Overcoming limitations in propane dehydrogenation by codesigning catalyst-membrane systems

Propylene production through propane dehydrogenation (PDH) is endothermic, and high temperatures required to achieve acceptable propane conversions lead to low selectivity and severe carbon-induced deactivation of conventional catalysts. We developed a catalyst-membrane system that removes the hydrogen by-product and can thus achieve propane conversions that exceed equilibrium limits. In this codesigned system, a silica/alumina (SiO2/Al2O3) hollow-fiber hydrogen membrane was packed with a selective platinum-tin (Pt1Sn1/SiO2) PDH catalyst on the tube side with hydrogen diffusing from the tube to the shell side. We demonstrate that the catalyst-membrane system can achieve propane conversions >140% of the nominal equilibrium conversion with a propylene selectivity >98% without deactivation of the system components. We also show that by introducing oxygen on the shell side of the catalyst-membrane system, we can couple the endothermic PDH reaction on the tube side with exothermic hydrogen oxidation on the shell side. This coupling results in higher rates of hydrogen transport, leading to further enhancements in the propane conversion as well as desired thermoneutral system operation.

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.

Flowing-Air-Induced Transformation to Promote the Dispersion of the CrOx Catalyst for Propane Dehydrogenation

Highly dispersed chromium (Cr)-based catalysts are promising candidates for the catalytic dehydrogenation of propane (DHP). However, the easier aggregation of Cr species into crystalline Cr₂O₃ at the high-temperature calcination and reaction process is a big challenge, which severely restricts the improvement of activity and stability of the DHP reaction. Herein, a flowing-air-induced transformation method was first proposed, and the catalytic performance of the prepared Cr/MCM-41 catalysts was found to be significantly improved compared to that of the Cr-based catalyst prepared by the traditional calcination method, even better than that of most of the reported Cr-based catalysts and some noble metal-based catalysts. X-ray absorption spectroscopy and in situ Raman spectroscopy as well as other characterization techniques demonstrated that the in situ calcination in flowing air could not only effectively restrain the conversion of Cr(VI) into Cr(III) but also largely improve the dispersion of Cr species. Furthermore, DHP activity is found to have a positive correlation with the amount of monomeric Cr(VI) species, which is proved to be the precursor of active coordinatively unsaturated Cr sites. Our proposed flowing-air-induced transformation method provides a general strategy for preparing the highly dispersed Cr-based catalysts and other metal oxide materials with varied valence and exhibits potential application prospects in industry.

Propane dehydrogenation: catalyst development, new chemistry, and emerging technologies

This review describes recent advances in the propane dehydrogenation process in terms of emerging technologies, catalyst development and new chemistry.

Insights into Cr/SiO2 catalysts during dehydrogenation of propane: an operando XAS investigation

In situ and operando XAS spectroscopic methods were applied to monitor the variations in the oxidation state and in the local structure of the chromium sites in a 2.0Cr/SiO_2-DHS catalyst during propane dehydrogenation under non-oxidative and different oxidative conditions.

Catalyst characterisation techniques and reaction cells operating at realistic conditions; towards acquisition of kinetically relevant information

Catalyst characterisation techniques and reaction cells operating at realistic conditions; towards acquisition of kinetically relevant information.

Shaping up operando spectroscopy: Raman characterization of a working honeycomb monolith

An operando reactor cell for honeycombs to study the effect of conformation on structure–activity relationships by surface Raman spectroscopy and gas-phase analysis.