Oxidative Dehydrogenation of Propane over a High Surface Area Boron Nitride Catalyst: Exceptional Selectivity for Olefins at High Conversion

Mechanochemically-derived iron atoms on defective boron nitride for stable propylene production

Single-atom catalysts (SACs), possessing a uniform metal site structure, are a promising class of materials for selective oxidations of hydrocarbons. However, their design for targeted applications requires careful choice of metal-host combinations and suitable synthetic techniques. Here, we report iron atoms stabilised on defective hexagonal boron nitride (h-BN) via mechanochemical activation in a ball mill as an effective catalyst for propylene production via N2O-mediated oxidative propane dehydrogenation (N2O-ODHP), reaching 95% selectivity at 6% propane conversion and maintaining stable performance for 40 h on stream. This solvent-free synthesis allows simultaneous carrier exfoliation and surface defect generation, creating anchoring sites for catalytically-active iron atoms. The incorporation of a small metal quantity (0.5 wt%) predominantly generates a mix of atomically-dispersed Fe2+ and Fe3+ species, as confirmed by combining advanced microscopy and electron paramagnetic resonance, UV-vis and X-ray photoelectron spectroscopy analyses. Single-atom iron favours selective propylene formation, while metal oxide nanoparticles yield large quantities of CO x and cracking by-products. The lack of acidic functionalities on h-BN, hindering coke formation, and firm stabilisation of Fe sites, preventing metal sintering, ensure stable operation. These findings showcase N2O-ODHP as a promising propylene production technology and foster wider adoption of mechanochemical activation as a viable method for SACs synthesis.

Photothermal oxidative dehydrogenation of propane to propylene over Cu/BN catalysts

Oxidative dehydrogenation of propane (ODHP) is a reaction with significant practical significance. As for the industrial application of ODHP, it is challenging to achieve high activity and high propylene selectivity simultaneously. In this study, to overcome this obstacle, we designed a series of Cu/BN catalysts with unique morphologies for establishing a photothermal ODHP system with high efficiency and selectivity. Characterization and evaluation results revealed that Cu/BN-NS and Cu/BN-NF with enlarged specific surface areas exhibited higher catalytic activities. The localized surface plasmon resonance (LSPR) effect of Cu nanoparticles further enhanced the photothermal catalytic performances of Cu/BN catalysts under visible light irradiation. To the best of our knowledge, it is the first time to establish a BN-based photothermal ODHP catalytic system. This study is expected to pave pathways to realize high activity and propylene selectivity for the practical application of ODHP.

Catalyst development for O2-assisted oxidative dehydrogenation of propane to propylene

O2-Assisted oxidative dehydrogenation of propane (O2-ODHP) could convert abundant shale gas into propylene as an important chemical raw material, meaning O2-ODHP has practical significance. Thermodynamically, high temperature is beneficial for O2-ODHP; however, high reaction temperature always causes the overoxidation of propylene, leading to a decline in its selectivity. In this regard, it is crucial to achieve low temperatures while maintaining high efficiency and selectivity during O2-ODHP. The use of catalytic technology provides more opportunities for achieving high-efficiency O2-ODHP under mild conditions. Up to now, many kinds of catalytic systems have been elaborately designed, including transition metal oxide catalysts (such as vanadium-based catalysts, molybdenum-based catalysts, etc.), transition metal-based catalysts (such as Pt nanoclusters), rare earth metal oxide catalysts (especially CeO2 related catalysts), and non-metallic catalysts (BN, other B-containing catalysts, and C-based catalysts). In this review, we have summarized the development progress of mainstream catalysts in O2-ODHP, aiming at providing a clear picture to the catalysis community and advancing this research field further.

Chemically exfoliated boron nanosheets for efficient oxidative dehydrogenation of propane

Oxidative dehydrogenation of propane (ODHP) is a promising technique for producing propene due to its low operative temperature and coke-resistant feature. Recently, boron-based catalysts have been widely investigated for ODHP owing to their brilliant performance. Herein, we report that boron in the form of nanosheets can be prepared feasibly by exfoliating layered MgB2 with hydrochloric acid, and can efficiently and stably catalyze ODHP. At 530 °C, the catalyst exhibits propene and ethene selectivities as high as 63.5% and 18.4%, respectively, at a 40% propane conversion. The olefin productivity reaches 2.48 golefin gcat-1 h-1, superior to the commercial h-BN and other reported boron-based catalysts. Even after testing for 100 h at 530 °C, the catalyst still maintains excellent stability. This work expands the effective boron-based catalyst family for ODHP and demonstrates the great potential of the new type of 2D material-boron nanosheet for energy and catalytic applications.

