Coke Formation during Propane Dehydrogenation over Ga-Rh Supported Catalytically Active Liquid Metal Solutions

Impact of Catalysis-Relevant Oxidation and Annealing Treatments on Nanostructured GaRh Alloys

In this study, we examine the surface-derived electronic and chemical structures of nanostructured GaRh alloys as a model system for supported catalytically active liquid metal solutions (SCALMS), a novel catalyst candidate for dehydrogenation reactions that are important for the petrochemical and hydrogen energy industry. It is reported that under ambient conditions, SCALMS tends to form a gallium oxide shell, which can be removed by an activation treatment at elevated temperatures and hydrogen flow to enhance the catalytic reactivity. We prepared a 7 at. % Rh containing the GaRh sample and interrogated the evolution of the surface chemical and electronic structure by photoelectron spectroscopy (complemented by scanning electron microscopy) upon performing surface oxidation and (activation treatment mimicking) annealing treatments in ultrahigh vacuum conditions. The initially pronounced Rh 4d and Fermi level-derived states in the valence band spectra disappear upon oxidation (due to formation of a GaOx shell) but reemerge upon annealing, especially for temperatures of 600 °C and above, i.e., when the GaOx shell is efficiently being removed and the Ga matrix is expected to be liquid. At the same temperature, new spectroscopic features at both the high and low binding energy sides of the Rh 3d5/2 spectra are observed, which we attribute to new GaRh species with depleted and enriched Rh contents, respectively. A liquefied and GaOx-free surface is also expected for GaRh SCALMS at reaction conditions, and thus the revealed high-temperature properties of the GaRh alloy provide insights about respective catalysts at work.

Supraparticles on beads for supported catalytically active liquid metal solutions - the SCALMS suprabead concept

A novel GaPt-based supported catalytically active liquid metal solution (SCALMS) material is developed by exploiting the suprabead concept: Supraparticles, i.e. micrometer-sized particles composed of nanoparticles assembled by spray-drying, are bonded to millimeter-sized beads. The suprabeads combine macroscale size with catalytic properties of nanoscale GaPt particles entrapped in their silica framework.

Dry reforming of methane over gallium-based supported catalytically active liquid metal solutions

Gallium-rich supported catalytically active liquid metal solutions (SCALMS) were recently introduced as a new way towards heterogeneous single atom catalysis. SCALMS were demonstrated to exhibit a certain resistance against coking during the dehydrogenation of alkanes using Ga-rich alloys of noble metals. Here, the conceptual catalytic application of SCALMS in dry reforming of methane (DRM) is tested with non-noble metal (Co, Cu, Fe, Ni) atoms in the gallium-rich liquid alloy. This study introduces SCALMS to high-temperature applications and an oxidative reaction environment. Most catalysts were shown to undergo severe oxidation during DRM, while Ga-Ni SCALMS retained a certain level of activity. This observation is explained by a kinetically controlled redox process, namely oxidation to gallium oxide species and re-reduction via H2 activation over Ni. Consequentially, this redox process can be shifted to the metallic side when using increasing concentrations of Ni in Ga, which strongly suppresses coke formation. Density-functional theory (DFT) based ab initio molecular dynamics (AIMD) simulations were performed to confirm the increased availability of Ni at the liquid alloy-gas interface. However, leaching of gallium via the formation of volatile oxidic species during the hypothesised redox cycles was identified indicating a critical instability of Ga-Ni SCALMS for prolonged test durations.

Unravelling the Surface Oxidation-Induced Evolution of the Electronic Structure of Gallium

Gallium is widely used in liquid metal catalyst fabrication, and its oxidized species is a well-known dielectric material. In the past decades, these two species have been well studied separately. However, the surface oxide layer-induced impact on the chemical and electronic structure of (liquid) gallium is still mostly unclear because of the extreme fast formation of thermodynamically stable surface Ga2O3. In this study, we used a combination of direct and inverse photoemission complemented by scanning electron microscopy to examine the surface properties of Ga and Ga oxide (on a SiOx/Si support) and the evolution of the surface structure upon stepwise oxidation and subsequent reduction at an elevated temperature. We find oxidation time-dependent self-limited formation of a substoichiometric Ga2O3-δ surface layer on the Ga nanoparticles. The valence band maximum (conduction band minimum) for this Ga2O3-δ is located at -3.8 (±0.1) eV [1.4 (±0.2) eV] with respect to the Fermi level, resulting in an electronic surface band gap of 5.2 (±0.2) eV. Upon annealing in ultrahigh vacuum conditions, the Ga2O3-δ surface layer can efficiently be removed when using temperatures of 600 °C and higher. This study reveals how the surface properties of Ga nanoparticles are influenced by stepwise oxidation-reduction, providing detailed insights that will benefit the optimization of this material class for different applications.

