Kinetics of non-oxidative propane dehydrogenation on Cr2O3 and the nature of catalyst deactivation from first-principles simulations

Advanced metal oxide catalysts for propane dehydrogenation: from design strategy to dehydrogenation performance

Propane dehydrogenation (PDH) technology has been considered an important breakthrough to cope with the ever-increasing demand for propylene. Developing high-performance non-noble metal catalysts has emerged as an effective approach for replacing the currently used commercial Pt- and Cr-based catalysts with high cost and toxicity. Metal oxides have attracted much attention as PDH catalysts due to their high C-H activity, abundant active sites, and desirable dehydrogenation pathways. Regulating the supports and active sites through the rational design of structure and composition provides a new promising platform to improve the dehydrogenation activity and stability of metal oxide catalysts. This review systematically summarizes the catalytic mechanism of PDH. The rational design of metal oxide catalysts with suitable supports and precisely modulated active sites is described with their catalytic performances. In addition, the important roles played by reaction conditions to promote PDH processes are discussed. Furthermore, combined with well-developed advanced characterization methods, the in-depth exploration of the metal oxide-based PDH catalysts is highlighted. Finally, some perspectives for metal oxide-based PDH catalysts are concisely proposed to achieve their future innovations and industrialization.

Highly Stable Propane Dehydrogenation on a Self-Supporting Single-Component Zn2SiO4 Catalyst

Current industrial propane dehydrogenation (PDH) processes predominantly use either toxic Cr-based or expensive Pt-based catalysts, necessitating urgent exploration for alternatives. Herein, we present Zn2SiO4, an easily prepared, cost-effective material, as a highly efficient and stable catalyst for PDH. Uniquely, Zn2SiO4 nanocrystals do not require dispersion on support materials, commonly needed for catalytic active oxide clusters, but function as a self-supporting catalyst instead. During the reaction's induction period, surface Zn species on the Zn2SiO4 crystal reduce to coordinately unsaturated ZnOx single sites, serving as highly active catalytic centers. The Zn2SiO4 catalyst demonstrates a stable performance over 200 hours of PDH operation at 550 °C. We further find that introducing a minuscule amount of CO2 into the propane feed significantly extends the catalyst lifespan to over 2000 hours. This enhancement arises from the special role of CO2 in facilitating the removal of strongly adsorbed H*, preventing the complete reduction of ZnOx. After prolonged reaction, the activity of Zn2SiO4 can be fully restored by etching the surface layer to expose fresh Zn species, available throughout the crystals. The combination of CO2introduction and catalytic site regeneration strategies is expected to enable a year-long PDH operation using a single batch of Zn2SiO4 catalyst.

Anionic oxyl radical formed on CrVI-oxo anchored on the defect site of the UiO-66 node facilitates methane to methanol conversion

The direct conversion of methane to methanol has attracted increasing interest due to abundant and low-cost natural gas resources. Herein, by anchoring Cr-oxo/-oxyhydroxides on UiO-66 metal-organic frameworks, we demonstrate that reactive anionic oxyl radicals can be formed by controlling the coordination environment based on the results of density functional theory calculations. The anionic oxyl radicals produced at the completely oxidized CrVI site acted as the active species for facile methane activation. The thermodynamically stable CrVI-oxo/-oxyhydroxides with the anionic oxyl radicals catalyze the activation of the methane C-H bond through a homolytic mechanism. An analysis of the results showed that the catalytic performance of the active oxyl species correlates with the reaction energy of methane activation and H adsorption energies. Following methanol formation, N2O can regenerate the active sites on the most stable CrVI oxyhydroxides, i.e., the Cr(O)4Hf species. The present study demonstrated that the anionic oxyl radicals formed on the anchored CrVI oxyhydroxides by tuning the coordination environment enabled facile methane activation and facilitated methanol production.

