Stabilizing the active phase of iron-based Fischer-Tropsch catalysts for lower olefins: mechanism and strategy

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.

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.

High-Dispersive Pd Nanoparticles on Hierarchical N-Doped Carbon Nanocages to Boost Electrochemical CO2 Reduction to Formate at Low Potential

Electrochemical CO2 reduction reaction (CO2 RR) to value-added chemicals/fuels is an effective strategy to achieve the carbon neutral. Palladium is the only metal to selectively produce formate via CO2 RR at near-zero potentials. To reduce cost and improve activity, the high-dispersive Pd nanoparticles on hierarchical N-doped carbon nanocages (Pd/hNCNCs) are constructed by regulating pH in microwave-assisted ethylene glycol reduction. The optimal catalyst exhibits high formate Faradaic efficiency of >95% within -0.05-0.30 V and delivers an ultrahigh formate partial current density of 10.3 mA cm-2 at the low potential of -0.25 V. The high performance of Pd/hNCNCs is attributed to the small size of uniform Pd nanoparticles, the optimized intermediates adsorption/desorption on modified Pd by N-doped support, and the promoted mass/charge transfer kinetics arising from the hierarchical structure of hNCNCs. This study sheds light on the rational design of high-efficient electrocatalysts for advanced energy conversion.

Physical mixing of a catalyst and a hydrophobic polymer promotes CO hydrogenation through dehydration

In many reactions restricted by water, selective removal of water from the reaction system is critical and usually requires a membrane reactor. We found that a simple physical mixture of hydrophobic poly(divinylbenzene) with cobalt-manganese carbide could modulate a local environment of catalysts for rapidly shipping water product in syngas conversion. We were able to shift the water-sorption equilibrium on the catalyst surface, leading to a greater proportion of free surface that in turn raised the rate of syngas conversion by nearly a factor of 2. The carbon monoxide conversion reached 63.5%, and 71.4% of the hydrocarbon products were light olefins at 250°C, outperforming poly(divinylbenzene)-free catalyst under equivalent reaction conditions. The physically mixed CoMn carbide/poly(divinylbenzene) catalyst was durable in the continuous test for 120 hours.

Direct Construction of K-Fe3C@C Nanohybrids Utilizing Waste Biomass of Pomelo Peel as High-Performance Fischer–Tropsch Catalysts

As the only renewable organic carbon source, abundant biomass has long been established and developed to mass-produce functionalized carbon materials. Herein, an extremely facile and green strategy was executed for the first time to in situ construct K-Fe3C@C nanohybrids directly by one-pot carbonizing the pomelo peel impregnated with Fe(NO3)3 solutions. The pyrolytically self-assembled nanohybrids were successfully applied in Fischer–Tropsch synthesis (FTS) and demonstrated high catalytic performance. Accordingly, the optimized K-Fe3C@C catalysts revealed excellent FTS activity (92.6% CO conversion) with highlighted C5+ hydrocarbon selectivity of 61.3% and light olefin (C2-4=) selectivity of 26.0% (olefin/paraffin (O/P) ratio of 6.2). Characterization results further manifest that the high performance was correlated with the in situ formation of the core-shell nanostructure consisting of Fe3C nanoparticles enwrapped by graphitized carbon shells and the intrinsic potassium promoter originated in pomelo peel during high-temperature carbonization. This work provided a facile approach for the low-cost mass-fabrication of high-performance FTS catalysts directly utilizing waste biomass without any chemical pre-treatment or purification.

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.

Unravelling the metal–support interactions in χ-Fe5C2/MgO catalysts for olefin synthesis directly from syngas

The structural and electronic modifications of χ-Fe5C2 by MgO contribute to the high selectivity towards lower olefins and the high catalyst stability.

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.

