CO2-facilitated upcycling of polyolefin plastics to aromatics at low temperature.

Plastics are one of the most produced synthetic materials and largest commodities, used in numerous sectors of human life. To upcycle waste plastics into value-added chemicals is a global challenge. Despite significant progress in pyrolysis and hydrocracking, which mainly leads to the formation of pyrolysis oil, catalytic upcycling to value-added aromatics, including benzene, toluene and xylene (BTX), in one step, is still limited by high reaction temperatures (>500°C) and a low yield. We report herein CO2-facilitated upcycling of polyolefins and their plastic products to aromatics below 300°C, enabled by a bifunctional Pt/MnOx-ZSM-5 catalyst. ZSM-5 catalyzes cracking of polyolefins and aromatization, generating hydrogen at the same time, while Pt/MnOx catalyzes the reaction of hydrogen with CO2, consequently driving the reaction towards aromatization. Isotope experiments reveal that 0.2 kg CO2 is consumed per 1.0 kg polyethylene and 90% of the consumed CO2 is incorporated into the aromatic products. Furthermore, this new process yields 0.63 kg aromatics (BTX accounting for 60%), comparing favorably with the conventional pyrolysis or hydrocracking processes, which produce only 0.33 kg aromatics. In this way, both plastic waste and the greenhouse gas CO2 are turned into carbon resources, providing a new strategy for combined waste plastics upcycling and carbon dioxide utilization.

Visualization of the Active Sites of Zinc-Chromium Oxides and the CO/H2 Activation Mechanism in Direct Syngas Conversion.

Despite wide studies demonstrating the versatility of the metal oxide-zeolite (OXZEO) catalyst concept to tackle the selectivity challenge in syngas chemistry, the active sites of metal oxides and the mechanism of CO/H2 activation remain to be elucidated. Herein, we demonstrate experimentally the role of Cr in zinc-chromium oxides and unveil visually, for the first time, the active sites for CO activation employing scanning transmission electron microscopy-electron energy loss spectroscopy using the volumetric density of surface carbon species as a descriptor. The ZnCr2O4 spinel surface with atomic ZnOx overlayer is the most active site for C-O bond dissociation, particularly at the narrow ZnCr2O4(110) facets constrained between the (311) and (111) facets, followed by the Cr-doped wurtzite ZnO surface. In comparison, the surfaces of ZnCr2O4 with aggregated ZnOx overlayers, pure ZnO, and the stoichiometric ZnCr2O4 exhibit a significantly lower activity. In situ synchrotron-based vacuum ultraviolet photoionization mass spectrometric study on different temperature programmed surface reactions with isotopes of C18O, 13CO, and D2 validates direct CO dissociation over ZnCrn oxides in CO, forming CH2 and further to hydrocarbons if H2 is present and CH2CO intermediates in syngas. The activity of CO dissociation and hydrogenation over ZnCrn oxides correlates well with the syngas-to-light-olefins activity of ZnCrn-SAPO-18 composite catalysts as a function of the Cr/Zn ratio.

Methyl radical chemistry in non-oxidative methane activation over metal single sites.

Molybdenum supported on zeolites has been extensively studied as a catalyst for methane dehydroaromatization. Despite significant progress, the actual intermediates and particularly the first C-C bond formation have not yet been elucidated. Herein we report evolution of methyl radicals during non-oxidative methane activation over molybdenum single sites, which leads selectively to value-added chemicals. Operando X-ray absorption spectroscopy and online synchrotron vacuum ultraviolet photoionization mass spectroscopy in combination with electron microscopy and density functional theory calculations reveal the essential role of molybdenum single sites in the generation of methyl radicals and that the formation rate of methyl radicals is linearly correlated with the number of molybdenum single sites. Methyl radicals transform to ethane in the gas phase, which readily dehydrogenates to ethylene in the absence of zeolites. This is essentially similar to the reaction pathway over the previously reported SiO2 lattice-confined single site iron catalyst. However, the availability of a zeolite, either in a physical mixture or as a support, directs the subsequent reaction pathway towards aromatization within the zeolite confined pores, resulting in benzene as the dominant hydrocarbon product. The findings reveal that methyl radical chemistry could be a general feature for metal single site catalysis regardless of the support (either zeolites MCM-22 and ZSM-5 or SiO2) whereas the reaction over aggregated molybdenum carbide nanoparticles likely facilitates carbon deposition through surface C-C coupling. These findings allow furthering the fundamental insights into non-oxidative methane conversion to value-added chemicals.

