Interfacial Fe5C2-Cu catalysts toward low-pressure syngas conversion to long-chain alcohols

Active learning streamlines development of high performance catalysts for higher alcohol synthesis

Developing efficient catalysts for syngas-based higher alcohol synthesis (HAS) remains a formidable research challenge. The chain growth and CO insertion requirements demand multicomponent materials, whose complex reaction dynamics and extensive chemical space defy catalyst design norms. We present an alternative strategy by integrating active learning into experimental workflows, exemplified via the FeCoCuZr catalyst family. Our data-aided framework streamlines navigation of the extensive composition and reaction condition space in 86 experiments, offering >90% reduction in environmental footprint and costs over traditional programs. It identifies the Fe65Co19Cu5Zr11 catalyst with optimized reaction conditions to attain higher alcohol productivities of 1.1 gHA h-1 gcat-1 under stable operation for 150 h on stream, a 5-fold improvement over typically reported yields. Characterization reveals catalytic properties linked to superior activities despite moderate higher alcohol selectivities. To better reflect catalyst demands, we devise multi-objective optimization to maximize higher alcohol productivity while minimizing undesired CO2 and CH4 selectivities. An intrinsic trade-off between these metrics is uncovered, identifying Pareto-optimal catalysts not readily discernible by human experts. Finally, based on feature-importance analysis, we formulate data-informed guidelines to develop performance-specific FeCoCuZr systems. This approach goes beyond existing HAS catalyst design strategies, is adaptable to broader catalytic transformations, and fosters laboratory sustainability.

Stabilized ε-Fe2C catalyst with Mn tuning to suppress C1 byproduct selectivity for high-temperature olefin synthesis

Accurately controlling the product selectivity in syngas conversion, especially increasing the olefin selectivity while minimizing C1 byproducts, remains a significant challenge. Epsilon Fe2C is deemed a promising candidate catalyst due to its inherently low CO2 selectivity, but its use is hindered by its poor high-temperature stability. Herein, we report the successful synthesis of highly stable ε-Fe2C through a N-induced strategy utilizing pyrolysis of Prussian blue analogs (PBAs). This catalyst, with precisely controlled Mn promoter, not only achieved an olefin selectivity of up to 70.2% but also minimized the selectivity of C1 byproducts to 19.0%, including 11.9% CO2 and 7.1% CH4. The superior performance of our ε-Fe2C-xMn catalysts, particularly in minimizing CO2 formation, is largely attributed to the interface of dispersed MnO cluster and ε-Fe2C, which crucially limits CO to CO2 conversion. Here, we enhance the carbon efficiency and economic viability of the olefin production process while maintaining high catalytic activity.

The Importance of Sintering-Induced Grain Boundaries in Copper Catalysis to Improve Carbon-Carbon Coupling

Syngas conversion serves as a gas-to-liquid technology to produce liquid fuels and valuable chemicals from coal, natural gas, or biomass. During syngas conversion, sintering is known to deactivate the catalyst owing to the loss of active surface area. However, the growth of nanoparticles might induce the formation of new active sites such as grain boundaries (GBs) which perform differently from the original nanoparticles. Herein, we reported a unique Cu-based catalyst, Cu nanoparticles with in situ generated GBs confined in zeolite Y (denoted as activated Cu/Y), which exhibited a high selectivity for C5+ hydrocarbons (65.3 C%) during syngas conversion. Such high selectivity for long-chain products distinguished activated Cu/Y from typical copper-based catalysts which mainly catalyze methanol synthesis. This unique performance was attributed to the GBs, while the zeolite assisted the stabilization through spatial confinement. Specifically, the GBs enabled H-assisted dissociation of CO and subsequent hydrogenation into CHx*. CHx* species not only serve as the initiator but also directly polymerize on Cu GBs, known as the carbide mechanism. Meanwhile, the synergy of GBs and their vicinal low-index facets led to the CO insertion where non-dissociative adsorbed CO on low-index facets migrated to GBs and inserted into the metal-alkyl bond for the chain growth.

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.

