Stability and Reactivity of ϵ−χ−θ Iron Carbide Catalyst Phases in Fischer−Tropsch Synthesis: Controlling μC

Nickel as Electrocatalyst for CO(2) Reduction: Effect of Temperature, Potential, Partial Pressure, and Electrolyte Composition

Electrochemical CO2 reduction on Ni has recently been shown to have the unique ability to produce longer hydrocarbon chains in small but measurable amounts. However, the effects of the many parameters of this reaction remain to be studied in more detail. Here, we have investigated the effect of temperature, bulk CO2 concentration, potential, the reactant, cations, and anions on the formation of hydrocarbons via a chain growth mechanism on Ni. We show that temperature increases the activity but also the formation of coke, which deactivates the catalyst. The selectivity and thus the chain growth probability is mainly affected by the potential and the electrolyte composition. Remarkably, CO reduction shows lower activity but a higher chain growth probability than CO2 reduction. We conclude that hydrogenation is likely to be the rate-determining step and hypothesize that this could happen either by *CO hydrogenation or by termination of the hydrocarbon chain. These insights open the way to further development and optimization of Ni for electrochemical CO2 reduction.

Spectroscopic characterization of carbon monoxide activation by neutral chromium carbides

Spectroscopic characterization of carbon monoxide activation by neutral metal carbides is of essential importance for understanding the structure-reactivity relationships of catalytic sites, but has been proven to be very challenging owing to the difficulty in size selection. Here, we report a size-specific infrared-vacuum ultraviolet spectroscopic study of the reactions between carbon monoxide with neutral chromium carbides. Quantum chemical calculations were carried out to identify the low-lying structures and to interpret the experimental features. The results reveal that the most stable structure of CrC3(CO)2 consists of a CCO ketenylidene unit and that of CrC4(CO)2 has a semi-bridging CO with a very low CO stretching vibrational frequency at 1821 cm-1. The electron structure analyses show that this semi-bridging CO is highly activated through the delocalized Cr-C-C three-center two-electron (3c-2e) interaction between the antibonding orbitals of CO and the metal carbide skeleton. The formation of these metal carbide carbonyls is found to be both thermodynamically exothermic and kinetically facile in the gas phase. The present findings have important implications for the mechanical understanding of the catalytic processes with isolated metal atoms/clusters dispersed on supports.

Towards understanding the lower CH4 selectivity of HCP-Co than FCC-Co in Fischer-Tropsch synthesis

In Fischer-Tropsch synthesis (FTS), the cobalt catalyst has higher C5+ and lower CH4 selectivity in the hcp phase than in the fcc phase. However, a detailed explanation of the intrinsic mechanism is still missing. The underlying reason was explored combining density functional theory, Wulff construction, and a particle-level descriptor based on the slab model of surfaces that are prevalent in the Wulff shape to provide single-particle level understanding. Using a particle-level indicator of the reaction rates, we have shown that it is more difficult to form CH4 on hcp-Co than on fcc-Co, due to the larger effective barrier difference of CH4 formation and C-C coupling on hcp-Co particles, which leads to the lower CH4 selectivity of hcp-Co in FTS. Among the exposed facets of fcc-Co, the (311) surface plays a pivotal role in promoting CH4 formation. The reduction of CH4 selectivity in cobalt-based FTS is achievable through phase engineering of Co from fcc to hcp or by tuning the temperature and size of the particles.

Novel heterogeneous Fe-based catalysts for carbon dioxide hydrogenation to long chain α-olefins-A review

The thermocatalytic conversion of carbon dioxide (CO2) into high value-added chemicals provides a strategy to address the environmental problems caused by excessive carbon emissions and the sustainable production of chemicals. Significant progress has been made in the CO2 hydrogenation to long chain α-olefins, but controlling C-O activation and C-C coupling remains a great challenge. This review focuses on the recent advances in catalyst design concepts for the synthesis of long chain α-olefins from CO2 hydrogenation. We have systematically summarized and analyzed the ingenious design of catalysts, reaction mechanisms, the interaction between active sites and supports, structure-activity relationship, influence of reaction process parameters on catalyst performance, and catalyst stability, as well as the regeneration methods. Meanwhile, the challenges in the development of the long chain α-olefins synthesis from CO2 hydrogenation are proposed, and the future development opportunities are prospected. The aim of this review is to provide a comprehensive perspective on long chain α-olefins synthesis from CO2 hydrogenation to inspire the invention of novel catalysts and accelerate the development of this process.