Self-evolved BOx anchored on Mg2B2O5 crystallites for high-performance oxidative dehydrogenation of propane

Oxidative dehydrogenation of propane (ODHP) is a promising process for producing propene. Recently, some boron-based catalysts have exhibited excellent olefin selectivity in ODHP. However, their complex synthetic routes and poor stability under high-temperature reaction conditions have hindered their practical application. Herein, we report a self-evolution method rather than conventional assembly approaches to acquire structures with excellent stability under a high propane conversion, from a single precursor-MgB2. The catalyst feasibly prepared and optimized exhibited a striking performance: 60% propane conversion with a 43.2% olefin yield at 535°C. The BOx corona pinned by the strong interaction with the borate enabled zero loss of the high conversion (around 40%) and olefins selectivity (above 80%) for over 100 h at 520°C. This all-in-one strategy of deriving all the necessary components from just one raw chemical provides a new way to synthesize effective and economic catalysts for potential industrial implementation.

Surface Chemistry and Catalytic Reactivity of Borocarbonitride in Oxidative Dehydrogenation of Propane

Borocarbonitride (BCN) materials are newly developed oxidative dehydrogenation catalysts that can efficiently convert alkanes to alkenes. However, BCN materials tend to form bulky B2 O3 due to over-oxidation at the high reaction temperature, resulting in significant deactivation. Here, we report a series of super stable BCN nanosheets for the oxidative dehydrogenation of propane (ODHP) reaction. The catalytic performance of the BCN nanosheets can be easily regulated by changing the guanine dosage. The control experiment and structural characterization indicate that the introduction of a suitable amount of carbon could prevent the formation of excessive B2 O3 from BCN materials and maintain the 2D skeleton at a high temperature of 520 °C. The best-performing catalyst BCN exhibits 81.9 % selectivity towards olefins with a stable propane conversion of 35.8 %, and the propene productivity reaches 16.2 mmol h-1  g-1 , which is much better than hexagonal BN (h-BN) catalysts. Density functional theory calculation results show that the presence of dispersed rather than aggregated carbon atoms can significantly affect the electronic microenvironment of h-BN, thereby boosting the catalytic activity of BCN.

Antiexfoliating h-BN⊃In2O3 Catalyst for Oxidative Dehydrogenation of Propane in a High-Temperature and Water-Rich Environment

Hexagonal boron nitride (h-BN) is regarded as one of the most efficient catalysts for oxidative dehydrogenation of propane (ODHP) with high olefin selectivity and productivity. However, the loss of the boron component under a high concentration of water vapor and high temperature seriously hinders its further development. How to make h-BN a stable ODHP catalyst is one of the biggest scientific challenges at present. Herein, we construct h-BN⊃xIn₂O₃ composite catalysts through the atomic layer deposition (ALD) process. After high-temperature treatment in ODHP reaction conditions, the In₂O₃ nanoparticles (NPs) are dispersed on the edge of h-BN and observed to be encapsulated by ultrathin boron oxide (BO_x) overlayer. A novel strong metal oxide-support interaction (SMOSI) effect between In₂O₃ NPs and h-BN is observed for the first time. The material characterization reveals that the SMOSI not only improves the interlayer force between h-BN layers with a pinning model but also reduces the affinity of the B-N bond toward O^• for inhibiting oxidative cutting of h-BN into fragments at a high temperature and water-rich environment. With the pinning effect of the SMOSI, the catalytic stability of h-BN⊃70In₂O₃ has been extended nearly five times than that of pristine h-BN, and the intrinsic olefin selectivity/productivity of h-BN is well maintained.

Subsurface nickel boosts the low-temperature performance of a boron oxide overlayer in propane oxidative dehydrogenation

Oxidative dehydrogenation of propane is a promising technology for the preparation of propene. Boron-based nonmetal catalysts exhibit remarkable selectivity toward propene and limit the generation of CO_x byproducts due to unique radical-mediated C-H activation. However, due to the high barrier of O-H bond cleavage in the presence of O₂, the radical initialization of the B-based materials requires a high temperature to proceed, which decreases the thermodynamic advantages of the oxidative dehydrogenation reaction. Here, we report that the boron oxide overlayer formed in situ over metallic Ni nanoparticles exhibits extraordinarily low-temperature activity and selectivity for the ODHP reaction. With the assistance of subsurface Ni, the surface specific activity of the BO_x overlayer reaches 93 times higher than that of bare boron nitride. A mechanistic study reveals that the strong affinity of the subsurface Ni to the oxygen atoms reduces the barrier of radical initiation and thereby balances the rates of the BO-H cleavage and the regeneration of boron hydroxyl groups, accounting for the excellent low-temperature performance of Ni@BO_x/BN catalysts.

