The quest for an efficient process to convert methane efficiently to fuels and high value-added chemicals such as olefins and aromatics is motivated by their increasing demands and recently discovered large reserves and resources of methane. Direct conversion to these chemicals can be realized either oxidatively via oxidative coupling of methane (OCM) or nonoxidatively via methane dehydroaromatization (MDA), which have been under intensive investigation for decades. While industrial applications are still limited by their low yield (selectivity) and stability issues, innovations in new catalysts and concepts are needed. The newly emerging strategy using iron single sites to catalyze methane conversion to olefins, aromatics, and hydrogen (MTOAH) attracted much attention when it was reported. Because the challenge lies in controlled dehydrogenation of the highly stable CH4 and selective C–C coupling, we focus mainly on the fundamentals of C–H activation and analyze the reaction pathways toward selective rou...

Direct Conversion of Methane to Value-Added Chemicals over Heterogeneous Catalysts: Challenges and Prospects

The direct production of liquid fuels from CO2 hydrogenation has attracted enormous interest for its significant roles in mitigating CO2 emissions and reducing dependence on petrochemicals. Here we report a highly efficient, stable and multifunctional Na-Fe3O4/HZSM-5 catalyst, which can directly convert CO2 to gasoline-range (C5-C11) hydrocarbons with selectivity up to 78% of all hydrocarbons while only 4% methane at a CO2 conversion of 22% under industrial relevant conditions. It is achieved by a multifunctional catalyst providing three types of active sites (Fe3O4, Fe5C2 and acid sites), which cooperatively catalyse a tandem reaction. More significantly, the appropriate proximity of three types of active sites plays a crucial role in the successive and synergetic catalytic conversion of CO2 to gasoline. The multifunctional catalyst, exhibiting a remarkable stability for 1,000 h on stream, definitely has the potential to be a promising industrial catalyst for CO2 utilization to liquid fuels.

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Directly converting CO 2 into a gasoline fuel

Although considerable progress has been made in carbon dioxide (CO2) hydrogenation to various C1 chemicals, it is still a great challenge to synthesize value-added products with two or more carbons, such as gasoline, directly from CO2 because of the extreme inertness of CO2 and a high C-C coupling barrier. Here we present a bifunctional catalyst composed of reducible indium oxides (In2O3) and zeolites that yields a high selectivity to gasoline-range hydrocarbons (78.6%) with a very low methane selectivity (1%). The oxygen vacancies on the In2O3 surfaces activate CO2 and hydrogen to form methanol, and C-C coupling subsequently occurs inside zeolite pores to produce gasoline-range hydrocarbons with a high octane number. The proximity of these two components plays a crucial role in suppressing the undesired reverse water gas shift reaction and giving a high selectivity for gasoline-range hydrocarbons. Moreover, the pellet catalyst exhibits a much better performance during an industry-relevant test, which suggests promising prospects for industrial applications.

Direct conversion of CO2 into liquid fuels with high selectivity over a bifunctional catalyst.

The use of well-defined materials in heterogeneous catalysis will open up numerous new opportunities for the development of advanced catalysts to address the global challenges in energy and the environment. This review surveys the roles of nanoparticles and isolated single atom sites in catalytic reactions. In the second section, the effects of size, shape, and metal-support interactions are discussed for nanostructured catalysts. Case studies are summarized to illustrate the dynamics of structure evolution of well-defined nanoparticles under certain reaction conditions. In the third section, we review the syntheses and catalytic applications of isolated single atomic sites anchored on different types of supports. In the final part, we conclude by highlighting the challenges and opportunities of well-defined materials for catalyst development and gaining a fundamental understanding of their active sites.

Well-Defined Materials for Heterogeneous Catalysis: From Nanoparticles to Isolated Single-Atom Sites.

