growth accelerated by the presence of the promoters.

Lower olefins from methane: recent advances

Modern methods for methane conversion to lower olefins having from 2 to 4 carbon atoms per molecule are generalized. Multistage processing of methane into ethylene and propylene via syngas or methyl chloride and methods for direct conversion of CH4 to ethylene are described. Direct conversion of syngas to olefins as well as indirect routes of the process via methanol or dimethyl ether are considered. Particular attention is paid to innovative methods of olefin synthesis. Recent achievements in the design of catalysts and development of new techniques for efficient implementation of oxidative coupling of methane and methanol conversion to olefins are analyzed and systematized. Advances in commercializing these processes are pointed out. Novel catalysts for Fischer – Tropsch synthesis of lower olefins from syngas and for innovative technique using oxide – zeolite hybrid catalytic systems are described. The promise of a new route to lower olefins by methane conversion via dimethyl ether is shown. Prospects for the synthesis of lower olefins via methyl chloride and using non-oxidative coupling of methane are discussed. The most efficient processes used for processing of methane to lower olefins are compared on the basis of degree of conversion of carbonaceous feed, possibility to integrate with available full-scale production, number of reaction stages and thermal load distribution.

The bibliography includes 346 references.

Interfacial Fe5C2-Cu catalysts toward low-pressure syngas conversion to long-chain alcohols

Long-chain alcohols synthesis (LAS, C₅₊OH) from syngas provides a promising route for the conversion of coal/biomass/natural gas into high-value chemicals. Cu-Fe binary catalysts, with the merits of cost effectiveness and high CO conversion, have attracted considerable attention. Here we report a nano-construct of a Fe₅C₂-Cu interfacial catalyst derived from Cu₄Fe₁Mg₄-layered double hydroxide (Cu₄Fe₁Mg₄-LDH) precursor, i.e., Fe₅C₂ clusters (~2 nm) are immobilized onto the surface of Cu nanoparticles (~25 nm). The interfacial catalyst exhibits a CO conversion of 53.2%, a selectivity of 14.8 mol% and a space time yield of 0.101 g g_cat⁻¹ h⁻¹ for long-chain alcohols, with a surprisingly benign reaction pressure of 1 MPa. This catalytic performance, to the best of our knowledge, is comparable to the optimal level of Cu-Fe catalysts operated at much higher pressure (normally above 3 MPa).

Long-chain alcohols synthesis from syngas conversion is a promising route for the production of high-value chemicals. Here the authors show that a heterogeneous Fe₅C₂/Cu catalyst derived from layered double hydroxides precursor exhibits excellent performance with a space time yield of 0.101 g g_cat⁻¹ h⁻¹ at a low pressure of 1 MPa.

Effects of alkali metal promoters on the structure–performance relationship of CoMn catalysts for Fischer–Tropsch synthesis

Alkali metal promoters are beneficial for the formation and facet-stabilization of Co₂C nanoprisms for the FTO reaction.

Spontaneous selective deposition of iron oxide nanoparticles on graphite as model catalysts

Iron oxide nanomaterials participate in redox processes that give them ideal properties for their use as earth-abundant catalysts. Fabricating nanocatalysts for such applications requires detailed knowledge of the deposition and growth. We report the spontaneous deposition of iron oxide nanoparticles on HOPG in defect areas and on step edges from a metal precursor solution. To study the nucleation and growth of iron oxide nanoparticles, tailored defects were created on the surface of HOPG using various ion sources that serve as the target sites for iron oxide nucleation. After solution deposition and annealing, the iron oxide nanoparticles were found to nucleate and coalesce at 400 °C. AFM revealed that the particles on the sp³ carbon sites enabled the nanoparticles to aggregate into larger particles. The iron oxide nanoparticles were characterized as having an Fe³⁺ oxidation state and two different oxygen species, Fe-O and Fe-OH/Fe-OOH, as determined by XPS. STEM imaging and EDS mapping confirmed that the majority of the nanoparticles grown were converted to hematite after annealing at 400 °C. A mechanism of spontaneous and selective deposition on the HOPG surface and transformation of the iron oxide nanoparticles is proposed. These results suggest a simple method for growing nanoparticles as a model catalyst.