Photocatalytic Oxidative Dehydrogenation of Propane for Selective Propene Production with TiO2

Oxidative dehydrogenation of propane (ODHP) as an exothermic process is a promising method to produce propene (C₃H₆) with lower energy consumption in chemical industry. However, the selectivity of the C₃H₆ product is always poor because of overoxidation. Herein, the ODHP reaction into C₃H₆ on a model rutile(R)-TiO₂(110) surface at low temperature via photocatalysis has been realized successfully. The results illustrate that photocatalytic oxidative dehydrogenation of propane (C₃H₈) into C₃H₆ can occur efficiently on R-TiO₂(110) at 90 K via a stepwise manner, in which the initial C-H cleavage occurs via the hole coupled C-H bond cleavage pathway followed by a radical mediated C-H cleavage to the C₃H₆ product. An exceptional selectivity of ∼90% for C₃H₆ production is achieved at about 13% propane conversion. The mechanistic model constructed in this study not only advances our understanding of C-H bond activation but also provides a new pathway for highly selective ODHP into C₃H₆ under mild conditions.

Boron nitride materials as emerging catalysts for oxidative dehydrogenation of light alkanes

Light olefins (C₂-C₄) play a crucial role as basic ingredients in chemical industry, and oxidative dehydrogenation (ODH) of light alkanes to olefins has been one of the popular routes since the shale gas revolution. ODH of light alkanes has advantages on energy-and-cost saving as compared with traditional direct dehydrogenation, but it is restricted by its overoxidation which results in the relatively low olefin selectivity. Boron nitride (BN), an interesting nanomaterial with an analogous structure to graphene, springs out and manifests the superior performance as advanced catalysts in ODH, greatly improving the olefin selectivity under high alkane conversion. In this review, we introduce BN nanomaterials in four dimensions together with typical methods of syntheses. Traditional catalysts for ODH are also referred as comparison on several indicators-olefin yields and preparation techniques, including the metal-based catalysts and the non-metal-based catalysts. We also surveyed the BN catalysts for ODH reaction in recent five years, focusing on the different dimensions of BN together with the synthetic routes accounting for the active sites and the catalytic ability. Finally, an outlook of the potential promotion on the design of BN-based catalysts and the possible routes for the exploration of BN-related catalytic mechanisms are proposed.

Research progress of CO2 oxidative dehydrogenation of propane to propylene over Cr-free metal catalysts

CO₂-assisted oxidative dehydrogenation of propane (CO₂-ODHP) is an attractive strategy to offset the demand gap of propylene due to its potentiality of reducing CO₂ emissions, especially under the demands of peaking CO₂ emissions and carbon neutrality. The introduction of CO₂ as a soft oxidant into the reaction not only averts the over-oxidation of products, but also maintains the high oxidation state of the redox-active sites. Furthermore, the presence of CO₂ increases the conversion of propane by coupling the dehydrogenation of propane (DHP) with the reverse water gas reaction (RWGS) and inhibits the coking formation to prolong the lifetime of catalysts via the reverse Boudouard reaction. An effective catalyst should selectively activate the C-H bond but suppress the C-C cleavage. However, to prepare such a catalyst remains challenging. Chromium-based catalysts are always applied in industrial application of DHP; however, their toxic properties are harmful to the environment. In this aspect, exploring environment-friendly and sustainable catalytic systems with Cr-free is an important issue. In this review, we outline the development of the CO₂-ODHP especially in the last ten years, including the structural information, catalytic performances, and mechanisms of chromium-free metal-based catalyst systems, and the role of CO₂ in the reaction. We also present perspectives for future progress in the CO₂-ODHP.

Water-Tolerant Boron-Substituted MCM-41 for Oxidative Dehydrogenation of Propane

Boron-based catalysts for oxidative dehydrogenation of propane (ODHP) have displayed excellent olefin selectivity. However, the drawback of deboronation leading to catalyst deactivation limited their scalable applications. Hereby, a series of mesoporous B-MCM-41 (BM-x, B/Si = 0.015-0.147) catalysts for ODHP were prepared by a simple hydrothermal synthesis method. It was found that propane conversion was increased and the initial reaction temperature was reduced with an increase of boron content, and the optimal values appeared on BM-2.0 (B/Si = 0.062), while olefins' (ethylene and propylene) selectivity was maintained at ca. 70-80%. Most importantly, BM-1.0 (B/Si = 0.048) exhibited favorable activity, stability, and water tolerance after washing treatment or long-time operation (e.g., propane conversion of ca. 15% and overall olefin selectivity of ca. 80% at 550 °C) because its high structural stability prevented boron leaches. These features were identified by X-ray diffraction (XRD), N₂ physisorption, inductively coupled plasma-mass spectrometry (ICP-MS), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS), and solid-state magic-angle-spinning nuclear magnetic resonance (MAS NMR) spectroscopy studies. The tri-coordinated B-OH species incorporated into the mesoporous silica framework are considered to be the active sites for ODHP.