Catalytic transformations of syngas (a mixture of H2 and CO), which is one of the most important C1-chemistry platforms, and CO2, a greenhouse gas released from human industrial activities but also a candidate of abundant carbon feedstock, into chemicals and fuels have attracted much attention in recent years. Fischer-Tropsch (FT) synthesis is a classic route of syngas chemistry, but the product selectivity of FT synthesis is limited by the Anderson-Schulz-Flory (ASF) distribution. The hydrogenation of CO2 into C2+ hydrocarbons involving C-C bond formation encounters similar selectivity limitation. The present article focuses on recent advances in breaking the selectivity limitation by using a reaction coupling strategy for hydrogenation of both CO and CO2 into C2+ hydrocarbons, which include key building-block chemicals, such as lower (C2-C4) olefins and aromatics, and liquid fuels, such as gasoline (C5-C11 hydrocarbons), jet fuel (C8-C16 hydrocarbons) and diesel fuel (C10-C20 hydrocarbons). The design and development of novel bifunctional or multifunctional catalysts, which are composed of metal, metal carbide or metal oxide nanoparticles and zeolites, for hydrogenation of CO and CO2 to C2+ hydrocarbons beyond FT synthesis will be reviewed. The key factors in controlling catalytic performances, such as the catalyst component, the acidity and mesoporosity of the zeolite and the proximity between the metal/metal carbide/metal oxide and zeolite, will be analysed to provide insights for designing efficient bifunctional or multifunctional catalysts. The reaction mechanism, in particular the activation of CO and CO2, the reaction pathway and the reaction intermediate, will be discussed to provide a deep understanding of the chemistry of the new C1 chemistry routes beyond FT synthesis.

New horizon in C1 chemistry: breaking the selectivity limitation in transformation of syngas and hydrogenation of CO2 into hydrocarbon chemicals and fuels

Although considerable progress has been made in direct synthesis gas (syngas) conversion to light olefins (C2(=)-C4(=)) via Fischer-Tropsch synthesis (FTS), the wide product distribution remains a challenge, with a theoretical limit of only 58% for C2-C4 hydrocarbons. We present a process that reaches C2(=)-C4(=) selectivity as high as 80% and C2-C4 94% at carbon monoxide (CO) conversion of 17%. This is enabled by a bifunctional catalyst affording two types of active sites with complementary properties. The partially reduced oxide surface (ZnCrO(x)) activates CO and H2, and C-C coupling is subsequently manipulated within the confined acidic pores of zeolites. No obvious deactivation is observed within 110 hours. Furthermore, this composite catalyst and the process may allow use of coal- and biomass-derived syngas with a low H2/CO ratio.

http://science.sciencemag.org/content/sci/351/6277/1065.full.pdf

Selective conversion of syngas to light olefins.

The key of syngas (a mixture of CO and H2) chemistry lies in controlled dissociative activation of CO and C–C coupling. We demonstrate here that a bifunctional catalyst of partially reducible manganese oxide in combination with SAPO-34 catalyzes the selective formation of light olefins, which validates the generality of the OX-ZEO (oxide-zeolite) concept for syngas conversion. Results from in situ ambient-pressure X-ray photoelectron spectroscopy, infrared spectroscopy, and temperature-programmed surface reactions reveal the critical role of oxygen vacancies on the oxide surface, where CO dissociates and is converted into surface carbonate and carbon species. They are converted to CO2 and CHx in the presence of H2. The limited C–C coupling and hydrogenation activities of MnO enable the reaction selectivity to be controlled by the confined pores of SAPO-34. Thus, a selectivity of light olefins up to 80% is achieved, far beyond the limitation of Anderson–Shultz–Flory distribution. These findings open up pos...

Role of Manganese Oxide in Syngas Conversion to Light Olefins

Direct conversion of syngas to aromatics

Enhanced aromatic selectivity by the sheet-like ZSM-5 in syngas conversion

The invention belongs to preparation of aromatic hydrocarbons from synthetic gas, and more specifically relates to a catalyst and a method for preparing aromatic hydrocarbons by direct conversion of synthetic gas. Synthetic gas is used as a reaction raw material, a conversion reaction is carried out on a fixed bed or a moving bed, the catalyst is a composite catalyst A+B, the catalyst A and the catalyst B are compounded by a mechanical mixing mode, an active composition of the catalyst A is an active metal oxide, and the catalyst B is one or two kinds or above of ZSM-5 molecular sieve or metal modified ZSM-5; the space between a geometric centre of the active metal oxide of the catalyst A and a geometric centre of particles of the catalyst B is between 5nm and 4mm, and preferably 5nm-1mm; the weight ratio of the active composition of the catalyst A to the catalyst B is 0.1-20 times. The pressure of the synthetic gas is 0.1-6MPa, the reaction temperature is 300-600 DEG C, and air speed is 500-8000h . The reaction process has good product yield and selectivity, selectivity of aromatic hydrocarbons reaches 50-85%, selectivity of by-product methane is lower than 15%, and the product and the method have good application prospects.

Junhao Yang

Papers

Selective conversion of syngas to light olefins.

Role of Manganese Oxide in Syngas Conversion to Light Olefins

Direct conversion of syngas to aromatics

Enhanced aromatic selectivity by the sheet-like ZSM-5 in syngas conversion

Catalyst and method for preparing aromatic hydrocarbons by direct conversion of synthetic gas