Tuning the selectivity of the CO2 hydrogenation reaction using boron-doped cobalt-based catalysts

Direct CO2 hydrogenation to value-added chemicals is a promising path toward realizing the "carbon-neutral" goal. However, controlling the selectivity of CO2 hydrogenation toward desired products (e.g., CO and CH4) using non-precious metal-based catalysts is important but challenging. It is imperative to explore catalysts with high activity and stability. Herein, boron-doped cobalt nanoparticles supported on H-ZSM-5 were devised for CO2 hydrogenation to produce CO in a gas-solid flow system. Our results demonstrate that boron doping not only increases the CO2 adsorption capability of the catalyst but also optimizes the electronic state of Co for CO desorption during hydrogenation process. As a result, the boron-doped cobalt catalysts displayed an enhanced CO selectivity of 94.5% and a CO2 conversion rate of 45.6%, which is much higher than that of Co-ZSM-5 without boron doping. This study shows that the strategic design of metal borides is important for controlling the selectivity of desired products in the CO2 hydrogenation reaction.

Promoting nonsymmetric C-C coupling to valuable oxygenates without metal catalysts in alkali aqueous medium

Efficient conversion of C1 molecules into multicarbon oxygenates is a promising avenue for energy storage. Herein, we synthesize adjustable alkanoic acids/alcohols from formate C1 molecules via a hydrothermal reaction without any metal catalyst participation. This is achieved via HCO* and HCOO- nonsymmetric C-C coupling by alkali catalysis in aqueous medium.

Enabling direct-growth route for highly efficient ethanol upgrading to long-chain alcohols in aqueous phase

Upgrading ethanol to long-chain alcohols (LAS, C6+OH) offers an attractive and sustainable approach to carbon neutrality. Yet it remains a grand challenge to achieve efficient carbon chain propagation, particularly with noble metal-free catalysts in aqueous phase, toward LAS production. Here we report an unconventional but effective strategy for designing highly efficient catalysts for ethanol upgrading to LAS, in which Ni catalytic sites are controllably exposed on surface through sulfur modification. The optimal catalyst exhibits the performance well exceeding previous reports, achieving ultrahigh LAS selectivity (15.2% C6OH and 59.0% C8+OH) at nearly complete ethanol conversion (99.1%). Our in situ characterizations, together with theoretical simulation, reveal that the selectively exposed Ni sites which offer strong adsorption for aldehydes but are inert for side reactions can effectively stabilize and enrich aldehyde intermediates, dramatically improving direct-growth probability toward LAS production. This work opens a new paradigm for designing high-performance non-noble metal catalysts for upgrading aqueous EtOH to LAS.

In-Situ-Formed Potassium-Modified Nickel-Zinc Carbide Boosts Production of Higher Alcohols beyond CH4 in CO2 Hydrogenation

Ni-based catalysts have been widely studied in the hydrogenation of CO2 to CH4 , but selective and efficient synthesis of higher alcohols (C2+ OH) from CO2 hydrogenation over Ni-based catalyst is still challenging due to successive hydrogenation of C1 intermediates leading to methanation. Herein, we report an unprecedented synthesis of C2+ OH from CO2 hydrogenation over K-modified Ni-Zn bimetal catalyst with promising activity and selectivity. Systematic experiments (including XRD, in situ spectroscopic characterization) and computational studies reveal the in situ generation of an active K-modified Ni-Zn carbide (K-Ni3 Zn1 C0.7 ) by carburization of Zn-incorporated Ni0 , which can significantly enhance CO2 adsorption and the surface coverage of alkyl intermediates, and boost the C-C coupling to C2+ OH rather than conventional CH4 . This work opens a new catalytic avenue toward CO2 hydrogenation to C2+ OH, and also provides an insightful example for the rational design of selective and efficient Ni-based catalysts for CO2 hydrogenation to multiple carbon products.