Enhanced Catalysis of Pt3 Clusters Supported on Graphene for N–H Bond Dissociation

We report an in-depth study of catalytic N–H bond dissociation with typical platinum clusters on graphene supports. Among all the pristine graphene- and defective graphene-supported Pt clusters of different sizes that were studied, the Pt 3/G cluster possesses the highest reactivity and lowest activation barriers for each step of N–H dissociation in the decomposition of ammonia. In analyzing the reaction coordinates and projected density of states of the outermost orbitals, we found that the standing triangular Pt 3 on graphene creates prominent Lewis acid/base pair sites, which accommodate the adsorption and subsequent dissociation of *NH x . In comparison, Pt 1 lacks complementary active sites (CAS), causing it to be adverse to nucleophilic reactions, and in contrast, the Pt 13 cluster has weakened interactions and depleted charge density from the support, resulting in the elimination of the CAS effect. A stable pyramid-structured Pt 4 also develops Lewis acid/base sites, especially on defective graphene, but the density of states is still lower than the stand-up Pt 3/G. These findings strongly demonstrate the importance and necessity of cluster active sites for catalytic reactions of polar molecules, novel three-atoms metal cluster catalysis, and the selectivity and catalytic performance in the designing of ammonia fuel cells.

Enhancement of Light Olefins Selectivity Over N-Doped Fischer-Tropsch Synthesis Catalyst Supported on Activated Carbon Pretreated with KMnO4

Ammonium iron citrate was used as an iron precursor in order to prepare N-doped catalysts supported on KMnO4 pretreated activated carbon (10MnK-AC). Iron nitride was synthesized in company with the formation of α-Fe2O3 on 10MnK-AC. The characterizations of the catalysts show that nitrogen atoms were doped into iron lattice rather than the networks of the carbon support. The performance of Fischer-Tropsch synthesis to light olefins (FTO) suggest an improvement in O/P ratio (olefins to paraffins molar ratio of C2–C4) over the iron catalysts supported on 10MnK-AC. The further promotion of light olefins selectivity (up to 44.7%) was obtained over FeN-10MnK-AC catalyst owing to the collaborative contribution of the electron donor effect of nitrogen and the suppression effect on the second hydrogenation over 10MnK-AC support.

Stabilizing the active phase of iron-based Fischer-Tropsch catalysts for lower olefins: mechanism and strategy

An iron carbonyl-mediated Ostwald-ripening-like growth mechanism of an Fe_xC_y active phase in Fischer–Tropsch synthesis is firstly revealed by in situ mass-spectrometric and theoretical analysis.

Fischer–Tropsch synthesis of lower olefins (FTO) is a classical yet modern topic of great significance in which the supported Fe-based nanoparticles are the most promising catalysts. The performance deterioration of catalysts is a big challenge due to the instability of the nanosized active phase of iron carbides. Herein, by in situ mass spectrometry, theoretical analysis, and atmospheric- and high-pressure experimental examinations, we revealed the Ostwald-ripening-like growth mechanism of the active phase of iron carbides in FTO, which involves the cyclic formation–decomposition of iron carbonyl intermediates to transport iron species from small particles to large ones. Accordingly, by suppressing the formation of iron carbonyl species with a high-N-content carbon support, the size and structure of the active phase were regulated and stabilized, and durable iron-based catalysts were conveniently obtained with the highest selectivity for lower olefins up to 54.1%. This study provides a practical strategy for exploring advanced FTO catalysts.

Structural evolution of carbon in an Fe@C catalyst during the Fischer–Tropsch synthesis reaction

A pseudo-in situ research method was applied to provide insight into the structural evolution of carbon in an Fe@C catalyst at different stages of the Fischer–Tropsch reaction.