Stabilization of ε-iron carbide as high-temperature catalyst under realistic Fischer-Tropsch synthesis conditions

Effects of surface hydrophobization on the phase evolution behavior of iron-based catalyst during Fischer-Tropsch synthesis

Iron-based Fischer-Tropsch synthesis (FTS) catalyst is widely used for syngas conversion, but its iron carbide active phase is easily oxidized into Fe3O4 by the water produced during reaction, leading to the deterioration of catalytic performance. Here, we show an efficient strategy for protecting the iron carbide active phase of FTS catalyst by surface hydrophobization. The hydrophobic surface can reduce the water concentration in the core vicinity of catalyst during syngas conversion, and thus inhibit the oxidation of iron species by water, which enhances the C - C coupling ability of catalyst and promotes the formation of long-chain olefins. More significantly, it is unraveled that appropriate shell thickness plays a crucial role in stabilizing the iron carbide active phase without Fe3O4 formation and achieving good catalytic performance.

The effect of an external magnetic field on the interaction of carbon monoxide with hematite

The effect of an external magnetic field on the activation energy (E*) of carbon monoxide interaction with hematite under isothermal conditions in the temperature range of 250 to 350 °C has been studied using in situ magnetometry. The dependence of E* of the reaction of magnetite formation on the magnetic field strength in the field strength range from 60 Oe to 3 kOe is shown for hematite nanoparticle samples deposited on 20 nm silica gel. An extreme field dependence of E* was observed.

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.

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.

Tailoring the CO2 Hydrogenation Performance of Fe-Based Catalyst via Unique Confinement Effect of the Carbon Shell

Even though Fe-based catalysts have been widely employed for CO2 hydrogenation into hydrocarbons, oxygenates, liquid fuels, etc., the precise regulation of their physicochemical properties is needed to enhance the catalytic performance. Herein, under the guidance of the traditional concept in heterogeneous catalysis-confinement effect, a core-shell structured catalyst Na-Fe3 O4 @C is constructed to boost the CO2 hydrogenation performance. Benefiting from the carbon-chain growth limitation, tailorable H2 /CO2 ratio on the catalytic interface, and unique electronic property that all endowed by the confinement effect, the selectivity and space-time yield of light olefins (C2 = -C4 = ) are as high as 47.4 % and 15.9 g molFe -1  h-1 , respectively, which are all notably higher than that from the shell-less counterpart. The function mechanism of the confinement effect in Fe-based catalysts are clarified in detail by multiple characterization and density functional theory (DFT). This work may offer a new prospect for the rational design of CO2 hydrogenation catalyst.

Recent Progress on Phase Engineering of Nanomaterials

As a key structural parameter, phase depicts the arrangement of atoms in materials. Normally, a nanomaterial exists in its thermodynamically stable crystal phase. With the development of nanotechnology, nanomaterials with unconventional crystal phases, which rarely exist in their bulk counterparts, or amorphous phase have been prepared using carefully controlled reaction conditions. Together these methods are beginning to enable phase engineering of nanomaterials (PEN), i.e., the synthesis of nanomaterials with unconventional phases and the transformation between different phases, to obtain desired properties and functions. This Review summarizes the research progress in the field of PEN. First, we present representative strategies for the direct synthesis of unconventional phases and modulation of phase transformation in diverse kinds of nanomaterials. We cover the synthesis of nanomaterials ranging from metal nanostructures such as Au, Ag, Cu, Pd, and Ru, and their alloys; metal oxides, borides, and carbides; to transition metal dichalcogenides (TMDs) and 2D layered materials. We review synthesis and growth methods ranging from wet-chemical reduction and seed-mediated epitaxial growth to chemical vapor deposition (CVD), high pressure phase transformation, and electron and ion-beam irradiation. After that, we summarize the significant influence of phase on the various properties of unconventional-phase nanomaterials. We also discuss the potential applications of the developed unconventional-phase nanomaterials in different areas including catalysis, electrochemical energy storage (batteries and supercapacitors), solar cells, optoelectronics, and sensing. Finally, we discuss existing challenges and future research directions in PEN.

Iron phosphide nanocrystals as an air-stable heterogeneous catalyst for liquid-phase nitrile hydrogenation

Iron-based heterogeneous catalysts are ideal metal catalysts owing to their abundance and low-toxicity. However, conventional iron nanoparticle catalysts exhibit extremely low activity in liquid-phase reactions and lack air stability. Previous attempts to encapsulate iron nanoparticles in shell materials toward air stability improvement were offset by the low activity of the iron nanoparticles. To overcome the trade-off between activity and stability in conventional iron nanoparticle catalysts, we developed air-stable iron phosphide nanocrystal catalysts. The iron phosphide nanocrystal exhibits high activity for liquid-phase nitrile hydrogenation, whereas the conventional iron nanoparticles demonstrate no activity. Furthermore, the air stability of the iron phosphide nanocrystal allows facile immobilization on appropriate supports, wherein TiO2 enhances the activity. The resulting TiO2-supported iron phosphide nanocrystal successfully converts various nitriles to primary amines and demonstrates high reusability. The development of air-stable and active iron phosphide nanocrystal catalysts significantly expands the application scope of iron catalysts.