Disentangling the activity-selectivity trade-off in catalytic conversion of syngas to light olefins.

Breaking the trade-off between activity and selectivity has been a long-standing challenge in the field of catalysis. We demonstrate the importance of disentangling the target reaction from the secondary reactions for the case of direct syngas conversion to light olefins by incorporating germanium-substituted AlPO-18 within the framework of the metal oxide-zeolite (OXZEO) catalyst concept. The attenuated strength of the catalytically active Brønsted acid sites allows enhancing the targeted carbon-carbon coupling of ketene intermediates to form olefins by increasing the active site density while inhibiting secondary reactions that consume the olefins. Thus, a light-olefins selectivity of 83% among hydrocarbons and carbon monoxide conversion of 85% were obtained simultaneously, leading to an unprecedented light-olefins yield of 48% versus current reported light-olefins yields of ≤27%.

Tuning the Crystal Phase to Form MnGaOx -Spinel for Highly Efficient Syngas to Light Olefins.

The oxide-zeolite (OXZEO) catalyst design concept has been demonstrated in an increasing number of studies as an alternative avenue for direct syngas conversion to light olefins. We report that face-centered cubic (FCC) MnGaOx -Spinel gives 40 % CO conversion, 81 % light olefins selectivity, and a 0.17 g gcat -1 h-1 space-time yield of light olefins in combination with SAPO-18. In comparison, solid solution MnGaOx (characterized by Mn-doped hexagonal close-packed (HCP) Ga2 O3 ) with a similar chemical composition gives a much inferior activity, i.e., the specific surface activity is one order of magnitude lower than the spinel oxide. Photoluminescence (PL), in situ Fourier-transform infrared (FT-IR), and density functional theory (DFT) calculations indicate that the superior activity of MnGaOx -Spinel can be attributed to its higher reducibility (higher concentration of oxygen vacancies) and the presence of coordinatively unsaturated Ga3+ sites, which facilitates the dissociation of the C-O bond via a more efficient ketene-acetate pathway to light olefins.

Chemistry of Ketene Transformation to Gasoline Catalyzed by H-SAPO-11.

Although ketene has been proposed to be an active intermediate in a number of reactions including OXZEO (metal oxide-zeolite)-catalyzed syngas conversion, dimethyl ether carbonylation, methanol to hydrocarbons, and CO2 hydrogenation, its chemistry and reaction pathway over zeolites are not well understood. Herein, we study the pathway of ketene transformation to gasoline range hydrocarbons over the molecular sieve H-SAPO-11 by kinetic analysis, in situ infrared spectroscopy, and solid-state nuclear magnetic resonance spectroscopy. It is demonstrated that butene is the reaction intermediate on the paths toward gasoline products. Ketene transforms to butene on the acid sites via either acetyl species following an acetic acid ketonization pathway or acetoacetyl species with keto-enol tautomerism following an acetoacetic acid decarboxylation pathway when in the presence of water. This study reveals experimentally for the first time insights into ketene chemistry in zeolite catalysis.

Dynamic confinement of SAPO-17 cages on the selectivity control of syngas conversion.

The OXZEO (oxide-zeolite) bifunctional catalyst concept has enabled selective syngas conversion to a series of value-added chemicals and fuels such as light olefins, aromatics and gasoline. Herein we report for the first time a dynamic confinement of SAPO-17 cages on the selectivity control of syngas conversion observed during an induction period. Structured illumination microscopy, intelligent gravimetric analysis, UV-Raman, X-ray diffraction, thermogravimetry and gas chromatography-mass spectrometer analysis indicate that this is attributed to the evolution of carbonaceous species as the reaction proceeds, which gradually reduces the effective space inside the cage. Consequently, the diffusion of molecules is hindered and the hindering is much more prominent for larger molecules such as C4+. As a result, the selectivity of ethylene is enhanced whereas that of C4+ is suppressed. Beyond the induction period, the product selectivity levels off. For instance, ethylene selectivity levels off at 44% and propylene selectivity at 31%, as well as CO conversion at 27%. The findings here bring a new fundamental understanding that will guide further development of selective catalysts for olefin synthesis based on the OXZEO concept.

Steering the reaction pathway of syngas-to-light olefins with coordination unsaturated sites of ZnGaOx spinel.