ZrO2-Promoted Cu-Co, Cu-Fe and Co-Fe Catalysts for Higher Alcohol Synthesis

The development of efficient catalysts for the direct synthesis of higher alcohols (HA) via CO hydrogenation has remained a prominent research challenge. While modified Fischer-Tropsch synthesis (m-FTS) systems hold great potential, they often retain limited active site density under operating conditions for industrially relevant performance. Aimed at improving existing catalyst architectures, this study investigates the impact of highly dispersed metal oxides of Co-Cu, Cu-Fe, and Co-Fe m-FTS systems and demonstrates the viability of ZrO2 as a general promoter in the direct synthesis of HA from syngas. A volcano-like composition-performance relationship, in which 5-10 mol % ZrO2 resulted in maximal HA productivity, governs all catalyst families. The promotional effect resulted in a 2.5-fold increase in HA productivity for the optimized Cu1Co4@ZrO2-5 catalyst (Cu:Co = 1:4, 5 mol % ZrO2) compared to its ZrO2-free counterpart and placed Co1Fe4@ZrO2-10 among the most productive systems (345 mgHA h-1 gcat-1) reported in this category under comparable operating conditions, with stable performance for at least 300 h. ZrO2 assumes an amorphous and defective nature on the catalysts, leading to enhanced H2 and CO activation, facilitated formation of metallic and carbide phases, and structural stabilization.

Hydrothermal conversion of biomass to fuels, chemicals and materials: A review holistically connecting product properties and marketable applications

Biomass is a renewable and carbon-neutral resource with good features for producing biofuels, biochemicals, and biomaterials. Among the different technologies developed to date to convert biomass into such commodities, hydrothermal conversion (HC) is a very appealing and sustainable option, affording marketable gaseous (primarily containing H₂, CO, CH₄, and CO₂), liquid (biofuels, aqueous phase carbohydrates, and inorganics), and solid products (energy-dense biofuels (up to 30 MJ/kg) with excellent functionality and strength). Given these prospects, this publication first-time puts together essential information on the HC of lignocellulosic and algal biomasses covering all the steps involved. Particularly, this work reports and comments on the most important properties (e.g., physiochemical and fuel properties) of all these products from a holistic and practical perspective. It also gathers vital information addressing selecting and using different downstream/upgrading processes to convert HC reaction products into marketable biofuels (HHV up to 46 MJ/kg), biochemicals (yield >90 %), and biomaterials (great functionality and surface area up to 3600 m²/g). As a result of this practical vision, this work not only comments on and summarizes the most important properties of these products but also analyzes and discusses present and future applications, establishing an invaluable link between product properties and market needs to push HC technologies transition from the laboratory to the industry. Such a practical and pioneering approach paves the way for the future development, commercialization and industrialization of HC technologies to develop holistic and zero-waste biorefinery processes.

Ruthenium-cobalt single atom alloy for CO photo-hydrogenation to liquid fuels at ambient pressures

Photothermal Fischer-Tropsch synthesis represents a promising strategy for converting carbon monoxide into value-added chemicals. High pressures (2-5 MPa) are typically required for efficient C-C coupling reactions and the production of C₅₊ liquid fuels. Herein, we report a ruthenium-cobalt single atom alloy (Ru₁Co-SAA) catalyst derived from a layered-double-hydroxide nanosheet precursor. Under UV-Vis irradiation (1.80 W cm^-2), Ru₁Co-SAA heats to 200 °C and photo-hydrogenates CO to C₅₊ liquid fuels at ambient pressures (0.1-0.5 MPa). Single atom Ru sites dramatically enhance the dissociative adsorption of CO, whilst promoting C-C coupling reactions and suppressing over-hydrogenation of CH_x* intermediates, resulting in a CO photo-hydrogenation turnover frequency of 0.114 s^-1 with 75.8% C₅₊ selectivity. Owing to the local Ru-Co coordination, highly unsaturated intermediates are generated during C-C coupling reactions, thereby improving the probability of carbon chain growth into C₅₊ liquid fuels. The findings open new vistas towards C₅₊ liquid fuels under sunlight at mild pressures.

A Simple Strategy Stabilizing for a CuFe/SiO2 Catalyst and Boosting Higher Alcohols’ Synthesis from Syngas

Stable F-T-based catalyst development in direct CO hydrogenation to higher alcohols is still a challenge at present. In this study, CuFe/SiO2 catalysts with a SiO2 support treated with a piranha solution were prepared and evaluated in a long-term reaction. The treated catalyst showed higher total alcohols’ selectivity and great stability during a reaction of more than 90 h. It was found that the treatment with the piranha solution enriched the surface hydroxyl groups on SiO2, so that the Cu–Fe active components could be firmly anchored and highly dispersed on the support, resulting in stable catalytic performance. Furthermore, the in situ DRIFTS revealed that the adsorption strength of CO on Cu+ on the treated catalyst surface was weakened, which made the C-O bond less likely to be cleaved and thus significantly inhibited the formation of hydrocarbon products. Meanwhile, the non-dissociated CO species were obviously enriched on the Cu0 surface, promoting the formation of alcohol products, and thus the selectivity of total alcohols was increased. This strategy will shed light on the design of supported catalysts with stabilized structures for a wide range of catalytic reactions.