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.

Differential chromatin binding preference is the result of the neo-functionalization of the TB1 clade of TCP transcription factors in grasses

The understanding of neo-functionalization of plant transcription factors (TFs) after gene duplication has been extensively focused on changes in protein-protein interactions, the expression pattern of TFs, or the variation of cis-elements bound by TFs. Yet, the main molecular role of a TF, that is, its specific chromatin binding for the direct regulation of target gene expression, continues to be mostly overlooked. Here, we studied the TB1 clade of the TEOSINTE BRANCHED 1, CYCLOIDEA, PROLIFERATING CELL FACTORS (TCP) TF family within the grasses (Poaceae). We identified an Asp/Gly amino acid replacement within the TCP domain, originated within a paralog TIG1 clade exclusive for grasses. The heterologous expression of Zea mays TB1 and its two paralogs BAD1 and TIG1 in Arabidopsis mutant plants lacking the TB1 ortholog BRC1 revealed distinct functions in plant development. Notably, the Gly acquired in the TIG1 clade does not impair TF homodimerization and heterodimerization, while it modulates chromatin binding preferences. We found that in vivo TF recognition of target promoters depends on this Asp/Gly mutation and directly impacts downstream gene expression and subsequent plant development. These results provided new insights into how natural selection fine-tunes gene expression regulation after duplication of TFs to define plant architecture.

Hydrogen spillover effects in the Fischer–Tropsch reaction over carbon nanotube supported cobalt catalysts

Support (CNTs) surface defect-induced hydrogen spillover significantly impacted the catalytic activity (turnover frequency, TOF) and methane selectivity evolution in cobalt-based Fischer–Tropsch synthesis.

Effect of Pyrolysis on iron-metal organic frameworks (MOFs) to Fe3C @ Fe5C2 for diesel production in Fischer-Tropsch Synthesis

The Fischer-Tropsch Synthesis (FTS) is a significant catalytic chemical reaction that produces ultra-clean fuels or chemicals with added value from a syngas mixture of CO and H₂ obtained from biomass, coal, or natural gas. The presence of sulfur is not considered good for producing liquid fuels for(FTS). In this study, we reveal that the presence of sulfur in ferric sulfate Fe₂(SO₄)₃ MOF provides the high amount, 52.50% of light hydrocarbons in the carbon chain distribution. The calcined ferric nitrate Fe(NO₃)₃ MOF reveals the highest 93.27% diesel production. Calcination is regarded as an essential factor in enhancing liquid fuel production. Here, we probed the calcination effect of Metal Organic Framework (MOF) on downstream application syngas to liquid fuels. The XRD results of MOF. N and P. MOF.N shows the formation of the active phase of iron carbide (Fe₅C₂), considered the most active phase of FTS. The scanning electron microscopy (SEM) images of iron sulfate MOF catalyst (P.MOF.S) reveals that the existence of sulfur creates pores inside the particles due to the reaction of free water molecules with the sulfur derivate. The surface functional groups of prepared MOFs and tested MOFS were analyzed by Fourier transforms infrared spectroscopy (FT-IR). The thermal stability of prepared MOFS was analyzed by Thermo gravimetric analysis (TGA). The surface areas and structural properties of the catalysts were measured by N2-Physiosorption technique.

The Conversion of Waste Biomass into Carbon-Supported Iron Catalyst for Syngas to Clean Liquid Fuel Production

Syngas has been utilized in the production of chemicals and fuels, as well as in the creation of electricity. Feedstock impurities, such as nitrogen, sulfur, chlorine, and ash, in syngas have a negative impact on downstream processes. Fischer–Tropsch synthesis is a process that relies heavily on temperature to increase the production of liquid fuels (FTS). In this study, waste biomass converted into activated carbon and then a carbon-supported iron-based catalyst was prepared. The catalyst at 200 °C and 350 °C was used to investigate the influence of temperature on the subsequent application of syngas to liquid fuels. Potassium (K) was used as a structural promoter in the Fe-C catalyst to boost catalyst activity and structural stability (Fe-C-K). Low temperatures (200 °C) cause 60% and 80% of diesel generation, respectively, without and with potassium promoter. At high temperatures (350 °C), the amount of gasoline produced is 36% without potassium promoter, and 72% with promoter. Iron carbon-supported catalysts with potassium promoter increase gasoline conversion from 36.4% (Fe-C) to 72.5% (Fe-C-K), and diesel conversion from 60.8% (Fe-C) to 80.0% (Fe-C-K). As seen by SEM pictures, iron particles with potassium promoter were found to be equally distributed on the surface of activated carbon.