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.

A DFT study towards dynamic structures of iron and iron carbide and their effects on the activity of the Fischer-Tropsch process

The Fe-based Fischer-Tropsch synthesis (FTS) catalyst shows a rich phase chemistry under pre-treatment and FTS conditions. The exact structural composition of the active site, whether iron or iron carbide (FeCx), is still controversial. Aiming to obtain an insight into the active sites and their role in affecting FTS activity, the swarm intelligence algorithm is implemented to search for the most stable Fe(100), Fe(110), Fe(210) surfaces with different carbon ratios. Then, ab initio atomistic thermodynamics and Wulffman construction were employed to evaluate the stability of these surfaces at different chemical potentials of carbon. Their FTS reactivity and selectivity were later assessed by semi-quantitative micro-kinetic equations. The results show that stability, reactivity, and selectivity of the iron are all affected by the carbonization process when the carbon ratio increases. Formation of the carbide, a rather natural process under experimental conditions, would moderately increase the turnover frequency (TOF), but both iron and iron carbide are active to the reaction.

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.

Stabilizing Co2C with H2O and K promoter for CO2 hydrogenation to C2+ hydrocarbons

The decomposition of cobalt carbide (Co₂C) to metallic cobalt in CO₂ hydrogenation results in a notable drop in the selectivity of valued C₂₊ products, and the stabilization of Co₂C remains a grand challenge. Here, we report an in situ synthesized K-Co₂C catalyst, and the selectivity of C₂₊ hydrocarbons in CO₂ hydrogenation achieves 67.3% at 300°C, 3.0 MPa. Experimental and theoretical results elucidate that CoO transforms to Co₂C in the reaction, while the stabilization of Co₂C is dependent on the reaction atmosphere and the K promoter. During the carburization, the K promoter and H₂O jointly assist in the formation of surface C^* species via the carboxylate intermediate, while the adsorption of C^* on CoO is enhanced by the K promoter. The lifetime of the K-Co₂C is further prolonged from 35 hours to over 200 hours by co-feeding H₂O. This work provides a fundamental understanding toward the role of H₂O in Co₂C chemistry, as well as the potential of extending its application in other reactions.

Effects of Different Reductive Agents on Zn-Promoted Iron Oxide Phases in the CO2–Fischer–Tropsch to Linear α-Olefins

The pretreatment atmosphere has a significant impact on the performance of iron-based catalysts in carbon dioxide (CO2) hydrogenation. In this study, we investigated the effects of carbon monoxide (CO), syngas (H2/CO), and hydrogen (H2) on the performance of iron-based catalysts during the pretreatment process. To evaluate the structural changes in catalysts after activation and reaction, we analyzed their morphology and particle size, the surface and bulk phase composition, carbon deposition, the desorption of linear α-olefins and reaction intermediates using transmission electron microscope (TEM), Raman spectroscopy, X-ray photoelectron spectroscopy (XPS), X-ray diffraction (XRD), Mössbauer spectroscopy (MES), temperature-programmed desorption (TPD), and in situ diffuse reflectance infrared Fourier transform spectroscopy (in situ DRIFTS). Raman and XPS showed that the H2 pretreatment catalyst caused the absence of iron carbides due to the lack of carbon source, and the CO and syngas pretreatment catalysts promoted the formation of carbon deposits and iron carbides. While the bulk phase of the CO and syngas pretreatment catalyst mainly consists of iron carbide (FeCx), XRD and MES revealed that the bulk phase of the H2 pretreatment catalyst primarily consisted of metallic iron (Fe) and iron oxide (FeOx). The composition of the phase is closely associated with its performance at the initial stage of the reaction. The formation of olefins and C5+ products is more encouraged by CO pretreatment catalysts than by H2 and syngas pretreatment catalysts, according to in situ DRIFTS evidence. Ethylene (C2H4)/propylene (C3H6)-TPD indicates that the CO pretreatment catalyst is more favorable for the desorption of olefins which improves the olefins selectivity. Based on the analysis of the TEM images, H2 pretreatment stimulated particle agglomeration and sintering. In conclusion, the results show that the CO-pretreatment catalyst has higher activity due to the inclusion of more FeOX and Fe3C. In particular, the presence of Fe3C was found to be more favorable for the formation of olefins and C5+ hydrocarbons. Furthermore, carbon deposition was relatively mild and more conducive to maintaining the balance of FeOx/FeCx on the catalyst surface.

