Effect of Boron Promotion on Coke Formation during Propane Dehydrogenation over Pt/γ-Al2O3 Catalysts

Formation of a Porous Crystalline Mg1-xAl2Oy Overlayer on Metal Catalysts via Controlled Solid-State Reactions for High-temperature Stable Catalysis

Catalyst deactivation by sintering and coking is a long-standing issue in metal-catalyzed harsh high-temperature hydrocarbon reactions. Ultrathin oxide coatings of metal nanocatalysts have recently appeared attractive to address this issue, while the porosity of the overlayer is difficult to control to preserve the accessibility of embedded metal nanoparticles, thus often leading to a large decrease in activity. Here, we report that a nanometer-thick alumina coating of MgAl2O4-supported metal catalysts followed by high-temperature reduction can transform a nonporous amorphous alumina overlayer into a porous Mg1-xAl2Oy crystalline spinel structure with a pore size of 2-3 nm and weakened acidity. The high porosity stems from the restrained Mg migration from the MgAl2O4 support to the alumina overlayer through solid-state reactions at high temperatures. The resulting Ni/MgAl2O4 and Pt/MgAl2O4 catalysts with a porous crystalline Mg1-xAl2Oy overlayer achieved remarkably high stability while preserving much higher activity than the corresponding alumina-coated Ni and Pt catalysts on MgO and Al2O3 supports in the reactions of dry reforming of methane and propane dehydrogenation, respectively.

Implications of Ga promotion and metal-oxide interface from tailored PtGa propane dehydrogenation catalysts supported on carbon

Propane Dehydrogenation is a key technology, where Pt-based catalysts have widely been investigated in industry and academia, with development exploring the use of promoters (Sn, Zn, Ga, etc.) and additives (Na, K, Ca, Si, etc.) towards improved catalytic performances. Recent studies have focused on the role of Ga promotion: while computations suggest that Ga plays a key role in enhancing catalytic selectivity and stability of PtGa catalysts through Pt-site isolation as well as morphological changes, experimental evidence are lacking because of the use of oxide supports that prevent more detailed investigation. Here, we develop a methodology to generate Pt and PtGa nanoparticles with tailored interfaces on carbon supports by combining surface organometallic chemistry (SOMC) and specific thermolytic molecular precursors containing or not siloxide ligands. This approach enables the preparation of supported nanoparticles, exhibiting or not an oxide interface, suitable for state-of-the art electron microscopy and XANES characterization. We show that the introduction of Ga enables the formation of homogenously alloyed, amorphous PtGa nanoparticles, in sharp contrast to highly crystalline monometallic Pt nanoparticles. Furthermore, the presence of an oxide interface is shown to stabilize the formation of small particles, at the expense of propene selectivity loss (formation of cracking side-products, methane/ethene), explaining the use of additives such as Na, K and Ca in industrial catalysts.

Ordered Hierarchical Porous Structure of PtSn/3DOMM-Al2O3 Catalyst for Promoting Propane Non-Oxidative Dehydrogenation

Herein, the hierarchical porous catalyst of 3-dimensional ordered macro-mesoporous (3DOMM) Al₂O₃ supported active PtSn nanoparticles (NPs) was prepared by the combined synthesized path of evaporation-induced self-assembly with colloid crystal template (EISA-CCT) methods. The hierarchical macro-mesoporous composite structure can markedly increase the specific surface area, accommodate the diffusion of propene, and decrease the number of surface acid sites. In addition, the special surface property and pore structure of 3DOMM-Al₂O₃ can modify the interaction between metals and substrates, as well as stabilize the metal nanoparticle, which promotes the formation of a highly active and stable PtSn phase. The PtSn/3DOMM-Al₂O₃ catalyst exhibits higher productivity and stability than PtSn/Al₂O₃ catalysts with macropore and mesopore structures. The PtSn/3DOMM-Al₂O₃ catalyst displays the best catalytic performance with propylene selectivity over 95% at a propane conversion of 33.9%. The study of the ordered hierarchical porous structure of PtSn/3DOMM-Al₂O₃ catalysts can contribute to obtaining improved catalysts in industrial processes.

A Robust and Efficient Propane Dehydrogenation Catalyst from Unexpectedly Segregated Pt2Mn Nanoparticles

The increasing demand for short chain olefins like propene for plastics production and the availability of shale gas make the development of highly performing propane dehydrogenation (PDH) catalysts, robust toward industrially applied harsh regeneration conditions, a highly important field of research. A combination of surface organometallic chemistry and thermolytic molecular precursor approach was used to prepare a nanometric, bimetallic Pt-Mn material (3 wt % Pt, 1.3 wt % Mn) supported on silica via consecutive grafting of a Mn and Pt precursor on surface OH groups present on the support surface, followed by a treatment under a H₂ flow at high temperature. The material exhibits a 70% fraction of the overall Mn as Mn^II single sites on the support surface; the remaining Mn is incorporated in segregated Pt₂Mn nanoparticles. The material shows great performance in PDH reaction with a low deactivation rate. In particular, it shows outstanding robustness during repeated regeneration cycles, with conversion and selectivity stabilizing at ca. 37 and 98%, respectively. Notably, a material with a lower Pt loading of only 0.05 wt % shows an outstanding catalytic performance─initial productivity of 4523 g_C3H6/g_Pt h and an extremely low k_d of 0.003 h^-1 under a partial pressure of H₂, which are among the highest reported productivities. A combined in situ X-ray absorption spectroscopy, scanning transmission electron microscopy, electron paramagnetic resonance, and metadynamics at the density functional theory level study could show that the strong interaction between the Mn^II-decorated support and the unexpectedly segregated Pt₂Mn particles is most likely responsible for the outstanding performance of the investigated materials.