Preparation of Nitrogen Doped Biochar-Based Iron Catalyst for Enhancing Gasoline-Range Hydrocarbons Production

Developing catalysts to obtain high space time yield (STY) of gasoline-range hydrocarbons via Fischer-Tropsch synthesis (FTS) is a huge challenge due to the restriction of Anderson-Schulz-Flory distribution. Herein, a nitrogen doped biochar-based iron catalyst was synthesized by a one-step method using sugar cane bagasse as carbon precursor, which exhibited an excellent gasoline STY of 8.65 g_C5-12 g_Fe^-1 h^-1, exceeding most reported catalysts. A strong positive relationship between the amount of pyrrolic N and long-chain hydrocarbons selectivity was displayed. The characterization results indicated that pyrrolic N configuration on anchor sites tuned effectively the dispersion of iron species and metal-support interaction as well as CO adsorption, improving the FTS performance.

A perspective on the controlled synthesis of iron-based nanoalloys for the oxygen reduction reaction

The worsening ecological environment is calling for clean energy alternatives, among which hydrogen fuel cells have been one of the hot topics. The commercialized Pt/C catalyst for the oxygen reduction reaction (ORR) in the cathode of fuel cells is suffering from its high cost, serious scarcity and so on. Hence, the exploration on alternative ORR catalysts has attracted much attention. Iron(Fe)-based nanoalloys have shown advantages of low cost, high abundance, and pleasant ORR activity. In this feature, we have summarized Fe-based nanoalloy structures and our recent progress on controllable synthesis as well as their ORR performance, including iron-platinum (Fe-Pt), iron carbide (Fe-C), and iron nitride (Fe-N). Finally, the perspective on this type of ORR electrocatalyst is also discussed.

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.

Effect of Different Iron Phases of Fe/SiO2 Catalyst in CO2 Hydrogenation under Mild Conditions

The effect of different active phases of Fe/SiO2 catalyst on the physio-chemical properties and the catalytic performance in CO2 hydrogenation under mild conditions (at 220 °C under an ambient pressure) was comprehensively studied in this work. The Fe/SiO2 catalyst was prepared by an incipient wetness impregnation method. Hematite (Fe2O3) in the calcined Fe/SiO2 catalyst was activated by hydrogen, carbon monoxide, and hydrogen followed by carbon monoxide, to form a metallic iron (Fe/SiO2-h), an iron carbide (Fe/SiO2-c), and a combination of a metallic iron and an iron carbide (Fe/SiO2-hc), respectively. All activated catalysts were characterized by XRD, Raman spectroscopy, N2 adsorption–desorption, H2-TPR, CO-TPR, H2-TPD, CO2-TPD, CO-TPD, NH3-TPD, and tested in a CO2 hydrogenation reaction. The different phases of the Fe/SiO2 catalyst are formed by different activation procedures and different reducing agents (H2 and CO). Among three different activated catalysts, the Fe/SiO2-c provides the highest CO2 hydrogenation performance in terms of maximum CO2 conversion, as well as the greatest selectivity toward long-chain hydrocarbon products, with the highest chain growth probability of 0.7. This is owing to a better CO2 and CO adsorption ability and a greater acidity on the carbide form of the Fe/SiO2-c surface, which are essential properties of catalysts for polymerization in FTs.

Ambient-pressure hydrogenation of CO2 into long-chain olefins

The conversion of CO₂ by renewable power-generated hydrogen is a promising approach to a sustainable production of long-chain olefins (C₄₊⁼) which are currently produced from petroleum resources. The decentralized small-scale electrolysis for hydrogen generation requires the operation of CO₂ hydrogenation in ambient-pressure units to match the manufacturing scales and flexible on-demand production. Herein, we report a Cu-Fe catalyst which is operated under ambient pressure with comparable C₄₊⁼ selectivity (66.9%) to that of the state-of-the-art catalysts (66.8%) optimized under high pressure (35 bar). The catalyst is composed of copper, iron oxides, and iron carbides. Iron oxides enable reverse-water-gas-shift to produce CO. The synergy of carbide path over iron carbides and CO insertion path over interfacial sites between copper and iron carbides leads to efficient C-C coupling into C₄₊⁼. This work contributes to the development of small-scale low-pressure devices for CO₂ hydrogenation compatible with sustainable hydrogen production.

