Recent advances in application of iron-based catalysts for CO hydrogenation to value-added hydrocarbons

Structure-Induced Iron Carbides for CO2 Hydrogenation into Liquid Fuels

Coal resources, due to their cheapness and high-energy density, are widely used in large quantities, causing greenhouse gas emissions in turn, and thus need to be utilized in a resourceful way to reduce carbon emissions. Herein, we designed an alternative route of value-added utilization using coal-based activated carbon support loaded with Fe nanoparticles for CO2 hydrogenation to liquid fuels. The coal-based derived carbon support with tunable structure, elemental composition, defects, and special surface area controlled by a proposed two-step coking-activation strategy, in which special scale-like or alveolate structures were obtained. It was demonstrated by characterization that the structure and defect of the carbon support affect the carburization behavior of iron species, and then the highest Fe5C2 content was found on FeK@AC-2.0-750 catalyst. The high level of exposure of active χ-Fe5C2 sites presents benign liquid fuel selectivity. In situ diffuse reflectance infrared Fourier transform spectroscopy and DFT calculation further support the improved carbon chain propagation over χ-Fe5C2 rather than θ-Fe3C. Compared with commercial carbon supports, its loaded Fe-based catalyst has a better performance with 29.3% CO2 conversion and 58.8% C5+ selectivity, respectively. These results provide new insights into the development of novel nanocarbons and the efficient utilization of coal-based resources as well as broaden the design of efficient iron-based catalysts for C1 chemistry.

Structure-reactivity relationships in CO2 hydrogenation to C2+ chemicals on Fe-based catalysts

Catalytic conversion of carbon dioxide (CO2) to value-added products represents an important avenue towards achieving carbon neutrality. In this respect, iron (Fe)-based catalysts were recognized as the most promising for the production of C2+ chemicals via the CO2 hydrogenation reaction. However, the complex structural evolution of the Fe catalysts, especially during the reaction, presents significant challenges for establishing the structure-reactivity relationships. In this review, we provide critical analysis of recent in situ and operando studies on the transformation of Fe-based catalysts in the hydrogenation of CO2 to hydrocarbons and alcohols. In particular, the effects of composition, promoters, support, and particle size on reactivity; the role of the catalyst's activation procedure; and the catalyst's evolution under reaction conditions will be addressed.

Understanding and Tuning the Effects of H2O on Catalytic CO and CO2 Hydrogenation

Catalytic COx (CO and CO2) hydrogenation to valued chemicals is one of the promising approaches to address challenges in energy, environment, and climate change. H2O is an inevitable side product in these reactions, where its existence and effect are often ignored. In fact, H2O significantly influences the catalytic active centers, reaction mechanism, and catalytic performance, preventing us from a definitive and deep understanding on the structure-performance relationship of the authentic catalysts. It is necessary, although challenging, to clarify its effect and provide practical strategies to tune the concentration and distribution of H2O to optimize its influence. In this review, we focus on how H2O in COx hydrogenation induces the structural evolution of catalysts and assists in the catalytic processes, as well as efforts to understand the underlying mechanism. We summarize and discuss some representative tuning strategies for realizing the rapid removal or local enrichment of H2O around the catalysts, along with brief techno-economic analysis and life cycle assessment. These fundamental understandings and strategies are further extended to the reactions of CO and CO2 reduction under an external field (light, electricity, and plasma). We also present suggestions and prospects for deciphering and controlling the effect of H2O in practical applications.