Enhancing catalytic activity of Cr2O3 in CO2-assisted propane dehydrogenation with effective dopant engineering: a DFT-based microkinetic simulation

Using CO2 as a mild oxidizing agent in propane dehydrogenation (PDH) presents an attractive pathway for the generation of propene while maintaining high selectivity. Cr2O3 is one of the most important catalysts used for the CO2-assisted PDH process. In this study, the doping of Cr2O3 with single atoms such as Ge, Ir, Ni, Sn, Zn, and Zr was used for the PDH process. The introduction of dopants significantly modifies the electronic structure of pristine Cr2O3, leading to substantial alterations in its catalytic capabilities. The dehydrogenation reactions were explored both in the absence and presence of CO2. The addition of CO2 introduces two distinct pathways for PDH. On physisorbed CO2 surfaces, Ge and Ni-Cr2O3 enhance dehydrogenation. On the dissociated surface, the CO* and O* species actively participate in the reaction. All doped surfaces exhibit low energy barriers for dehydrogenation, except undoped Cr2O3 on dissociated CO2 surfaces. The Ni-Cr2O3 surface emerges as the most active surface for dehydrogenation of propane in all scenarios. Additionally, the catalytic surface is re-oxidized through H2 release, and doped surfaces facilitate coke removal via the reverse Boudouard reaction more efficiently than undoped Cr2O3. Microkinetics simulations identify the removal of the first H-atom as the rate-determining step. CO2 reduces the apparent activation energy, directly impacting C3H8 conversion and C3H6 formation. This study offers a decisive description of Cr2O3 modification for the CO2-assisted PDH process.

Heterogeneous Pt-catalyzed transfer dehydrogenation of long-chain alkanes with ethylene

The dehydrogenation of long-chain alkanes to olefins and alkylaromatics is a challenging endothermic reaction, typically requiring harsh conditions which can lead to low selectivity and coking. More favorable thermodynamics can be achieved by using a hydrogen acceptor, such as ethylene. In this work, the potential of heterogeneous platinum catalysts for the transfer dehydrogenation of long-chain alkanes is investigated, using ethylene as a convenient hydrogen acceptor. Pt/C and Pt-Sn/C catalysts were prepared via a simple polyol method and characterized with CO pulse chemisorption, HAADF-STEM, and EDX measurements. Conversion of ethylene was monitored via gas-phase FTIR, and distribution of liquid products was analyzed via GC-FID, GC-MS, and 1H-NMR. Compared to unpromoted Pt/C, Sn-promoted catalysts show lower initial reaction rates, but better resistance to catalyst deactivation, while increasing selectivity towards alkylaromatics. Both reaction products and ethylene were found to inhibit the reaction significantly. At 250 °C for 22 h, TON up to 28 and 86 mol per mol Pt were obtained for Pt/C and PtSn2/C, respectively, with olefin selectivities of 94% and 53%. The remaining products were mainly unbranched alkylaromatics. These findings show the potential of simple heterogeneous catalysts in alkane transfer dehydrogenation, for the preparation of valuable olefins and alkylaromatics, or as an essential step in various tandem reactions.

Iterative multiscale and multi-physics computations for operando catalyst nanostructure elucidation and kinetic modeling

Modern heterogeneous catalysis has benefitted immensely from computational predictions of catalyst structure and its evolution under reaction conditions, first-principles mechanistic investigations, and detailed kinetic modeling, which are rungs on a multiscale workflow. Establishing connections across these rungs and integration with experiments have been challenging. Here, operando catalyst structure prediction techniques using density functional theory simulations and ab initio thermodynamics calculations, molecular dynamics, and machine learning techniques are presented. Surface structure characterization by computational spectroscopic and machine learning techniques is then discussed. Hierarchical approaches in kinetic parameter estimation involving semi-empirical, data-driven, and first-principles calculations and detailed kinetic modeling via mean-field microkinetic modeling and kinetic Monte Carlo simulations are discussed along with methods and the need for uncertainty quantification. With these as the background, this article proposes a bottom-up hierarchical and closed loop modeling framework incorporating consistency checks and iterative refinements at each level and across levels.

