Elucidating Surface and Bulk Phase Transformation in Fischer–Tropsch Synthesis Catalysts and Their Influences on Catalytic Performance

Structure-reactivity relationships in CO2 hydrogenation to C2+ chemicals on Fe-based catalysts

Catalytic conversion of carbon dioxide (CO2) to value-added products represents an important avenue towards achieving carbon neutrality. In this respect, iron (Fe)-based catalysts were recognized as the most promising for the production of C2+ chemicals via the CO2 hydrogenation reaction. However, the complex structural evolution of the Fe catalysts, especially during the reaction, presents significant challenges for establishing the structure-reactivity relationships. In this review, we provide critical analysis of recent in situ and operando studies on the transformation of Fe-based catalysts in the hydrogenation of CO2 to hydrocarbons and alcohols. In particular, the effects of composition, promoters, support, and particle size on reactivity; the role of the catalyst's activation procedure; and the catalyst's evolution under reaction conditions will be addressed.

Understanding and Tuning the Effects of H2O on Catalytic CO and CO2 Hydrogenation

Catalytic COx (CO and CO2) hydrogenation to valued chemicals is one of the promising approaches to address challenges in energy, environment, and climate change. H2O is an inevitable side product in these reactions, where its existence and effect are often ignored. In fact, H2O significantly influences the catalytic active centers, reaction mechanism, and catalytic performance, preventing us from a definitive and deep understanding on the structure-performance relationship of the authentic catalysts. It is necessary, although challenging, to clarify its effect and provide practical strategies to tune the concentration and distribution of H2O to optimize its influence. In this review, we focus on how H2O in COx hydrogenation induces the structural evolution of catalysts and assists in the catalytic processes, as well as efforts to understand the underlying mechanism. We summarize and discuss some representative tuning strategies for realizing the rapid removal or local enrichment of H2O around the catalysts, along with brief techno-economic analysis and life cycle assessment. These fundamental understandings and strategies are further extended to the reactions of CO and CO2 reduction under an external field (light, electricity, and plasma). We also present suggestions and prospects for deciphering and controlling the effect of H2O in practical applications.

Facilely tuning the coating layers of Fe nanoparticles from iron carbide to iron nitride for different performance in Fenton-like reactions

In this study, a series of Fe-based materials are facilely synthesized using MIL-88A and melamine as precursors. Changing the mass ratio of melamine and MIL-88A could tune the coating layers of generated zero-valent iron (Fe0) particles from Fe3C to Fe3N facilely. Compared to Fe/Fe3N@NC sample, Fe/Fe3C@NC exhibits better catalytic activity and stability to degrade carbamazepine (CBZ) with peroxymonosulfate (PMS) as oxidant. Free radical quenching tests, open-circuit potential (OCP) test and electron paramagnetic resonance spectra (EPR) prove that hydroxyl radicals (OH) and superoxide radical (O2-) are dominant reactive oxygen species (ROSs) with Fe/Fe3C@NC sample. For Fe/Fe3N@NC sample, the main ROSs are changed into sulfate radicals (SO4-) and high valent iron-oxo (Fe (IV)=O) species. In addition, the better conductivity of Fe3C is beneficial for the electron transfer from Fe0 to the Fe3C, thus could keep the activity of the surface sites and obtain better stability. DFT calculation reveals the better adsorption and activation ability of Fe3C than Fe3N. Moreover, PMS can also be adsorbed on the Fe sites of Fe3N with shorter FeO bonds and longer SO bonds than on Fe3C, the Fe (IV)=O is thus present in the Fe/Fe3N@NC/PMS system. This study provides a novel strategy for the development of highly active Fe-based materials for Fenton-like reactions and thus could promote their real application.

Facet sensitivity of iron carbides in Fischer-Tropsch synthesis

Fischer-Tropsch synthesis (FTS) is a structure-sensitive reaction of which performance is strongly related to the active phase, particle size, and exposed facets. Compared with the full-pledged investigation on the active phase and particle size, the facet effect has been limited to theoretical studies or single-crystal surfaces, lacking experimental reports of practical catalysts, especially for Fe-based catalysts. Herein, we demonstrate the facet sensitivity of iron carbides in FTS. As the prerequisite, {202} and {112} facets of χ-Fe5C2 are fabricated as the outer shell through the conformal reconstruction of Fe3O4 nanocubes and octahedra, as the inner cores, respectively. During FTS, the activity and stability are highly sensitive to the exposed facet of iron carbides, whereas the facet sensitivity is not prominent for the chain growth. According to mechanistic studies, {202} χ-Fe5C2 surfaces follow hydrogen-assisted CO dissociation which lowers the activation energy compared with the direct CO dissociation over {112} surfaces, affording the high FTS activity.