Ga-Pt supported catalytically active liquid metal solutions (SCALMS) prepared by ultrasonication - influence of synthesis conditions on n-heptane dehydrogenation performance

Supported catalytically active liquid metal solution (SCALMS) materials represent a recently developed class of heterogeneous catalysts, where the catalytic reaction takes place at the highly dynamic interface of supported liquid alloys. Ga nuggets were dispersed into nano-droplets in propan-2-ol using ultrasonication followed by the addition of Pt in a galvanic displacement reaction - either directly into the Ga/propan-2-ol dispersion (in situ) or consecutively onto the supported Ga droplets (ex situ). The in situ galvanic displacement reaction between Ga and Pt was studied in three different reaction media, namely propan-2-ol, water, and 20 vol% water containing propan-2-ol. TEM investigations reveal that the Ga-Pt reaction in propan-2-ol resulted in the formation of Pt aggregates on top of Ga nano-droplets. In the water/propan-2-ol mixture, the desired incorporation of Pt into the Ga matrix was achieved. The ex situ prepared Ga-Pt SCALMS were tested in n-heptane dehydrogenation. Ga-Pt SCALMS synthesized in pure alcoholic solution showed equal dehydrogenation and cracking activity. Ga-Pt SCALMS prepared in pure water, in contrast, showed mainly cracking activity due to oxidation of Ga droplets. The Ga-Pt SCALMS material prepared in water/propan-2-ol resulted in high activity, n-heptene selectivity of 63%, and only low cracking tendency. This can be attributed to the supported liquid Ga-Pt alloy where Pt atoms are present in the liquid Ga matrix at the highly dynamic catalytic interface.

Ga-Ni supported catalytically active liquid metal solutions (SCALMS) for selective ethylene oligomerization

Non-precious metal supported catalytically active liquid metal solutions exhibit attractive performance in ethylene oligomerization. It is found for the Ga-Ni system on silica that the performance depends strongly on the applied Ga/Ni ratio. Ga-rich systems forming liquid alloys exhibit a far higher Ni-based catalytic activity than solid intermetallic compounds or Ni nanoparticles.

GaPt Supported Catalytically Active Liquid Metal Solution Catalysis for Propane Dehydrogenation-Support Influence and Coking Studies

Supported catalytically active liquid metal solutions (SCALMS) of Pt in Ga (2 at.-% Pt) were studied in the temperature range of 500 to 600 °C for propane dehydrogenation. A facile synthesis procedure using ultrasonication was implemented and compared to a previously reported organo-chemical route for gallium deposition. The procedure was applied to synthesize GaPt-SCALMS catalyst on silica (SiO₂), alumina (Al₂O₃), and silicon carbide (SiC) to investigate the effect of the support material on the catalytic performance. The SiC-based SCALMS catalyst showed the highest activity, while SiO₂-based SCALMS showed the highest stability and lowest cracking tendency at higher temperatures. The selectivity toward propene for the SiO₂-based catalyst remained above 93% at 600 °C. The catalysts were analyzed for coke content after use by temperature-programmed oxidation (TPO) and Raman spectroscopy. While the SiC- and SiO₂-supported SCALMS systems showed hardly any coke formation, the Al₂O₃-supported systems suffered from pronounced coking. SEM-EDX analyses of the catalysts before and after reaction indicated that no perceivable morphological changes occur during reaction. The SCALMS catalysts under investigation are compared with supported Pt and supported GaPt solid-phase catalyst, and possible deactivation pathways are discussed.

