Retraction of "Hydrogenolysis of Polyethylene and Polypropylene into Propane over Cobalt-Based Catalysts"

[This retracts the article DOI: 10.1021/jacsau.2c00402.].

Economic and Environmental Competitiveness of Ethane-Based Technologies for Vinyl Chloride Synthesis

The synthesis of the vinyl chloride monomer (VCM), employed to manufacture poly(vinyl chloride) (PVC) plastic, primarily relies on oil-derived ethylene, resulting in high costs and carbon footprint. Natural gas-derived ethane in VCM synthesis has long been considered a transformative feedstock to lower emissions and expenses. In this work, we evaluate the environmental potential and economics of recently developed catalytic ethane chlorination technologies for VCM synthesis. We consider the ethylene-based business-as-usual (BAU) route and two different ethane-based processes evaluated at their current development level and their full potential, i.e., ideal conversion and selectivity. All routes are assessed under two temporal scenarios: present (2020) and prospective (2050). Combining process simulation and life cycle assessment (LCA), we find that catalytic ethane chlorination technologies can lower the production cost by 32% at their current development state and by 56% when considering their full potential. Though environmentally disadvantageous in the 2020 scenario, they emerge as more sustainable alternatives to the BAU in the 2050 scenario, reducing the carbon footprint of VCM synthesis by up to 26% at their current state and up to 58% at their full potential. Going beyond VCM synthesis, our results highlight prospective LCA as a powerful tool for assessing the true environmental implications of emerging technologies under more decarbonized future energy scenarios.

Hydrogenolysis of Polyethylene and Polypropylene into Propane over Cobalt-Based Catalysts

The development of technologies to recycle polyethylene (PE) and polypropylene (PP), globally the two most produced polymers, is critical to increase plastic circularity. Here, we show that 5 wt % cobalt supported on ZSM-5 zeolite catalyzes the solvent-free hydrogenolysis of PE and PP into propane with weight-based selectivity in the gas phase over 80 wt % after 20 h at 523 K and 40 bar H2. This catalyst significantly reduces the formation of undesired CH4 (≤5 wt %), a product which is favored when using bulk cobalt oxide or cobalt nanoparticles supported on other carriers (selectivity ≤95 wt %). The superior performance of Co/ZSM-5 is attributed to the stabilization of dispersed oxidic cobalt nanoparticles by the zeolite support, preventing further reduction to metallic species that appear to catalyze CH4 generation. While ZSM-5 is also active for propane formation at 523 K, the presence of Co promotes stability and selectivity. After optimizing the metal loading, it was demonstrated that 10 wt % Co/ZSM-5 can selectively catalyze the hydrogenolysis of low-density PE (LDPE), mixtures of LDPE and PP, as well as postconsumer PE, showcasing the effectiveness of this technology to upcycle realistic plastic waste. Cobalt supported on zeolites FAU, MOR, and BEA were also effective catalysts for C2-C4 hydrocarbon formation and revealed that the framework topology provides a handle to tune gas-phase selectivity.

Ethane-Based Catalytic Process for Vinyl Chloride Manufacture

The use of ethane as a platform molecule for the manufacture of polyvinyl chloride (PVC) is a longstanding challenge, which would allow to reduce the raw material costs and CO₂ emissions to produce this plastic. Herein, we discover that rare earth oxychlorides catalyze in a selective (up to 90 %) and stable (>50 h on stream) manner the reaction of ethane and molecular chlorine into 1,2-dichloroethane, which, upon established cracking, will translate into an order of magnitude higher vinyl chloride productivity compared to ethane oxychlorination technologies. In addition, representative europium oxychloride was supported on suitable carriers and was demonstrated to be selective (up to 90 %) and stable (>40 h on stream) in extrudate form. These findings bring the ethane-based production of PVC one step closer to implementation.