Recent advances in the routes and catalysts for ethanol synthesis from syngas

Ethanol, as one of the important bulk chemicals, is widely used in modern society. It can be produced by fermentation of sugar, petroleum refining, or conversion of syngas (CO/H₂). Among these approaches, conversion of syngas to ethanol (STE) is the most environmentally friendly and economical process. Although considerable progress has been made in STE conversion, control of CO activation and C-C growth remains a great challenge. This review highlights recent advances in the routes and catalysts employed in STE technology. The catalyst designs and pathway designs are summarized and analysed for the direct and indirect STE routes, respectively. In the direct STE routes (i.e., one-step synthesis of ethanol from syngas), modified catalysts of methanol synthesis, modified catalysts of Fischer-Tropsch synthesis, Mo-based catalysts, noble metal catalysts and multifunctional catalysts are systematically reviewed based on their catalyst designs. Further, in the indirect STE routes (i.e., multi-step processes for ethanol synthesis from syngas via methanol/dimethyl ether as intermediates), carbonylation of methanol/dimethyl ether followed by hydrogenation, and coupling of methanol with CO to form dimethyl oxalate followed by hydrogenation, are outlined according to their pathway designs. The goal of this review is to provide a comprehensive perspective on STE technology and inspire the invention of new catalysts and pathway designs in the near future.

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.

Catalytic Transformation of PET and CO2 into High-Value Chemicals

Polyethylene terephthalate (PET) and CO₂ , two chemical wastes that urgently need to be transformed in the environment, are converted simultaneously in a one-pot catalytic process through the synergistic coupling of three reactions: CO₂ hydrogenation, PET methanolysis and dimethyl terephthalate (DMT) hydrogenation. More interestingly, the chemical equilibria of both reactions were shifted forward due to a revealed dual-promotion effect, leading to significantly enhanced PET depolymerization. The overall methanol yield from CO₂ hydrogenation exceeded the original thermodynamic equilibrium limit since the methanol was in situ consumed in the PET methanolysis. The degradation of PET by a stoichiometric ratio of methanol was significantly enhanced because the primary product, DMT was hydrogenated to dimethyl cyclohexanedicarboxylate (DMCD) or p-xylene (PX). This synergistic catalytic process provides an effective way to simultaneously recycle two wastes, polyesters and CO₂ , for producing high-value chemicals.

Efficient Recycling Blast Furnace Slag by Constructing Ti-Embedded Layered Double Hydroxide as Visible-Light-Driven Photocatalyst

In this work, a strategy of heat treatment-precipitation has been developed to recycle Ti-containing metallurgical solid waste by forming Ti-embedded MgAl layered double hydroxide (TMA-LDH). This facile and simple route is featured by the dedicated utilization of the composition of slag with high overall recovery efficiency. Importantly, as-obtained product exhibits visible light response distinctly different from that of pristine MA-LDH ascribed to the Fe doping inherited from initial slag. Its mesoporous nanostructure also provides more microchannels for mass and carrier transfer. As such, excellent photocatalytic activity towards degradation of tetracycline hydrochloride is achieved, and 88% removal could be obtained in 60 min. Furthermore, 44% increase in efficiency than that of Ti-excluded LDH also indicates the synergistically promoting effect of Ti incorporation. Mechanism investigation suggests that Ti incorporation regulates the electronic structure of pristine LDH with more active sites, and favors the formation of radicals with improved oxidative ability for photocatalysis.

Selective C2+ alcohol synthesis by CO2 hydrogenation via a reaction-coupling strategy

The synergy of primary and promoting catalysts in close proximity facilitates the migration and insertion of CO*/CHxO* species, thus accelerating HA productivity over a multifunctional catalyst.

CuCo alloy nanonets derived from CuCo2O4 spinel oxides for higher alcohols synthesis from syngas

Porous CuCo alloy nanonets were used as superior catalysts for higher alcohol synthesis from syngas. The catalyst was fabricated via structural topological transformation of CuCo2O4 spinel precursor.