Ethane Dehydrogenation over the Core-Shell Pt-Based Alloy Catalysts: Driven by Engineering the Shell Composition and Thickness

Pt-based catalysts as the commercial catalysts in ethane dehydrogenation (EDH) face one of the main challenges of realizing the balance between coke formation and catalytic activity. In this work, a strategy to drive the catalytic performance of EDH on Pt-Sn alloy catalysts is proposed by rationally engineering the shell surface structure and thickness of core-shell Pt@Pt₃Sn and Pt₃Sn@Pt catalysts from a theoretical perspective. Eight types of Pt@Pt₃Sn and Pt₃Sn@Pt catalysts with different Pt and Pt₃Sn shell thicknesses are considered and compared with the industrially used Pt and Pt₃Sn catalysts. Density functional theory (DFT) calculations completely describe the reaction network of EDH, including the side reactions of deep dehydrogenation and C-C bond cracking. Kinetic Monte Carlo (kMC) simulations reveal the influences of the catalyst surface structure, experimentally related temperatures, and reactant partial pressures. The results show that CHCH* is the main precursor for coke formation, and Pt@Pt₃Sn catalysts generally have higher C₂H₄(g) activity and lower selectivity compared to those of Pt₃Sn@Pt catalysts, which is attributed to the unique surface geometrical and electronic properties. 1Pt₃Sn@4Pt and 1Pt@4Pt₃Sn are screened out as catalysts exhibiting excellent performance; especially, the 1Pt₃Sn@4Pt catalyst has much higher C₂H₄(g) activity and 100% C₂H₄(g) selectivity compared to those of 1Pt@4Pt₃Sn and the widely used Pt and Pt₃Sn catalysts. The two descriptors C₂H₅* adsorption energy and reaction energy of its dehydrogenation to C₂H₄* are proposed to qualitatively evaluate the C₂H₄(g) selectivity and activity, respectively. This work facilitates a valuable exploration for optimizing the catalytic performance of core-shell Pt-based catalysts in EDH and reveals the great importance of the fine control of the catalyst shell surface structure and thickness.

In Situ Generated Boron Peroxo as Mild Oxidant in Propane Oxidative Dehydrogenation Revealed by Density Functional Theory Study

Boron-based materials catalyzing oxidative dehydrogenation is emerging as a promising protocol for efficient conversion of light alkanes to olefins, while the origin of its remarkable selectivity remains unclear. By means of density functional theory calculations, this work addresses the crucial role of boron peroxo as the mild oxidant in propane ODH: (1) Surface boron peroxo species can be generated in situ in the presence of peroxo species, preferably at the >B-O-B< sites of the zigzag edge, and show high activity to dehydrogenate propane (ΔG^⧧ = 13.5 kcal/mol, ΔG = 8.9 kcal/mol). (2) The >B-O-O· site shows high discriminability of secondary H over primary H of the propane molecule, leading to significantly higher yield of iso-propyl (CH₃ĊHCH₃) than n-propyl (CH₃CH₂ĊH₂); thus, propene formation is favored over deep oxidation. This provides physical insights into the origin of the remarkable olefin selectivity in the boron-containing ODH catalytic systems.

Non-Oxidative Propane Dehydrogenation on CrOx-ZrO2-SiO2 Catalyst Prepared by One-Pot Template-Assisted Method