Plasma Tuning Local Environment of Hexagonal Boron Nitride for Oxidative Dehydrogenation of Propane

Hexagonal boron nitride (h-BN) has lately received great attention in the oxidative dehydrogenation (ODH) reaction of propane to propylene for its extraordinary olefin selectivity in contrast to metal oxides. However, high crystallinity of commercial h-BN and elusive cognition of active sites hindered the enhancement of utilization efficiency. Herein, four kinds of plasmas (N₂ , O₂ , H₂ , Ar) were accordingly employed to regulate the local chemical environment of h-BN. N₂ -treated BN exhibited a remarkable activity, i.e., 26.0 % propane conversion with 89.4 % selectivity toward olefins at 520 °C. Spectroscopy demonstrated that "three-boron center" N-defects in the catalyst played a pivotal role in facilitating the conversion of propane. While the sintering effect of the "BO_x " species in O₂ -treated BN, led to the suppressed catalytic performance (12.4 % conversion at 520 °C).

Stable and selective catalysts for propane dehydrogenation operating at thermodynamic limit

Intentional ("on-purpose") propylene production through nonoxidative propane dehydrogenation (PDH) holds great promise for meeting the increasing global demand for propylene. For stable performance, traditional alumina-supported platinum-based catalysts require excess tin and feed dilution with hydrogen; however, this reduces per-pass propylene conversion and thus lowers catalyst productivity. We report that silica-supported platinum-tin (Pt₁Sn₁) nanoparticles (<2 nanometers in diameter) can operate as a PDH catalyst at thermodynamically limited conversion levels, with excellent stability and selectivity to propylene (>99%). Atomic mixing of Pt and Sn in the precursor is preserved upon reduction and during catalytic operation. The benign interaction of these nanoparticles with the silicon dioxide support does not lead to Pt-Sn segregation and formation of a tin oxide phase that can occur over traditional catalyst supports.

Isolated boron in zeolite for oxidative dehydrogenation of propane

Oxidative dehydrogenation of propane (ODHP) is a key technology for producing propene from shale gas, but conventional metal oxide catalysts are prone to overoxidation to form valueless CO _x Boron-based catalysts were recently found to be selective for this reaction, and B-O-B oligomers are generally regarded as active centers. We show here that the isolated boron in a zeolite framework without such oligomers exhibits high activity and selectivity for ODHP, which also hinders full hydrolysis for boron leaching in a humid atmosphere because of the B-O-SiO _x linkage, achieving superior durability in a long-period test. Furthermore, we demonstrate an isolated boron with a -B[OH…O(H)-Si]₂ structure in borosilicate zeolite as the active center, which enables the activation of oxygen and a carbon-hydrogen bond to catalyze the ODHP.

Oxidative dehydrogenation of light alkanes to olefins on metal-free catalysts

Metal-free boron- and carbon-based catalysts have shown both great fundamental and practical value in oxidative dehydrogenation (ODH) of light alkanes. In particular, boron-based catalysts show a superior selectivity toward olefins, excellent stability and atom-economy to valuable carbon-based products by minimizing CO2 emission, which are highly promising in future industrialization. The carbonaceous catalysts also exhibited impressive behavior in the ODH of light alkanes helped along by surface oxygen-containing functional groups. This review surveyed and compared the preparation methods of the boron- and carbon-based catalysts and their characterization, their performance in the ODH of light alkanes, and the mechanistic issues of the ODH including the identification of the possible active sites and the exploration of the underlying mechanisms. We discussed different boron-based materials and established versatile methodologies for the investigation of active sites and reaction mechanisms. We also elaborated on the similarities and differences in catalytic and kinetic behaviors, and reaction mechanisms between boron- and carbon-based metal-free materials. A perspective of the potential issues of metal-free ODH catalytic systems in terms of their rational design and their synergy with reactor engineering was sketched.

Oxidative dehydrogenation of propane on the oxygen adsorbed edges of boron nitride nanoribbons

A N₂O/NOx-type site on the boron nitride nanoribbon edge is proposed as highly selective, active site for the oxidative dehydrogenation of propane.

