Understanding the Enhanced Lifetime of SAPO-34 in a Direct Syngas-to-Hydrocarbons Process

Recent advances in bifunctional synthesis gas conversion to chemicals and fuels with a comparison to monofunctional processes

In order to meet the climate goals of the Paris Agreement and limit the potentially catastrophic consequences of climate change, we must move away from the use of fossil feedstocks for the production of chemicals and fuels. The conversion of synthesis gas (a mixture of hydrogen, carbon monoxide and/or carbon dioxide) can contribute to this. Several reactions allow to convert synthesis gas to oxygenates (such as methanol), olefins or waxes. In a consecutive step, these products can be further converted into chemicals, such as dimethyl ether, short olefins, or aromatics. Alternatively, fuels like gasoline, diesel, or kerosene can be produced. These two different steps can be combined using bifunctional catalysis for direct conversion of synthesis gas to chemicals and fuels. The synergistic effects of combining two different catalysts are discussed in terms of activity and selectivity and compared to processes based on consecutive reaction with single conversion steps. We found that bifunctional catalysis can be a strong tool for the highly selective production of dimethyl ether and gasoline with high octane numbers. In terms of selectivity bifunctional catalysis for short olefins or aromatics struggles to compete with processes consisting of single catalytic conversion steps.

Kinetic Model for the Direct Conversion of CO2/CO into Light Olefins over an In2O3-ZrO2/SAPO-34 Tandem Catalyst

An original kinetic model is proposed for the direct production of light olefins by hydrogenation of CO2/CO (COx) mixtures over an In2O3-ZrO2/SAPO-34 tandem catalyst, quantifying deactivation by coke. The reaction network comprises 12 individual reactions, and deactivation is quantified with expressions dependent on the concentration of methanol (as coke precursor) and H2O and H2 (as agents attenuating coke formation). The experimental results were obtained in a fixed-bed reactor under the following conditions: In2O3-ZrO2/SAPO-34 mass ratio, 0/1-1/0; 350-425 °C; 20-50 bar; H2/COx ratio, 1-3; CO2/COx ratio, 0-1; space time, 0-10 gIn2O3-ZrO2 h molC-1, 0-20 gSAPO-34 h molC-1; time, up to 500 h; H2O and CH3OH in the feed, up to 5% vol. The utility of the model for further scale-up studies is demonstrated by its application in optimizing the process variables (temperature, pressure, and CO2/COx ratio). The model predicts an olefin yield higher than 7% (selectivity above 60%), a COx conversion of 12% and a CO2 conversion of 16% at 415 °C and 50 bar, for a CO2/COx = 0.5 in the feed. Additionally, an analysis of the effect of In2O3-ZrO2 and SAPO-34 loading in the configuration of the tandem catalyst is conducted, yielding 17% olefins and complete conversion of CO2 under full water removal conditions.

The Oxygenate-Mediated Conversion of COx to Hydrocarbons─On the Role of Zeolites in Tandem Catalysis

Decentralized chemical plants close to circular carbon sources will play an important role in shaping the postfossil society. This scenario calls for carbon technologies which valorize CO2 and CO with renewable H2 and utilize process intensification approaches. The single-reactor tandem reaction approach to convert COx to hydrocarbons via oxygenate intermediates offers clear benefits in terms of improved thermodynamics and energy efficiency. Simultaneously, challenges and complexity in terms of catalyst material and mechanism, reactor, and process gaps have to be addressed. While the separate processes, namely methanol synthesis and methanol to hydrocarbons, are commercialized and extensively discussed, this review focuses on the zeolite/zeotype function in the oxygenate-mediated conversion of COx to hydrocarbons. Use of shape-selective zeolite/zeotype catalysts enables the selective production of fuel components as well as key intermediates for the chemical industry, such as BTX, gasoline, light olefins, and C3+ alkanes. In contrast to the separate processes which use methanol as a platform, this review examines the potential of methanol, dimethyl ether, and ketene as possible oxygenate intermediates in separate chapters. We explore the connection between literature on the individual reactions for converting oxygenates and the tandem reaction, so as to identify transferable knowledge from the individual processes which could drive progress in the intensification of the tandem process. This encompasses a multiscale approach, from molecule (mechanism, oxygenate molecule), to catalyst, to reactor configuration, and finally to process level. Finally, we present our perspectives on related emerging technologies, outstanding challenges, and potential directions for future research.

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.