A series of CrO_x-ZrO₂-SiO₂ (CrZrSi) catalysts was prepared by a "one-pot" template-assisted evaporation-induced self-assembly process. The chromium content varied from 4 to 9 wt.% assuming Cr₂O₃ stoichiometry. The catalysts were characterized by XRD, SEM-EDX, temperature-programmed reduction (TPR-H₂), Raman spectroscopy, and X-ray photoelectron spectroscopy. The catalysts were tested in non-oxidative propane dehydrogenation at 500-600 °C. The evolution of active sites under the reaction conditions was investigated by reductive treatment of the catalysts with H₂. The catalyst with the lowest Cr loading initially contained amorphous Cr³⁺ and dispersed Cr⁶⁺ species. The latter reduced under reaction conditions forming Cr³⁺ oxide species with low activity in propane dehydrogenation. The catalysts with higher Cr loadings initially contained highly dispersed Cr³⁺ species stable under the reaction conditions and responsible for high catalyst activity. Silica acted both as a textural promoter that increased the specific surface area of the catalysts and as a stabilizer that inhibited crystallization of Cr₂O₃ and ZrO₂ and provided the formation of coordinatively unsaturated Zr⁴⁺ centers. The optimal combination of Cr³⁺ species and coordinatively unsaturated Zr⁴⁺ centers was achieved in the catalyst with the highest Cr loading. This catalyst showed the highest efficiency.

A critical evaluation of the catalytic role of CO2 in propane dehydrogenation catalyzed by chromium oxide from a DFT-based microkinetic simulation

Propane dehydrogenation under CO₂ is an important catalytic route to obtain propene with a good balance between selectivity and stability. However, a precise description of the catalytic role of CO₂ in propane dehydrogenation is still absent. In this work, we focus on the elucidation of the role of CO₂ by using DFT-based microkinetic simulation. The influence of CO₂ is categorized as direct and indirect effects. It was found that the chemisorbed CO₂ can directly abstract hydrogen from propane and propyl with a comparable barrier to the counterpart at the surface oxygen site. On the other hand, the dissociation of CO₂ yields active surface species of CO* and O* which are actively involved in the removal of surface hydroxyls. It is found that the TOFs of both propane conversion and propene formation are significantly increased with the presence of CO₂, which is explained by the reduced apparent activation energy. The primary hydrogen abstraction is identified to be the most influential step from the DRC analysis. The main effects of CO₂ are concluded to be removing hydrogen and restoring oxygen vacancies from reaction pathway analysis.

Kinetic Monte Carlo simulations for heterogeneous catalysis: Fundamentals, current status, and challenges

Kinetic Monte Carlo (KMC) simulations in combination with first-principles (1p)-based calculations are rapidly becoming the gold-standard computational framework for bridging the gap between the wide range of length scales and time scales over which heterogeneous catalysis unfolds. 1p-KMC simulations provide accurate insights into reactions over surfaces, a vital step toward the rational design of novel catalysts. In this Perspective, we briefly outline basic principles, computational challenges, successful applications, as well as future directions and opportunities of this promising and ever more popular kinetic modeling approach.

One-step conversion of lignin-derived alkylphenols to light arenes by co-breaking of C–O and C–C bonds

The selectivity for light arenes, including benzene and toluene, in the conversion of 4-ethylphenol reaches 55.7% with 84.0% selectivity for arenes.

Propane to olefins tandem catalysis: a selective route towards light olefins production

On-purpose synthetic routes for propylene production have emerged in the last couple of decades in response to the increasing demand for plastics and a shift to shale gas feedstocks for ethylene production. Propane dehydrogenation (PDH), an efficient and selective route to produce propylene, saw booming investments to fill the so-called propylene gap. In the coming years, however, a fluctuating light olefins market will call for flexibility in end-product of PDH plants. This can be achieved by combining PDH with propylene metathesis in a single step, propane to olefins (PTO), which allows production of mixtures of propylene, ethylene and butenes, which are important chemical building blocks for a.o. thermoplastics. The metathesis technology introduced by Phillips in the 1960s and mostly operated in reverse to produce propylene, is thus undergoing a renaissance of scientific and technological interest in the context of the PTO reaction. In this review, we will describe the state-of-the-art of PDH, propylene metathesis and PTO reactions, highlighting the open challenges and opportunities in the field. While the separate PDH and metathesis reactions have been extensively studied in the literature, understanding the whole PTO tandem-catalysis system will require new efforts in theoretical modelling and operando spectroscopy experiments, to gain mechanistic insights into the combined reactions and finally improve catalytic selectivity and stability for on-purpose olefins production.