DFT studies on the reaction mechanism for the selective oxidative dehydrogenation of light alkanes by BN catalysts

The oxidative dehydrogenation (ODH) reaction mechanism of ethane and propane catalyzed by two kinds of oxygen-species-terminated BN materials, namely BN nanotubes and h-BN, was studied by the B3LYP-D3 functional with the 6-31G(d,p) basis set.

Serendipity in Catalysis Research: Boron-Based Materials for Alkane Oxidative Dehydrogenation

Light olefins such as ethylene and propylene form the foundation of the modern chemical industry, with yearly production volumes well into the hundreds of millions of metric tons. Currently, these light olefins are mainly produced via energy-intensive steam cracking. Alternatively, oxidative dehydrogenation (ODH) of light alkanes to produce olefins allows for lower operation temperatures and extended catalyst lifetimes, potentially leading to valuable process efficiencies. The potential benefits of this route have led to significant research interest due to the wide availability of natural gas from shale deposits. Advances in this area have still not yielded catalysts that are sufficiently selective to olefins for industrial implementation, and ODH still remains a holy grail of selective alkane oxidation research. The main challenge in selective oxidation lies in preventing the overoxidation of the desired product, such as propylene during propane oxidation, to CO and CO₂. Research into selective heterogeneous catalysts for the oxidative dehydrogenation of propane has led to the extensive use of vanadium oxide-based catalysts, and studies on the surface mechanism involved have been used to improve the catalytic activity of the material. Despite decades of research, however, selectivity toward propylene has not proven satisfactory at industrially relevant conversions. It is imperative for new catalytic systems that minimize product overoxidation to be developed for future applications of oxidative dehydrogenation processes. While rational catalyst design has been successful in developing homogeneous catalyst systems, its practical use in heterogeneous catalyst development remains modest. The complexity of surfaces with a variety of terminations and bulk structures, let alone their modification by the chemical potential of a reaction mixture, makes heterogeneous catalyst discovery serendipitous in many cases. The catalyst family presented in this Account is no exception. The importance of catalysis research lies in exploring the science behind serendipity. In this Account, we will first present our initial discovery of boron nitride (BN) as an unexpected catalyst for the oxidative dehydrogenation of light alkanes. Beyond its surprising activity, BN also drew interest due to its low selectivity to carbon oxides. This observation made BN distinct from previously studied metal oxide catalysts for selective alkane oxidation. We narrowed down its unique reactivity to the oxygen functionalization of the catalyst surface, particularly the formation of B-O species as probed by various spectroscopic techniques. In investigating the critical role of each of the structural elements during ODH, we discovered that not only BN but an entire class of boron-containing compounds are active and selective for the formation of propylene from propane. All these materials form a complex oxidized surface with a distribution of BO _x surface sites. This discovery opens the doors to a new field of boron-based oxidation chemistry that currently has more questions than answers. We aim to make this Account a starting point for the research community to explore these new materials to understand their surface mechanisms and the surface species that offer a unique selectivity toward olefinic products. Effective use of these materials may lead to novel processes for efficient use of abundant light alkane resources by oxidation chemistry.

Fabrication and application of BN nanoparticles, nanosheets and their nanohybrids

Smart implementation of novel advanced nanomaterials is the key for the solution of many complex problems of modern science. In recent years, there has been a great interest in the synthesis and application of boron nitride (BN) nanotubes because of their unique physical, chemical, and mechanical properties. By contrast, the synthesis, characterization and exploration of other morphological types of BN nanostructure - BN nanoparticles and BN nanosheets - have received less attention. However, the detailed investigations on advantages of every morphological BN type for specific applications have only recently been started. One of the promising directions is the utilization of BN-based nanohybrids. This review is dedicated to the in-depth analysis of recently published works on the fabrication and application of BN nanoparticles, nanosheets, and their nanohybrids. It covers a variety of developed synthetic methods toward fabrication of such nanostructures, and their specific application potentials in catalysis, drug delivery, tribology and structural materials. Finally, the review focuses on the theoretical aspects of this quickly emerging field.

Oxidative dehydrogenation of propane over Pt–Sn/Si-beta catalysts: key role of Pt–Sn interaction

Bimetallic Pt–Sn catalysts supported on dealuminated Si-beta zeolite were prepared via wet impregnation and the nanoscale close contact between Pt and Sn species in Pt–Sn/Si-beta was confirmed by electron microscopy analyses.

Progress in selective oxidative dehydrogenation of light alkanes to olefins promoted by boron nitride catalysts

We highlight recent progress on a newly-developed catalyst system, boron nitride, for selective oxidative dehydrogenation of light alkanes.