An Efficient Catalyst Derived from Carboxylated Lignin-Anchored Iron Nanoparticle Compounds for Carbon Monoxide Hydrogenation Application

Catalytic activity and target product selectivity are strongly correlated to the size, crystallographic phase, and morphology of nanoparticles. In this study, waste lignin from paper pulp industry is employed as the carbon source, which is modified with carboxyl groups at the molecular level to facilitate anchoring of metals, and a new type of carbon-based catalyst was obtained after carbonization. As a result, the size of the metal particles is effectively controlled by the chelation between -COO- and Fe3+. Furthermore, Fe/CM-CL with a particle size of 1.5-2.5 nm shows excellent catalytic performance, the conversion of carbon monoxide reaches 82.3%, and the selectivity of methane reaches 73.2%.

Insight into the Fischer–Tropsch mechanism on hcp-Fe7C3 (211) by density functional theory: the roles of surface carbon and vacancies

Iron carbide phases discovered in the spent iron catalysts have proved to be active in the Fischer–Tropsch process. The surface carbon of the iron carbide played a key role in the Fischer–Tropsch mechanism. Since there are two surface carbons, C1 and C2, on the hcp-Fe₇C₃ (211), which are close to each other, their reaction mechanisms would be significant. Hence, the DFT calculations were performed to investigate the Fischer–Tropsch mechanism involving the surface carbon. It was found that the HC¹ + C² pathway was the major C–C coupling reaction pathway with an effective energy barrier of 0.97 eV. Ethane would be the major C₂ product from the HC¹C2 species through the stepwise hydrogenation pathway due to the high adsorption energy of ethylene (1.67 eV). After the desorption process of ethane, the carbon vacancy would form. The carbon vacancy was found to be the CO activation site through the CO direct dissociation pathway and the carbon vacancy would recover. It was concluded that the defect-hcp-Fe₇C₃ (211) is the high active facet of the Fischer–Tropsch synthesis, the carbon vacancy sites are the CO activation sites and the surface carbon sites are the C–C coupling sites. The surface carbons not only act as the chain initiation sites but also act as the chain growth sites in the Fischer–Tropsch mechanism on hcp-Fe₇C₃ (211).

The Fischer–Tropsch mechanism on hcp-Fe₇C₃ (211): the circulation of the surface carbon.

Role of C-Defective Sites in CO Adsorption over ϵ-Fe2 C and η-Fe2 C Fischer-Tropsch Catalysts

Herein, we report the crucial importance of C-defective sites on the CO adsorption over ϵ-Fe₂ C and η-Fe₂ C Fischer-Tropsch catalysts via systematic DFT calculations. The simulated XRD and Wulff construction show the significant differences in their equilibrium shapes and most exposed surfaces. It is observed that the ϵ-Fe₂ C exposes a high proportion (89 %) of facets (1 2 ‾ 1) with similar structure to that of η-Fe₂ C (011) which has been proved to be the active surface of CO activation.

Carbon-Based Nanocages: A New Platform for Advanced Energy Storage and Conversion

Energy storage and conversion play a crucial role in modern energy systems, and the exploration of advanced electrode materials is vital but challenging. Carbon-based nanocages consisting of sp² carbon shells feature a hollow interior cavity with sub-nanometer microchannels across the shells, high specific surface area with a defective outer surface, and tunable electronic structure, much different from the intensively studied nanocarbons such as carbon nanotubes and graphene. These structural and morphological characteristics make carbon-based nanocages a new platform for advanced energy storage and conversion. Up-to-date synthetic strategies of carbon-based nanocages, the utilization of their unique porous structure and morphology for the construction of composites with foreign active species, and their significant applications to the advanced energy storage and conversion are reviewed. Structure-performance correlations are discussed in depth to highlight the contribution of carbon-based nanocages. The research challenges and trends are also envisaged for deepening and extending the study and application of this multifunctional material.

Facile fabrication of porous Fe@C nanohybrids from natural magnetite as excellent Fischer-Tropsch catalysts

Fe-Based catalysts play crucial roles in Fischer-Tropsch synthesis (FTS). Herein, we for the first time demonstrate a facile sol-gel approach using natural magnetite and citric acid to fabricate porous Fe@C nanohybrids as FTS catalysts. Excellent FTS activity and stability were revealed and attributed to the formation of an Fe3C active phase and a core-shell structure. This flexible synthesis strategy clearly highlights the promising application of such materials in FTS.