Upgrading CO2 to sustainable aromatics via perovskite-mediated tandem catalysis

The directional transformation of carbon dioxide (CO2) with renewable hydrogen into specific carbon-heavy products (C6+) of high value presents a sustainable route for net-zero chemical manufacture. However, it is still challenging to simultaneously achieve high activity and selectivity due to the unbalanced CO2 hydrogenation and C-C coupling rates on complementary active sites in a bifunctional catalyst, thus causing unexpected secondary reaction. Here we report LaFeO3 perovskite-mediated directional tandem conversion of CO2 towards heavy aromatics with high CO2 conversion (> 60%), exceptional aromatics selectivity among hydrocarbons (> 85%), and no obvious deactivation for 1000 hours. This is enabled by disentangling the CO2 hydrogenation domain from the C-C coupling domain in the tandem system for Iron-based catalyst. Unlike other active Fe oxides showing wide hydrocarbon product distribution due to carbide formation, LaFeO3 by design is endowed with superior resistance to carburization, therefore inhibiting uncontrolled C-C coupling on oxide and isolating aromatics formation in the zeolite. In-situ spectroscopic evidence and theoretical calculations reveal an oxygenate-rich surface chemistry of LaFeO3, that easily escape from the oxide surface for further precise C-C coupling inside zeolites, thus steering CO2-HCOOH/H2CO-Aromatics reaction pathway to enable a high yield of aromatics.

Hydrogen Spillover-Driven Dynamic Evolution and Migration of Iron Oxide for Structure Regulation of Versatile Magnetic Nanocatalysts

Magnetic nanocatalysts with properties of easy recovery, induced heating, or magnetic levitation play a crucial role in advancing intelligent techniques. Herein, we report a method for the synthesis of versatile core-shell-type magnetic nanocatalysts through "noncontact" hydrogen spillover-driven reduction and migration of iron oxide with the assistance of Pd. In situ analysis techniques were applied to visualize the dynamic evolution of the magnetic nanocatalysts. Pd facilitates the dissociation of hydrogen molecules into activated H*, which then spills and thus drives the iron oxide reduction, gradual outward split, and migration through the carbonaceous shell. By controlling the evolution stage, nanocatalysts having diverse architectures including core-shell, split core-shell, or hollow type, each featuring Pd or PdFe loaded on the carbon shell, can be obtained. As a showcase, a magnetic nanocatalyst (Pd-loaded split core-shell) can hydrogenate crotonaldehyde to butanal (26 624 h-1 in TOF, ∼100% selectivity), outperforming reported Pd-based catalysts. This is due to the synergy of the enhanced local magnetothermal effect and the preferential adsorption of -C═C on Pd with a small d bandwidth. Another catalyst (PdFe-loaded split core-shell) also delivers a robust performance in phenylacetylene semihydrogenation (100% conversion, 97.5% selectivity) as PdFe may inhibit the overhydrogenation of -C═C. Importantly, not only Pd, other noble metals (e.g., Pt, Ru, and Au) also showed a similar property, revealing a general rule that hydrogen spillover drives the dynamic reduction, splitting, and migration of encapsulated nanosized iron oxide, resulting in diverse structures. This study would offer a structure-controllable fabrication of high-performance magnetic nanocatalysts for various applications.

An optimal Fe-C coordination ensemble for hydrocarbon chain growth: a full Fischer-Tropsch synthesis mechanism from machine learning

Fischer-Tropsch synthesis (FTS, CO + H2 → long-chain hydrocarbons) because of its great significance in industry has attracted huge attention since its discovery. For Fe-based catalysts, after decades of efforts, even the product distribution remains poorly understood due to the lack of information on the active site and the chain growth mechanism. Herein powered by a newly developed machine-learning-based transition state (ML-TS) exploration method to treat properly reaction-induced surface reconstruction, we are able to resolve where and how long-chain hydrocarbons grow on complex in situ-formed Fe-carbide (FeCx) surfaces from thousands of pathway candidates. Microkinetics simulations based on first-principles kinetics data further determine the rate-determining and the selectivity-controlling steps, and reveal the fine details of the product distribution in obeying and deviating from the Anderson-Schulz-Flory law. By showing that all FeCx phases can grow coherently upon each other, we demonstrate that the FTS active site, namely the A-P5 site present on reconstructed Fe3C(031), Fe5C2(510), Fe5C2(021), and Fe7C3(071) terrace surfaces, is not necessarily connected to any particular FeCx phase, rationalizing long-standing structure-activity puzzles. The optimal Fe-C coordination ensemble of the A-P5 site exhibits both Fe-carbide (Fe4C square) and metal Fe (Fe3 trimer) features.