The conversion of CO2 by renewable power-generated hydrogen is a promising approach to a sustainable production of long-chain olefins. Here the authors report a Cu-Fe catalyst which achieves the hydrogenation of CO2 into long-chain olefins under ambient pressure via the synergy of carbide mechanism and CO insertion mechanism.

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.

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).

Functionalized Carbon Materials in Syngas Conversion

Functionalized carbon materials are widely used in heterogeneous catalysis due to their unique properties such as adjustable surface properties, excellent thermal conductivity, high surface areas, tunable porosity, and moderate interactions with guest metals. The transformation of syngas into hydrocarbons (known as the Fischer-Tropsch synthesis) or oxygenates is an exothermic reaction and is typically catalyzed by transition metals dispersed on functionalized supports. Various carbon materials have been employed in syngas conversions not only for improving the performance or decreasing the dosage of expensive active metals but also for building model catalysts for fundamental research. This article provides a critical review on recent advances in the utilization of carbon materials, in particular the recently developed functionalized nanocarbon materials, for syngas conversions to either hydrocarbons or oxygenates. The unique features of carbon materials in dispersing metal nanoparticles, heteroatom doping, surface modification, and building special nanoarchitectures are highlighted. The key factors that control the reaction course and the reaction mechanism are discussed to gain insights for the rational design of efficient carbon-supported catalysts for syngas conversions. The challenges and future opportunities in developing functionalized carbon materials for syngas conversions are briefly analyzed.

In Situ Active Site for CO Activation in Fe-Catalyzed Fischer-Tropsch Synthesis from Machine Learning

In situ-formed iron carbides (FeC_x) are the key components responsible for Fischer-Tropsch synthesis (FTS, CO + H₂ → long-chain hydrocarbons) on Fe-based catalysts in industry. The true active site is, however, highly controversial despite more than a century of study, which is largely due to the combined complexity in both FeC_x structures and mechanism of CO hydrogenation. Herein powered by machine learning simulation, millions of structure candidates for FeC_x bulk and surfaces are explored under FTS conditions, which leads to resolving the active site for CO activation. This is achieved without a priori input from experiment by first constructing the thermodynamics convex hull of bulk phases, followed by identifying the low surface energy surfaces and evaluating the adsorption ability of CO and H, and finally determining the lowest energy reaction pathway of CO activation. Rich information on FeC_x structures and CO hydrogenation pathways is gleaned: (i) Fe₅C₂, Fe₇C₃, and Fe₂C are the three stable bulk phases under FTS in producing olefins, where Fe₇C₃ and Fe₂C have multiple energetically nearly degenerate bulk crystal phases; (ii) only three low surface energy surfaces of these bulk phases, namely, χ-Fe₅C₂(510), χ-Fe₅C₂(111), and η-Fe₂C(111), expose the Fe sites that can adsorb H atoms exothermically, where the surface Fe:C ratio is 2, 1.75, and 2, respectively; (iii) CO activation via direct dissociation can occur at the surface C vacancies (e.g., with a barrier of 1.1 eV) that are created dynamically via hydrogenation. These atomic-level understandings facilitate the building of the structure-activity correlation and designing better FT catalysts.

Biosugarcane-based carbon support for high-performance iron-based Fischer-Tropsch synthesis

Exploiting new carbon supports with adjustable metal-support interaction and low price is of prime importance to realize the maximum active iron efficiency and industrial-scale application of Fe-based catalysts for Fischer-Tropsch synthesis (FTS). Herein, a simple, tunable, and scalable biochar support derived from the sugarcane bagasse was successfully prepared and was first used for FTS. The metal-support interaction was precisely controlled by functional groups of biosugarcane-based carbon material and different iron species sizes. All catalysts synthesized displayed high activities, and the iron-time-yield of Fe₄/C_bio even reached 1,198.9 μmol g_Fe⁻¹ s⁻¹. This performance was due to the unique structure and characteristics of the biosugarcane-based carbon support, which possessed abundant C−O, C=O (η¹(O) and η²(C, O)) functional groups, thus endowing the moderate metal-support interaction, high dispersion of active iron species, more active ε-Fe₂C phase, and, most importantly, a high proportion of Fe_xC/Fe_surf, facilitating the maximum iron efficiency and intrinsic activity of the catalyst.

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A kind of carbon support, derived from the sugarcane bagasse, is prepared

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This biochar catalyst reaches an excellent FTY value in Fischer-Tropsch synthesis

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Functional groups and Fe species sizes regulate metal-support interactions

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Superior performance is due to abundant functional groups and ε-Fe₂C