Reaction Dynamics of CO2 Hydrogenation on Iron Catalysts Using ReaxFF Molecular Dynamics Simulation

The conversion of CO2 to hydrocarbons using catalysts is a promising route to utilize CO2 and produce more valuable chemicals in a sustainable manner. Recent studies have shown that iron-based catalysts perform well for the hydrogenation of CO2. While the hydrogenation reaction mechanism in the gas phase is straightforward, when catalyzed by iron it has been demonstrated to involve various chemical transformations, and the selectivity and conversion are strongly dependent on the particle size. To further investigate the dependence of the reactivity of iron catalysts on cluster size, we performed reactive molecular dynamics simulations using the ReaxFF force field (ReaxFF-MD) for iron nanoclusters of various sizes in a CO2 and H2-rich environment. We demonstrated that the homogeneous hydrogenation of CO2 was correctly described by this ReaxFF model. The dissociation mechanism of CO2 on the Fe4, Fe16 clusters, and the bcc(100) Fe slab agrees with previous DFT results. The ReaxFF-MD simulations suggest a strong dependence of reactivity on the cluster size, with the Fe4 cluster having the highest reactivity. We show that ReaxFF-MD provides a route to understand reaction mechanisms in these nonequilibrium reactive processes where fast processes and local minima are important.

In Situ Carbon-Confined MoSe2 Catalyst with Heterojunction for Highly Selective CO2 Hydrogenation to Methanol

The synthesis of methanol from CO2 hydrogenation is an effective measure to deal with global climate change and an important route for the chemical fixation of CO2. In this work, carbon-confined MoSe2 (MoSe2@C) catalysts were prepared by in situ pyrolysis using glucose as a carbon source. The physico-chemical properties and catalytic performance of CO2 hydrogenation to yield methanol were compared with MoSe2 and MoSe2/C. The results of the structure characterization showed MoSe2 displayed few layers and a small particle size. Owing to the synergistic effect of the Mo2C-MoSe2 heterojunction and in situ carbon doping, MoSe2@C with a suitable C/Mo mole ratio in the precursor showed excellent catalytic performance in the synthesis of methanol from CO2 hydrogenation. Under the optimal catalyst MoSe2@C-55, the selectivity of methanol reached 93.7% at a 9.7% conversion of CO2 under optimized reaction conditions, and its catalytic performance was maintained without deactivation during a continuous reaction of 100 h. In situ diffuse infrared Fourier transform spectroscopy studies suggested that formate and CO were the key intermediates in CO2 hydrogenation to methanol.

Novel heterogeneous Fe-based catalysts for carbon dioxide hydrogenation to long chain α-olefins-A review

The thermocatalytic conversion of carbon dioxide (CO2) into high value-added chemicals provides a strategy to address the environmental problems caused by excessive carbon emissions and the sustainable production of chemicals. Significant progress has been made in the CO2 hydrogenation to long chain α-olefins, but controlling C-O activation and C-C coupling remains a great challenge. This review focuses on the recent advances in catalyst design concepts for the synthesis of long chain α-olefins from CO2 hydrogenation. We have systematically summarized and analyzed the ingenious design of catalysts, reaction mechanisms, the interaction between active sites and supports, structure-activity relationship, influence of reaction process parameters on catalyst performance, and catalyst stability, as well as the regeneration methods. Meanwhile, the challenges in the development of the long chain α-olefins synthesis from CO2 hydrogenation are proposed, and the future development opportunities are prospected. The aim of this review is to provide a comprehensive perspective on long chain α-olefins synthesis from CO2 hydrogenation to inspire the invention of novel catalysts and accelerate the development of this process.

Synthesis of Liquid Hydrocarbon via Direct Hydrogenation of CO2 over FeCu-Based Bifunctional Catalyst Derived from Layered Double Hydroxides

Here, we report a Na-promoted FeCu-based catalyst with excellent liquid hydrocarbon selectivity and catalytic activity. The physiochemical properties of the catalysts were comprehensively characterized by various characterization techniques. The characterization results indicate that the catalytic performance of the catalysts was closely related to the nature of the metal promoters. The Na-AlFeCu possessed the highest CO2 conversion due to enhanced CO2 adsorption of the catalysts by the introduction of Al species. The introduction of excess Mg promoter led to a strong methanation activity of the catalyst. Mn and Ga promoters exhibited high selectivity for light hydrocarbons due to their inhibition of iron carbides generation, resulting in a lack of chain growth capacity. The Na-ZnFeCu catalyst exhibited the optimal C5+ yield, owing to the fact that the Zn promoter improved the catalytic activity and liquid hydrocarbon selectivity by modulating the surface CO2 adsorption and carbide content. Carbon dioxide (CO2) hydrogenation to liquid fuel is considered a method for the utilization and conversion of CO2, whereas satisfactory activity and selectivity remains a challenge. This method provides a new idea for the catalytic hydrogenation of CO2 and from there the preparation of high-value-added products.