Significant progress has been demonstrated in the development of bifunctional oxide-zeolite catalyst concept to tackle the selectivity challenge in syngas chemistry. Despite general recognition on the importance of defect sites of metal oxides for CO/H2 activation, the actual structure and catalytic roles are far from being well understood. We demonstrate here that syngas conversion can be steered along a highly active and selective pathway towards light olefins via ketene-acetate (acetyl) intermediates by the surface with coordination unsaturated metal species, oxygen vacancies and zinc vacancies over ZnGaOx spinel-SAPO-34 composites. It gives 75.6% light-olefins selectivity and 49.5% CO conversion. By contrast, spinel-SAPO-34 containing only a small amount of oxygen vacancies and zinc vacancies gives only 14.9% light olefins selectivity at 6.6% CO conversion under the same condition. These findings reveal the importance to tailor the structure of metal oxides with coordination unsaturated metal sites/oxygen vacancies in selectivity control within the oxide-zeolite framework for syngas conversion and being anticipated also for CO2 hydrogenation.

Oxide-Zeolite-Based Composite Catalyst Concept That Enables Syngas Chemistry beyond Fischer-Tropsch Synthesis.

Syngas chemistry has been under study since Fischer-Tropsch synthesis (FTS) was invented in the 1920s. Despite the successful applications of FTS as the core technology of coal-to-liquid and gas-to-liquid processes in industry, the product selectivity control of syngas conversion still remains a great challenge, particularly for value-added chemicals such as light olefins. Recent studies show that the catalyst design concept of OXZEO (oxide-zeolite-based composite) enables direct syngas conversion to mixed light olefins with a selectivity reaching 80% and to ethylene with a selectivity of 83% among hydrocarbons. They both well-surpass the limits predicated by the Anderson-Schultz-Flory model via the conventional FTS route (58% and 30%, respectively). Furthermore, this catalyst concept allows one-step synthesis of gasoline-range isoparaffins and aromatic compounds, which is otherwise not possible in conventional FTS. A rapidly growing number of studies demonstrate the versatility of this concept and may form a technology platform for utilization of carbon resources including coal, natural gas, and biomass via syngas to a variety of basic chemicals and fuels. However, the selectivity control mechanism is far from being understood. Therefore, we focus mainly on the catalytic roles of the bifunctionalities of OXZEO while reviewing the development of bifunctional catalysts for selective syngas conversion by taking syngas-to-light olefins as an example. With this, we intend to provide insights into the selectivity control mechanism of the OXZEO concept in order to understand the challenges and prospects for future development of much more active and more selective catalysts.

C-C Bond Formation in Syngas Conversion over Zinc Sites Grafted on ZSM-5 Zeolite.

Despite significant progress achieved in Fischer-Tropsch synthesis (FTS) technology, control of product selectivity remains a challenge in syngas conversion. Herein, we demonstrate that Zn2+ -ion exchanged ZSM-5 zeolite steers syngas conversion selectively to ethane with its selectivity reaching as high as 86 % among hydrocarbons (excluding CO2 ) at 20 % CO conversion. NMR spectroscopy, X-ray absorption spectroscopy, and X-ray fluorescence indicate that this is likely attributed to the highly dispersed Zn sites grafted on ZSM-5. Quasi-in-situ solid-state NMR, obtained by quenching the reaction in liquid N2 , detects C2 species such as acetyl (-COCH3 ) bonding with an oxygen, ethyl (-CH2 CH3 ) bonding with a Zn site, and epoxyethane molecules adsorbing on a Zn site and a Brønsted acid site of the catalyst, respectively. These species could provide insight into C-C bond formation during ethane formation. Interestingly, this selective reaction pathway toward ethane appears to be general because a series of other Zn2+ -ion exchanged aluminosilicate zeolites with different topologies (for example, SSZ-13, MCM-22, and ZSM-12) all give ethane predominantly. By contrast, a physical mixture of ZnO-ZSM-5 favors formation of hydrocarbons beyond C3+ . These results provide an important guide for tuning the product selectivity in syngas conversion.

High-Quality Gasoline Directly from Syngas by Dual Metal Oxide-Zeolite (OX-ZEO) Catalysis.

Despite significant efforts towards the direct conversion of syngas into liquid fuels, the selectivity remains a challenge, particularly with regard to high-quality gasoline with a high octane number and a low content of aromatic compounds. Herein, we show that zeolites with 1D ten-membered-ring (10-MR) channel structures such as SAPO-11 and ZSM-22 in combination with zinc- and manganese-based metal oxides (Zna Mnb Ox ) enable the selective synthesis of gasoline-range hydrocarbons C5 -C11 directly from syngas. The gasoline selectivity reached 76.7 % among hydrocarbons, with only 2.3 % CH4 at 20.3 % CO conversion. The ratio of isoparaffins to n-paraffins was as high as 15, and the research octane number was estimated to be 92. Furthermore, the content of aromatic compounds in the gasoline was as low as 16 %. The composition and structure of Zna Mnb Ox play an important role in determining the overall activity. This process constitutes a potential technology for the one-step synthesis of environmentally friendly gasoline with a high octane number from a variety of carbon resources via syngas.