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.

Effects of Silica Shell Encapsulated Nanocrystals on Active χ-Fe5C2 Phase and Fischer-Tropsch Synthesis

Among various iron carbide phases, χ-Fe₅C₂, a highly active phase in Fischer-Tropsch synthesis, was directly synthesized using a wet-chemical route, which makes a pre-activation step unnecessary. In addition, χ-Fe₅C₂ nanoparticles were encapsulated with mesoporous silica for protection from deactivation. Further structural analysis showed that the protective silica shell had a partially ordered mesoporous structure with a short range. According to the XRD result, the sintering of χ-Fe₅C₂ crystals did not seem to be significant, which was believed to be the beneficial effect of the protective shell providing restrictive geometrical space for nanoparticles. More interestingly, the protective silica shell was also found to be effective in maintaining the phase of χ-Fe₅C₂ against re-oxidation and transformation to other iron carbide phases. Fischer-Tropsch activity of χ-Fe₅C₂ in this study was comparable to or higher than those from previous reports. In addition, CO₂ selectivity was found to be very low after stabilization.

Single-Phase θ-Fe3C Derived from Prussian Blue and Its Catalytic Application in Fischer-Tropsch Synthesis

Elucidation of the intrinsic catalytic principle of iron carbides remains a substantial challenge in iron-catalyzed Fischer-Tropsch synthesis (FTS), due to possible interference from other Fe-containing species. Here, we propose a facile approach to synthesize single-phase θ-Fe3C via the pyrolysis of a molecularly defined Fe-C complex (Fe4[Fe(CN)6]3), thus affording close examination of its catalytic behavior during FTS. The crystal structure of prepared θ-Fe3C is unambiguously verified by combined XRD and MES measurement, demonstrating its single-phase nature. Strikingly, single-phase θ-Fe3C exhibited excellent selectivity to light olefins (77.8%) in the C2-C4 hydrocarbons with less than 10% CO2 formation in typical FTS conditions. This strategy further succeeds with promotion of Mn, evident for its wide-ranging compatibility for the promising industrial development of catalysts. This work offers a facile approach for oriented preparation of single-phase θ-Fe3C and provides an in-depth understanding of its intrinsic catalytic performance in FTS.

A Single Source, Scalable Route for Direct Isolation of Earth-Abundant Nanometal Carbide Water-Splitting Electrocatalysts

Single-phase M_xCs (M = Fe, Co, and Ni) were prepared by solvothermal conversion of Prussian blue single source precursors. The single source precursor is prepared in water, and the conversion process is carried out in alkylamines at reaction temperatures above 200 °C. The reaction is scalable using a commercial source of Fe-PB. High-resolution transmission electron microscopy, X-ray photoelectron microscopy, and powder X-ray diffraction confirm that carbides have thin oxide termination but lack graphitic surfaces. Electrocatalytic activity reveals that Fe₃C and Co₂C are oxygen evolution reaction electrocatalysts, while Ni₃C is a bifunctional [OER and hydrogen evolution reaction (HER)] electrocatalyst.