Effect of Surface Oxidation on Oxidative Propane Dehydrogenation over Chromia: An Ab Initio Multiscale Kinetic Study

An increasingly utilized way for the production of propene is propane dehydrogenation. The reaction presents an alternative to conventional processes based on petroleum resources. In this work, we investigate theoretically how Cr₂O₃ catalyzes this reaction in oxidative and reducing environments. Although previous studies showed that the reduced catalyst is selective for the non-oxidative dehydrogenation of propane, real operating conditions are oxidative. Herein, we use multiscale modeling to investigate the difference between the oxidized and reduced catalyst and their performance. The complete reaction pathway for propane dehydrogenation, including C-C cracking, formation of side products (propyne, ethane, ethylene, acetylene, and methane), and catalyst coking on oxidized and reduced surfaces of α-Cr₂O₃(0001), is calculated using density functional theory with the Hubbard correction. Parameters describing adsorption, desorption, and surface reactions are used in a kinetic Monte Carlo simulation, which employed industrially relevant conditions (700-900 K, pressures up to 2 bar, and varying oxidants: N₂O, O₂, and none). We observe that over the reduced surface, propene and hydrogen form with high selectivity. When oxidants are used, the surface is oxidized, which changes the reaction mechanism and kinetics. During a much faster reaction, H₂O forms as a coproduct in a Mars-van Krevelen cycle. Additionally, CO₂ is also formed, which represents waste and adversely affects the selectivity. It is shown that the oxidized surface is much more active but prone to the formation of CO₂, while the reduced surface is less active but highly selective toward propene. Moreover, the effect of the oxidant used is investigated, showing that N₂O is preferred to O₂ due to higher selectivity and less catalyst coking. We show that there exists an optimum degree of surface oxidation, where the yield of propene is maximized. The coke, which forms during the reaction, can be burnt away as CO₂ with oxygen.

Process Intensification of the Propane Dehydrogenation Considering Coke Formation, Catalyst Deactivation and Regeneration—Transient Modelling and Analysis of a Heat-Integrated Membrane Reactor

A heat-integrated packed-bed membrane reactor is studied based on detailed, transient 2D models for coupling oxidative and thermal propane dehydrogenation in one apparatus. The reactor is structured in two telescoped reaction zones to figure out the potential of mass and heat integration between the exothermic oxidative propane dehydrogenation (ODH) in the shell side, including membrane-assisted oxygen dosing and the endothermic, high selective thermal propane dehydrogenation (TDH) in the inner core. The developing complex concentration, temperature and velocity fields are studied, taking into account simultaneous coke growth corresponding with a loss of catalyst activity. Furthermore, the catalyst regeneration was included in the simulation in order to perform an analysis of a periodic operating system of deactivation and regeneration periods. The coupling of the two reaction chambers in a new type of membrane reactor offers potential at oxygen shortage and significantly improves the achievable propene yield in comparison with fixed bed and well-established membrane reactors in the distributor configuration without inner mass and heat integration. The methods developed allow an overall process optimization with respect to maximum spacetime yield as a function of production and regeneration times.

C-H bond activation in light alkanes: a theoretical perspective

Alkanes are the major constituents of natural gas and crude oil, the feedstocks for the chemical industry. The efficient and selective activation of C-H bonds can convert abundant and low-cost hydrocarbon feedstocks into value-added products. Due to the increasing global demand for light alkenes and their corresponding polymers as well as synthesis gas and hydrogen production, C-H bond activation of light alkanes has attracted widespread attention. A theoretical understanding of C-H bond activation in light hydrocarbons via density functional theory (DFT) and microkinetic modeling provides a feasible approach to gain insight into the process and guidelines for designing more efficient catalysts to promote light alkane transformation. This review describes the recent progress in computational catalysis that has addressed the C-H bond activation of light alkanes. We start with direct and oxidative C-H bond activation of methane, with emphasis placed on kinetic and mechanistic insights obtained from DFT assisted microkinetic analysis into steam and dry reforming, and the partial oxidation dependence on metal/oxide surfaces and nanoparticle size. Direct and oxidative activation of the C-H bond of ethane and propane on various metal and oxide surfaces are subsequently reviewed, including the elucidation of active sites, intriguing mechanisms, microkinetic modeling, and electronic features of the ethane and propane conversion processes with a focus on suppressing the side reaction and coke formation. The main target of this review is to give fundamental insight into C-H bond activation of light alkanes, which can provide useful guidance for the optimization of catalysts in future research.