Role of Zr loading into In2O3 catalysts for the direct conversion of CO2/CO mixtures into light olefins

The effect of the ZrO₂ content on the performance (activity, selectivity, stability) of In₂O₃-ZrO₂ catalyst has been studied on the hydrogenation of CO₂/CO mixtures. This effect is a key feature for the viability of using In₂O₃-ZrO₂/SAPO-34 tandem catalysts for the direct conversion of CO₂ and syngas into olefins via oxygenates as intermediates. The interest of co-feeding syngas together with CO₂ resides in jointly valorizing syngas derived from biomass or wastes (via gasification) and supplying the required H₂. The experiments of methanol synthesis and direct synthesis of olefins, with In₂O₃-ZrO₂ and In₂O₃-ZrO₂/SAPO-34 catalysts, respectively, have been carried out under the appropriate conditions for the direct olefins synthesis (400 °C, 30 bar, H₂/CO_X ratio = 3) in an isothermal fixed bed reactor at low space time values (kinetic conditions) to evaluate the behavior and deactivation of the catalysts. The Zr/In ratio of 1/2 favors the conversion of CO₂ and CO_X, attaining good oxygenates selectivity, and prevents the sintering attributable to the over-reduction of the In₂O₃ (more significant for syngas feeds). The improvement is more remarkable in the direct olefins synthesis, where the thermodynamic equilibrium of methanol formation is displaced, and methanation suppressed (in a greater extent for feeds with high CO content). With the In₂O₃-ZrO₂/SAPO-34 tandem catalysts, the conversion of CO_x almost 5 folds respect oxygenates synthesis with In₂O₃-ZrO₂ catalyst, meaning the yield of the target products boosts from ∼0.5% of oxygenates to >3% of olefins (selectivity >70%) for mixtures of CO₂/CO_X of 0.5, where an optimum performance has been obtained.

MAPO-18 Catalysts for the Methanol to Olefins Process: Influence of Catalyst Acidity in a High-Pressure Syngas (CO and H2) Environment

The transition from integrated petrochemical complexes toward decentralized chemical plants utilizing distributed feedstocks calls for simpler downstream unit operations. Less separation steps are attractive for future scenarios and provide an opportunity to design the next-generation catalysts, which function efficiently with effluent reactant mixtures. The methanol to olefins (MTO) reaction constitutes the second step in the conversion of CO2, CO, and H2 to light olefins. We present a series of isomorphically substituted zeotype catalysts with the AEI topology (MAPO-18s, M = Si, Mg, Co, or Zn) and demonstrate the superior performance of the M(II)-substituted MAPO-18s in the conversion of MTO when tested at 350 °C and 20 bar with reactive feed mixtures consisting of CH3OH/CO/CO2/H2. Co-feeding high pressure H2 with methanol improved the catalyst activity over time, but simultaneously led to the hydrogenation of olefins (olefin/paraffin ratio < 0.5). Co-feeding H2/CO/CO2/N2 mixtures with methanol revealed an important, hitherto undisclosed effect of CO in hindering the hydrogenation of olefins over the Brønsted acid sites (BAS). This effect was confirmed by dedicated ethene hydrogenation studies in the absence and presence of CO co-feed. Assisted by spectroscopic investigations, we ascribe the favorable performance of M(II)APO-18 under co-feed conditions to the importance of the M(II) heteroatom in altering the polarity of the M-O bond, leading to stronger BAS. Comparing SAPO-18 and MgAPO-18 with BAS concentrations ranging between 0.2 and 0.4 mmol/gcat, the strength of the acidic site and not the density was found to be the main activity descriptor. MgAPO-18 yielded the highest activity and stability upon syngas co-feeding with methanol, demonstrating its potential to be a next-generation MTO catalyst.

Conditions for the Joint Conversion of CO2 and Syngas in the Direct Synthesis of Light Olefins Using In2O3–ZrO2/SAPO-34 Catalyst

The conditions for promoting the joint conversion of CO₂ and syngas in the direct synthesis of light olefins have been studied. In addition, given the relevance for the viability of the process, the stability of the In₂O₃–ZrO₂/SAPO-34 (InZr/S34) catalyst has also been pursued. The CO+CO₂ (CO_x) hydrogenation experimental runs were conducted in a packed bed isothermal reactor under the following conditions: 375–425 °C; 20–40 bar; space time, 1.25–20 g_catalyst h mol_C^–1; H₂/(CO_x) ratio in the feed, 1–3; CO₂/(CO_x) ratio in the feed, 0.5; time on stream (TOS), up to 24 h. Analyzing the reaction indices (CO₂ and CO_x conversions, yield and selectivity of olefins and paraffins, and stability), the following have been established as suitable conditions: 400 °C, 30 bar, 5–10 g_cat h mol_C^–1, CO₂/CO_x = 0.5, and H₂/CO_x = 3. Under these conditions, the catalyst is stable (after an initial period of deactivation by coke), and olefin yield and selectivity surpass 4 and 70%, respectively, with light paraffins as byproducts. Produced olefin yields follow propylene > ethylene > butenes. The conditions of the process (low pressure and low H₂/CO_x ratio) may facilitate the integration of sustainable H₂ production with PEM electrolyzers and the covalorization of CO₂ and syngas obtained from biomass.