Quantification of Redox Sites during Catalytic Propane Oxychlorination by Operando EPR Spectroscopy

Identification and quantification of redox-active centers at relevant conditions for catalysis is pivotal to understand reaction mechanisms and requires development of advanced operando methods. Herein, we demonstrate operando EPR spectroscopy as an important technique to quantify the oxidation state of representative CrPO₄ and EuOCl catalysts during propane oxychlorination, an attractive route for propylene production. In particular, we show that the space-time-yield of C₃ H₆ correlates with the amount of Cr²⁺ and Eu²⁺ ions generated over the catalysts during reaction. These results provide a powerful strategy to gather quantitative understanding of selective alkane oxidation, which could potentially be extrapolated to other functionalization approaches and operating conditions.

Status and prospects of the decentralised valorisation of natural gas into energy and energy carriers

We critically review the recent advances in process, reactor, and catalyst design that enable process miniaturisation for decentralised natural gas upgrading into electricity, liquefied natural gas, fuels and chemicals.

Operando Photoelectron Photoion Coincidence Spectroscopy Unravels Mechanistic Fingerprints of Propane Activation by Catalytic Oxyhalogenation

Herein, we demonstrate operando photoelectron photoion coincidence (PEPICO) spectroscopy as a pivotal technique for evidencing unprecedented mechanistic insights by isomer-selective radical detection within complex hydrocarbon-functionalization reaction networks, such as those of catalyzed propane oxychlorination and oxybromination. In particular, while the oxychlorination is surface-confined, we show that in oxybromination alkane activation follows a gas-phase reaction mechanism with evolved bromine and bromine radicals, favoring 2-propyl over 1-propyl radical formation, as evidenced by isomer-selective threshold photoelectron analysis. Furthermore, we provide new mechanistic insights into the cracking and coking pathways that are observed in oxybromination. The first entails propargyl radical formation from consecutive hydrogen abstraction of propyl radicals, ultimately yielding benzene. The second originates from C-C bond cleavage in propane to ethyl and methyl radicals, which produce CH₄ and C₂H₄, or undergo chain-growth reactions, forming C₄-C₆ species.

Transformation of titanium carbide into mesoporous titania for catalysed HBr oxidation

TiC oxidises via a combination of spot-oxidation and shrinking core mechanisms, resulting in a mesoporous, high-performance TiO₂–TiC composite for bromine production via catalysed HBr oxidation.

Mechanistic Understanding of Halogen-mediated Catalytic Processes for Selective Natural Gas Functionalization

Development of catalytic technologies enabling the direct functionalization of light alkanes, main components of abundant natural gas, into value-added chemicals and liquid fuels is quite possibly the key strategy to transit from the oil to the renewables era. A cornerstone to meet this great challenge comprises the in-depth understanding of complex reaction mechanisms over dynamic surfaces, allowing to elucidate catalyst design criteria for selective alkane functionalization processes. Prominent examples are the oxybromination of methane into bromomethanes (CH3Br+CH2Br2) and the oxychlorination of ethane into ethylene, which are the two highly selective routes (selectivity ?98.5%) that have been proposed to involve gas-phase pathways or purely surface-driven reactions, respectively. Herein, we review our recent efforts to uncover these complex reaction schemes that combine kinetic analysis with advanced operando characterization techniques, including prompt-gamma activation analysis and photoelectron photoion coincidence spectroscopy, ultimately rationalized by density functional theory calculations. In particular, alkane activation to methyl bromide in oxybromination was found to occur in the gas-phase with evolved bromine and bromine radical species, thus enabling to decouple the formation of highly reactive methane-derived intermediates from the catalyst surface that are prone towards combustion. In contrast, the selectivity control in ethane oxychlorination is achieved via a purely surface-driven functionalization of ethane into ethyl chloride, which is further dehydrochlorinated to ethylene over chlorine modified active centers.

Halogen type as a selectivity switch in catalysed alkane oxyhalogenation

The type of halogen enables a powerful selectivity control ranging from olefins in oxychlorination to alkyl bromides in oxybromination over europium oxyhalide catalysts.