Propylene Synthesis: Recent Advances in the Use of Pt-Based Catalysts for Propane Dehydrogenation Reaction

Propylene is one of the most important feedstocks in the chemical industry, as it is used in the production of widely diffused materials such as polypropylene. Conventionally, propylene is obtained by cracking petroleum-derived naphtha and is a by-product of ethylene production. To ensure adequate propylene production, an alternative is needed, and propane dehydrogenation is considered the most interesting process. In literature, the catalysts that have shown the best performance in the dehydrogenation reaction are Cr-based and Pt-based. Chromium has the non-negligible disadvantage of toxicity; on the other hand, platinum shows several advantages, such as a higher reaction rate and stability. This review article summarizes the latest published results on the use of platinum-based catalysts for the propane dehydrogenation reaction. The manuscript is based on relevant articles from the past three years and mainly focuses on how both promoters and supports may affect the catalytic activity. The published results clearly show the crucial importance of the choice of the support, as not only the use of promoters but also the use of supports with tuned acid/base properties and particular shape can suppress the formation of coke and prevent the deep dehydrogenation of propylene.

C-H bond activation in light alkanes: a theoretical perspective

Alkanes are the major constituents of natural gas and crude oil, the feedstocks for the chemical industry. The efficient and selective activation of C-H bonds can convert abundant and low-cost hydrocarbon feedstocks into value-added products. Due to the increasing global demand for light alkenes and their corresponding polymers as well as synthesis gas and hydrogen production, C-H bond activation of light alkanes has attracted widespread attention. A theoretical understanding of C-H bond activation in light hydrocarbons via density functional theory (DFT) and microkinetic modeling provides a feasible approach to gain insight into the process and guidelines for designing more efficient catalysts to promote light alkane transformation. This review describes the recent progress in computational catalysis that has addressed the C-H bond activation of light alkanes. We start with direct and oxidative C-H bond activation of methane, with emphasis placed on kinetic and mechanistic insights obtained from DFT assisted microkinetic analysis into steam and dry reforming, and the partial oxidation dependence on metal/oxide surfaces and nanoparticle size. Direct and oxidative activation of the C-H bond of ethane and propane on various metal and oxide surfaces are subsequently reviewed, including the elucidation of active sites, intriguing mechanisms, microkinetic modeling, and electronic features of the ethane and propane conversion processes with a focus on suppressing the side reaction and coke formation. The main target of this review is to give fundamental insight into C-H bond activation of light alkanes, which can provide useful guidance for the optimization of catalysts in future research.

Effect of Pore Connectivity of Pore-Opened Hierarchical MOR Zeolites on Catalytic Behaviors and Coke Formation in Ethanol Dehydration

The hierarchical zeolite is one of the most promising materials for catalytic applications. However, the effect of its pore connectivity on catalytic behaviors and coke formation has not clearly been revealed. In this contribution, we demonstrate the visualization of the mesopore architecture in three-dimensional perspectives together with the pore connectivity network of pore-opened hierarchical mordenite (MOR), fabricated by the seed-assisted template-free synthesis followed by the fluoride treatment via the electron tomography (ET) technique. Interestingly, the pore-opened zeolites clearly display higher catalytic performance (approximately 80% of ethylene yield) in ethanol dehydration with respect to the parent one due to their additional pore-opened structures connected to the external surfaces of zeolites. In addition, the effect of pore connectivity network on the coke location and type obtained from ethanol conversion has been observed. It was found that the porous structure of the etched sample is directly connected to the external surface, and then, the large area of crystals can contribute to the reaction. Conversely, only a small amount of closed mesopores is observed inside the crystals in the case of the untreated sample, and therefore, the molecules cannot easily penetrate inside crystals for the catalytic reaction. These results open up promising perspectives for the development of hierarchical catalysts including fabrication by the template-free synthesis approach, pore-architecture characterization, and catalytic applications.

Metal-based catalysts for the non-oxidative dehydrogenation of light alkanes to light olefins

This review provides an overview of metal-based catalysts, including Pt-, Pd-, Rh- and Ni-based bimetallic catalysts for non-oxidative dehydrogenation of light alkanes to olefins.

Recent progress in heterogeneous metal and metal oxide catalysts for direct dehydrogenation of ethane and propane

Metal and metal oxide catalysts for non-oxidative ethane/propane dehydrogenation are outlined with respect to catalyst synthesis, structure–property relationship and catalytic mechanism.