Waste toner-derived porous iron oxide pigments with enhanced catalytic degradation property

'Wealth from Waste' is an emerging concept, since it leads an effective waste treatment and waste recyclability. On the other hand, cost effective production iron oxide (IO) nanomaterials is still needed to develop, owing to their wide applications. Herein, we proposed a simple direct calcination method to prepare porous IO (Fe₃O₄ and Fe₂O₃) nanomaterials from waste toner powder. Characterization techniques reveal that a structural change happened from Fe₃O₄ to γ-Fe₂O₃ and γ-Fe₂O₃ to α-Fe₂O₃ at the calcination temperature of 500 °C and 700 °C respectively. Consequently, optical (band gap) and magnetic parameters of IO samples were significantly varied. The pigment characteristics of the IO samples were evaluated using Commission Internationale de l'Eclairage (CIE) analysis. IO900 sample has shown good brown-red coloration (L* = 43.11, a* = 13.26 and b* = 5.69) and it also exhibited good stability in acidic and basic conditions. Practical applicability of IO pigments were also tested by mixing with plaster of paris (PP) powder. Further, porous IO samples were also used as catalysts in the reductive degradation of methyl orange (MO) dye in presence of excess sodium borohydride (NaBH₄). IO, prepared at 900 °C exhibited ∼99.9% reduction efficiency within 40 min. Recycling experiments indicated that IO900 possess good stability up to seven cycles. The present porous IO samples will become potential in pigment and environmental remediation.

Switchable Tuning CO2 Hydrogenation Selectivity by Encapsulation of the Rh Nanoparticles While Exposing Single Atoms

The switch of CO₂ hydrogenation selectivity from CH₄ to CO over TiO₂ supported Rh catalysts is accomplished via selective encapsulation of Rh nanoparticles while exposing Rh single atoms by high-temperature reduction (HTR) according to their different strong metal-support interaction (SMSI) occurrence conditions, which can be reversed by subsequent oxidation treatment.

Tandem Reactions over Zeolite-Based Catalysts in Syngas Conversion

Syngas conversion can play a vital role in providing energy and chemical supplies while meeting environmental requirements as the world gradually shifts toward a net-zero. While prospects of this process cannot be doubted, there is a lingering challenge in distinct product selectivity over the bulk transitional metal catalysts. To advance research in this respect, composite catalysts comprising traditional metal catalysts and zeolites have been deployed to distinct product selectivity while suppressing side reactions. Zeolites are common but highly efficient materials used in the chemical industry for hydroprocessing. Combining the advantages of zeolites and some transition metal catalysts has promoted the catalytic production of various hydrocarbons (e.g., light olefins, aromatics, and liquid fuels) and oxygenates (e.g., methanol, dimethyl ether, formic acid, and higher alcohols) from syngas. In this outlook, a thorough revelation on recent progress in syngas conversion to various products over metal-zeolite composite catalysts is validated. The strategies adopted to couple the metal species and zeolite material into a composite as well as the consequential morphologies for specific product selectivity are highlighted. The key zeolite descriptors that influence catalytic performance, such as framework topologies, proximity and confinement effects, acidities and cations, pore systems, and particle sizes are discussed to provide a deep understanding of the significance of zeolites in syngas conversion. Finally, an outlook regarding challenges and opportunities for syngas conversion using zeolite-based catalysts to meet emerging energy and environmental demands is also presented.