An Efficient Way to Model Complex Iron Carbides: A Benchmark Study of DFTB2 against DFT

Iron carbides have attracted increasing attention in recent years due to their enormous potential in catalytic fields, such as Fischer-Tropsch synthesis and the growth of carbon nanotubes. Theoretical calculations can provide a more thorough understanding of these reactions at the atomic scale. However, due to the extreme complexity of the active phases and surface structures of iron carbides at the operando conditions, calculations based on density functional theory (DFT) are too costly for realistically large models of iron carbide particles. Therefore, a cheap and efficient quantum mechanical simulation method with accuracy comparable to DFT is desired. In this work, we adopt the spin-polarized self-consistent charge density functional tight-binding (DFTB2) method for iron carbides by reparametrization of the repulsive part of the Fe-C interactions. To assess the performance of the improved parameters, the structural and electronic properties of iron carbide bulks and clusters obtained with DFTB2 method are compared with the previous experimental values and the results obtained with DFT approach. Calculated lattice parameters and density of states are close to DFT predictions. The benchmark results show that the proposed parametrization of Fe-C interactions provides transferable and balanced description of iron carbide systems. Therefore, spin-polarized DFTB2 is valued as an efficient and reliable method for the description of iron carbide systems.

In Situ Active Site for Fe-Catalyzed Fischer-Tropsch Synthesis: Recent Progress and Future Challenges

Fischer-Tropsch synthesis (FTS) that converts syngas into long-chain hydrocarbons is a key technology in the chemical industry. As one of the best catalysts for FTS, the Fe-based composite develops rich solid phases (metal, oxides, and carbides) in the catalytic reaction, which triggered the quest for the true active site in catalysis in the past century. Recent years have seen great advances in probing the active-site structure using modern experimental and theoretical tools. This Perspective serves to highlight these latest achievements, focusing on the geometrical structure and thermodynamic stability of Fe carbide bulk phases, the exposed surfaces, and their relationship to FTS activity. The current reaction mechanisms on CO activation and carbon chain growth are also discussed, in the context of theoretical models and experimental evidence. We also present the outlook regarding the current challenges in Fe-based FTS.

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.

Selective olefin production on silica based iron catalysts in Fischer–Tropsch synthesis

Mixed phases of Fe3O4 and Fe5C2, interacting properly with SiO2, produce highly selective olefins from syngas.

Enhanced stability of a fused iron catalyst under realistic Fischer–Tropsch synthesis conditions: insights into the role of iron phases (χ-Fe5C2, θ-Fe3C and α-Fe)

The performance and stability of fused-Fe catalyst in FTS reaction are enhanced through the control synthesis of iron phases (χ-Fe5C2, θ-Fe3C and α-Fe).

Effect of the Zr promoter on precipitated iron-based catalysts for high-temperature Fischer–Tropsch synthesis of light olefins

FeMnxZr and FeMnxZr2Na catalysts prepared by coprecipitation and impregnation methods were applied to investigate the promoting effects of Zr on iron-based catalysts for high-temperature Fischer–Tropsch synthesis (HTFT).

The influence of hydrophobicity on Fischer-Tropsch synthesis catalysts

We review scientific works carried out on the influence of surface hydrophobicity on activity and product selectivity of supported cobalt and iron catalysts during Fischer-Tropsch synthesis (FTS). The characteristics of the surface of catalyst support may influence metal-support interactions, which leads to various degrees of metal dispersion and reducibility. Also, these support surface properties may influence the mass transfer of reactants and products at the catalyst active sites and subsequently affects the performance of the catalyst during FTS. Pre-silylated and post-silylated catalysts have been used to study the influence of surface hydrophobicity on the performance of FTS catalysts. The enhancement of FTS activity by hydrophobicity was mainly ascribed to the improved reducibility of metal oxide species. Furthermore, post-silylated supported iron catalysts favoured the suppression of water-gas shift (WGS) reaction, thereby hindering CO2 formation.