Oxide-Zeolite-Based Composite Catalyst Concept That Enables Syngas Chemistry beyond Fischer-Tropsch Synthesis

Syngas chemistry has been under study since Fischer-Tropsch synthesis (FTS) was invented in the 1920s. Despite the successful applications of FTS as the core technology of coal-to-liquid and gas-to-liquid processes in industry, the product selectivity control of syngas conversion still remains a great challenge, particularly for value-added chemicals such as light olefins. Recent studies show that the catalyst design concept of OXZEO (oxide-zeolite-based composite) enables direct syngas conversion to mixed light olefins with a selectivity reaching 80% and to ethylene with a selectivity of 83% among hydrocarbons. They both well-surpass the limits predicated by the Anderson-Schultz-Flory model via the conventional FTS route (58% and 30%, respectively). Furthermore, this catalyst concept allows one-step synthesis of gasoline-range isoparaffins and aromatic compounds, which is otherwise not possible in conventional FTS. A rapidly growing number of studies demonstrate the versatility of this concept and may form a technology platform for utilization of carbon resources including coal, natural gas, and biomass via syngas to a variety of basic chemicals and fuels. However, the selectivity control mechanism is far from being understood. Therefore, we focus mainly on the catalytic roles of the bifunctionalities of OXZEO while reviewing the development of bifunctional catalysts for selective syngas conversion by taking syngas-to-light olefins as an example. With this, we intend to provide insights into the selectivity control mechanism of the OXZEO concept in order to understand the challenges and prospects for future development of much more active and more selective catalysts.

Conversion of syngas into light olefins over bifunctional ZnCeZrO/SAPO-34 catalysts: regulation of the surface oxygen vacancy concentration and its relation to the catalytic performance

Surface oxygen vacancies can improve the formation of methanol intermediates and promote their evolution into olefin products for syngas-to-olefins over Zn_0.5CeZrO_x/SAPO-34.

Applications of Zeolites to C1 Chemistry: Recent Advances, Challenges, and Opportunities

C1 chemistry, which is the catalytic transformation of C1 molecules including CO, CO₂ , CH₄ , CH₃ OH, and HCOOH, plays an important role in providing energy and chemical supplies while meeting environmental requirements. Zeolites are highly efficient solid catalysts used in the chemical industry. The design and development of zeolite-based mono-, bi-, and multifunctional catalysts has led to a booming application of zeolite-based catalysts to C1 chemistry. Combining the advantages of zeolites and metallic catalytic species has promoted the catalytic production of various hydrocarbons (e.g., methane, light olefins, aromatics, and liquid fuels) and oxygenates (e.g., methanol, dimethyl ether, formic acid, and higher alcohols) from C1 molecules. The key zeolite descriptors that influence catalytic performance, such as framework topologies, nanoconfinement effects, Brønsted acidities, secondary-pore systems, particle sizes, extraframework cations and atoms, hydrophobicity and hydrophilicity, and proximity between acid and metallic sites are discussed to provide a deep understanding of the significance of zeolites to C1 chemistry. An outlook regarding challenges and opportunities for the conversion of C1 resources using zeolite-based catalysts to meet emerging energy and environmental demands is also presented.

Light Olefin Diffusion during the MTO Process on H-SAPO-34: A Complex Interplay of Molecular Factors

The methanol-to-olefins process over H-SAPO-34 is characterized by its high shape selectivity toward light olefins. The catalyst is a supramolecular system consisting of nanometer-sized inorganic cages, decorated by Brønsted acid sites, in which organic compounds, mostly methylated benzene species, are trapped. These hydrocarbon pool species are essential to catalyze the methanol conversion but may also clog the pores. As such, diffusion of ethene and propene plays an essential role in determining the ultimate product selectivity. Enhanced sampling molecular dynamics simulations based on either force fields or density functional theory are used to determine how molecular factors influence the diffusion of light olefins through the 8-ring windows of H-SAPO-34. Our simulations show that diffusion through the 8-ring in general is a hindered process, corresponding to a hopping event of the diffusing molecule between neighboring cages. The loading of different methanol, alkene, and aromatic species in the cages may substantially slow down or facilitate the diffusion process. The presence of Brønsted acid sites in the 8-ring enhances the diffusion process due to the formation of a favorable π-complex host-guest interaction. Aromatic hydrocarbon pool species severely hinder the diffusion and their spatial distribution in the zeolite crystal may have a significant effect on the product selectivity. Herein, we unveil how molecular factors influence the diffusion of light olefins in a complex environment with confined hydrocarbon pool species, high olefin loadings, and the presence of acid sites by means of enhanced molecular dynamics simulations under operating conditions.

Opportunities for less-explored zeolitic materials in the syngas-to-olefins pathway over nanoarchitectured catalysts: a mini review

The continuous demand for olefins has stimulated recent research to develop appropriate technology to produce olefins from alternative resources.

New horizon in C1 chemistry: breaking the selectivity limitation in transformation of syngas and hydrogenation of CO2 into hydrocarbon chemicals and fuels

Recent advances in bifunctional catalysis for conversion of syngas and hydrogenation of CO₂ into chemicals and fuels have been highlighted.