First-Principles-Based Multiscale Modelling of Nonoxidative Butane Dehydrogenation on Cr2O3(0001)

Propane (C3H8) and butane (C4H10) are short straight-chain alkane molecules that are difficult to convert catalytically. Analogous to propane, butane can be dehydrogenated to butenes (also known as butylenes) or butadiene, which are used industrially as raw materials when synthesizing various chemicals (plastics, rubbers, etc.). In this study, we present results of detailed first-principles-based multiscale modelling of butane dehydrogenation, consisting of three size- and time-scales. The reaction is modelled over Cr2O3(0001) chromium oxide, which is commonly used in the industrial setting. A complete 108-step reaction pathway of butane (C4H10) dehydrogenation was studied, yielding 1-butene (CH2CHCH2CH3) and 2-butene (CH3CHCHCH3), 1-butyne (CHCCH2CH3) and 2-butyne (CH3CCCH3), butadiene (CH2CHCHCH2), butenyne (CH2CHCCH), and ultimately butadiyne (CHCCCH). We include cracking and coking reactions (yielding C1, C2, and C3 hydrocarbons) in the model to provide a thorough description of catalyst deactivation as a function of the temperature and time. Density functional theory calculations with the Hubbard U model were used to study the reaction on the atomistic scale, resulting in the complete energetics and first-principles kinetic parameters for the dehydrogenation reaction. They were cast in a kinetic model using mean-field microkinetics and kinetic Monte Carlo simulations. The former was used to obtain gas equilibrium conditions in the steady-state regime, which were fed in the latter to provide accurate surface kinetics. A full reactor simulation was used to account for the macroscopic properties of the catalytic particles: their loading, specific surface area, and density and reactor parameters: size, design, and feed gas flow. With this approach, we obtained first-principles estimates of the catalytic conversion, selectivity to products, and time dependence of the catalyst activity, which can be paralleled to experimental data. We show that 2-butene is the most abundant product of dehydrogenation, with selectivity above 90% and turn-over frequency above 10-3 s-1 at T = 900 K. Butane conversion is below 5% at such low temperature, but rises above 40% at T > 1100 K. Activity starts to drop after ∼6 h because of surface poisoning with carbon. We conclude that the dehydrogenation of butane is a viable alternative to conventional olefin production processes.

Ab Initio Multiscale Process Modeling of Ethane, Propane and Butane Dehydrogenation Reactions: A Review

Olefins are among the most important structural building blocks for a plethora of chemical reaction products, including petrochemicals, biomaterials and pharmaceuticals. An ever-increasing economic demand has urged scientists, engineers and industry to develop novel technical methods for the dehydrogenation of parent alkane molecules. In particular, the catalysis over precious metal or metal oxide catalysts has been put forward as an alternative way route to thermal-, steam- and fluid catalytic cracking (FCC). Multiscale system modeling as a tool to theoretically understand processes has in the past decade period evolved from a rudimentary measurement-complementing approach to a useful engineering environment. Not only can it predict various experimentally obtained parameters, such as conversion, activity, and selectivity, but it can help us to simulate trends, when changing applicative operating conditions, such as surface gas temperature or pressure, or even support us in the search for the type of materials, their geometrical properties and phases for a better functional performance. An overview of the current set state of the art for saturated organic short chain hydrocarbons (ethane, propane and butane) is presented. Studies that combine at least two different dimensional scales, ranging from atomistic-, bridging across mechanistic mesoscale kinetics, towards reactor- or macroscale, are focused on. Insights considering reactivity are compared.