Dehydrogenation of light alkanes to mono-olefins

In the past several decades, light alkane dehydrogenation to mono-olefins, especially propane dehydrogenation to propylene has gained widespread attention and much development in the field of research and commercial application. Under suitable conditions, the supported Pt-Sn and CrO_x catalysts widely used in industry exhibit satisfactory dehydrogenation activity and selectivity. However, the high cost of Pt and the potential environmental problems of CrO_x have driven researchers to improve the coking and sintering resistance of Pt catalysts, and to find new non-noble metal and environment-friendly catalysts. As for the development of the reactor, it should be noted that low operation pressure is beneficial for improving the single-pass conversion, decreasing the amount of unconverted alkane recycled back to the reactor, and reducing the energy consumption of the whole process. Therefore, the research direction of reactor improvement is towards reducing the pressure drop. This review is aimed at introducing the characteristics of the dehydrogenation reaction, the progress made in the development of catalysts and reactors, and a new understanding of reaction mechanism as well as its guiding role in the development of catalyst and reactor.

A Comprehensive Study of Coke Deposits on a Pt-Sn/SBA-16 Catalyst during the Dehydrogenation of Propane

Catalytic propane dehydrogenation is an attractive method to produce propylene while avoiding the issues of its traditional synthesis via naphtha steam cracking of naphtha. In this contribution, a series of Pt-Sn/SBA-16 catalysts were synthesized and evaluated for this purpose. Bimetallic Pt-Sn catalysts were more active than catalysts containing only Pt. The catalyst with the best performance was assessed at different reaction times of 0, 60, 180, and 300 min. The evolution of coke deposits was also studied. Thermogravimetric analysis demonstrated the presence of two types of coke on the catalyst surface at low and high temperature, respectively. Raman results showed an increased coke’s crystal size from 60 to 180 min on stream, and from 180 to 300 min under reaction, Raman suggested a reduction in the crystal size of coke. Also transmission electron microscopy confirmed a more evident agglomeration of metallic particles with reaction times higher than 180 min. These results are consistent with the phenomena called “coke migration” and the cause is often explained by coke movement near the particle to the support; it can also be explained due to sintering of the metallic particle, which we propose as a more suitable explanation.

Metal-based catalysts for the non-oxidative dehydrogenation of light alkanes to light olefins

This review provides an overview of metal-based catalysts, including Pt-, Pd-, Rh- and Ni-based bimetallic catalysts for non-oxidative dehydrogenation of light alkanes to olefins.

Recent progress in heterogeneous metal and metal oxide catalysts for direct dehydrogenation of ethane and propane

Metal and metal oxide catalysts for non-oxidative ethane/propane dehydrogenation are outlined with respect to catalyst synthesis, structure–property relationship and catalytic mechanism.

Capturing spatially resolved kinetic data and coking of Ga–Pt supported catalytically active liquid metal solutions during propane dehydrogenation in situ

Spatially resolved kinetic data of gallium–platinum SCALMS was captured while elucidating the effect of carrier material on coke formation.

Mobility and versatility of the liquid bismuth promoter in the working iron catalysts for light olefin synthesis from syngas

Liquid metals are a new emerging and rapidly growing class of materials and can be considered as efficient promoters and active phases for heterogeneous catalysts for sustainable processes. Because of low cost, high selectivity and flexibility, iron-based catalysts are the catalysts of choice for light olefin synthesis via Fischer-Tropsch reaction. Promotion of iron catalysts supported by carbon nanotubes with bismuth, which is liquid under the reaction conditions, results in a several fold increase in the reaction rate and in a much higher light olefin selectivity. In order to elucidate the spectacular enhancement of the catalytic performance, we conducted extensive in-depth characterization of the bismuth-promoted iron catalysts under the reacting gas and reaction temperatures by a combination of cutting-edge in situ techniques: in situ scanning transmission electron microscopy, near-atmospheric pressure X-ray photoelectron spectroscopy and in situ X-ray adsorption near edge structure. In situ scanning transmission electron microscopy conducted under atmospheric pressure of carbon monoxide at the temperature of catalyst activation showed iron sintering proceeding via the particle migration and coalescence mechanism. Catalyst activation in carbon monoxide and in syngas leads to liquid bismuth metallic species, which readily migrate over the catalyst surface with the formation of larger spherical bismuth droplets and iron-bismuth core-shell structures. In the working catalysts, during Fischer-Tropsch synthesis, metallic bismuth located at the interface of iron species undergoes continuous oxidation and reduction cycles, which facilitate carbon monoxide dissociation and result in the substantial increase in the reaction rate.