In Situ Surface-Sensitive Investigation of Multiple Carbon Phases on Fe(110) in the Fischer–Tropsch Synthesis

Carbide formation on iron-based catalysts is an integral and, arguably, the most important part of the Fischer–Tropsch synthesis process, converting CO and H₂ into synthetic fuels and numerous valuable chemicals. Here, we report an in situ surface-sensitive study of the effect of pressure, temperature, time, and gas feed composition on the growth dynamics of two distinct iron–carbon phases with the octahedral and trigonal prismatic coordination of carbon sites on an Fe(110) single crystal acting as a model catalyst. Using a combination of state-of-the-art X-ray photoelectron spectroscopy at an unprecedentedly high pressure, high-energy surface X-ray diffraction, mass spectrometry, and theoretical calculations, we reveal the details of iron surface carburization and product formation under semirealistic conditions. We provide a detailed insight into the state of the catalyst’s surface in relation to the reaction.

In Situ and Ex Situ X-ray Diffraction and Small-Angle X-ray Scattering Investigations of the Sol-Gel Synthesis of Fe3N and Fe3C

Iron nitride (Fe₃N) and iron carbide (Fe₃C) nanoparticles can be prepared via sol-gel synthesis. While sol-gel methods are simple, it can be difficult to control the crystalline composition, i.e., to achieve a Rietveld-pure product. In a previous in situ synchrotron study of the sol-gel synthesis of Fe₃N/Fe₃C, we showed that the reaction proceeds as follows: Fe₃O₄ → FeO_x → Fe₃N → Fe₃C. There was considerable overlap between the different phases, but we were unable to ascertain whether this was due to the experimental setup (side-on heating of a quartz capillary which could lead to thermal gradients) or whether individual particle reactions proceed at different rates. In this paper, we use in situ wide- and small-angle X-ray scattering (wide-angle X-ray scattering (WAXS) and small-angle X-ray scattering (SAXS)) to demonstrate that the overlapping phases are indeed due to variable reaction rates. While the initial oxide nanoparticles have a small range of diameters, the size range expands considerably and very rapidly during the oxide-nitride transition. This has implications for the isolation of Rietveld-pure Fe₃N, and in an extensive laboratory study, we were indeed unable to isolate phase-pure Fe₃N. However, we made the surprising discovery that Rietveld-pure Fe₃C nanoparticles can be produced at 500 °C with a sufficient furnace dwell time. This is considerably lower than the previous reports of the sol-gel synthesis of Fe₃C nanoparticles.

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).

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.

Controllable assembly of Fe3O4–Fe3C@MC by in situ doping of Mn for CO2 selective hydrogenation to light olefins

Mn in situ doped Fe3C anchored in mesoporous carbon was prepared and employed for converting CO2 to light olefins successfully. The in situ doped Mn modified the ratio of FeOx/FeCx and surface electron density, which optimized the C/H on active sites.

Fischer–Tropsch Synthesis: Effect of the Promoter’s Ionic Charge and Valence Level Energy on Activity

In this contribution, we examine the effect of the promoter´s ionic charge and valence orbital energy on the catalytic activity of Fe-based catalysts, based on in situ synchrotron X-ray powder diffraction (SXRPD), temperature-programmed-based techniques (TPR, TPD, CO-TP carburization), and Fischer–Tropsch synthesis catalytic testing studies. We compared the promoting effects of K (a known promoter for longer-chained products) with Ba, which has a similar ionic radius but has double the ionic charge. Despite being partially “buried” in a crystalline BaCO3 phase, the carburization of the Ba-promoted catalyst was more effective than that of K; this was primarily due to its higher (2+) ionic charge. With Ba2+, higher selectivity to methane and lighter products were obtained compared to the K-promoted catalysts; this is likely due to Ba´s lesser capability of suppressing H adsorption on the catalyst surface. An explanation is provided in terms of a more limited mixing between electron-filled Ba2+ 5p and partially filled Fe 3d orbitals, which are expected to be important for the chemical promotion, as they are further apart in energy compared to the K+ 3p and Fe 3d orbitals.

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.