Shape-Selective Zeolites Promote Ethylene Formation from Syngas via a Ketene Intermediate.

Syngas conversion by Fischer-Tropsch synthesis (FTS) is characterized by a wide distribution of hydrocarbon products ranging from one to a few carbon atoms. Reported here is that the product selectivity is effectively steered toward ethylene by employing the oxide-zeolite (OX-ZEO) catalyst concept with ZnCrOx -mordenite (MOR). The selectivity of ethylene alone reaches as high as 73 % among other hydrocarbons at a 26 % CO conversion. This selectivity is significantly higher than those obtained in any other direct syngas conversion or the multistep process methanol-to-olefin conversion. This highly selective pathway is realized over the catalytic sites within the 8-membered ring (8MR) side pockets of MOR via a ketene intermediate rather than methanol in the 8MR or 12MR channels. This study provides substantive evidence for a new type of syngas chemistry with ketene as the key reaction intermediate and enables extraordinary ethylene selectivity within the OX-ZEO catalyst framework.

Direct conversion of syngas to aromatics.

A composite catalyst combining the partially reducible ZnCrOx with zeolite ZSM-5 enables direct conversion of syngas to aromatics, with a selectivity to aromatics reaching 73.9% at a single pass CO conversion of 16.0%.

Size-dependence of carbon nanotube confinement in catalysis.

An increasing number of studies have demonstrated that confinement within carbon nanotubes (CNTs) provides an effective approach for the modulation of catalysis. It was generally predicted that confinement became stronger with a decreasing diameter of CNTs. However, our present study here overturns the previous expectation: the influence on catalysis is not monotonic. Instead, it exhibits a volcano relationship with CNT diameter. Taking Pt catalyzing O2 conversion and Re catalyzing N2 conversion as probes using density functional theory, we show that only within tubes with an i.d. of ∼1 nm can the activity of metal clusters be enhanced to its maximum. Furthermore, confinement only enhances the catalytic activity of metals with strong intrinsic binding with reactants, whereas it is suppressed for those with weak binding. These findings shed further light on the fundamental effects of confinement on catalysis, and could guide more rational design of confined catalysts.

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

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 routes of OCM, MDA, and MTOAH. With this, we intend to provide some insights into their reaction mechanisms and implications for future development of highly selective catalysts for direct conversion of methane to high value-added chemicals.

Selective conversion of syngas to light olefins.

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.

A single iron site confined in a graphene matrix for the catalytic oxidation of benzene at room temperature.

Coordinatively unsaturated (CUS) iron sites are highly active in catalytic oxidation reactions; however, maintaining the CUS structure of iron during heterogeneous catalytic reactions is a great challenge. Here, we report a strategy to stabilize single-atom CUS iron sites by embedding highly dispersed FeN4 centers in the graphene matrix. The atomic structure of FeN4 centers in graphene was revealed for the first time by combining high-resolution transmission electron microscopy/high-angle annular dark-field scanning transmission electron microscopy with low-temperature scanning tunneling microscopy. These confined single-atom iron sites exhibit high performance in the direct catalytic oxidation of benzene to phenol at room temperature, with a conversion of 23.4% and a yield of 18.7%, and can even proceed efficiently at 0°C with a phenol yield of 8.3% after 24 hours. Both experimental measurements and density functional theory calculations indicate that the formation of the Fe═O intermediate structure is a key step to promoting the conversion of benzene to phenol. These findings could pave the way toward highly efficient nonprecious catalysts for low-temperature oxidation reactions in heterogeneous catalysis and electrocatalysis.

N-doped graphene as an electron donor of iron catalysts for CO hydrogenation to light olefins.

N-doped graphene used as an efficient electron donor of iron catalysts for CO hydrogenation can achieve a high selectivity of around 50% for light olefins, significantly superior to the selectivity of iron catalysts on conventional carbon materials, e.g. carbon black with a selectivity of around 30% at the same reaction conditions.

Toward fundamentals of confined catalysis in carbon nanotubes.

An increasing number of experimental studies have demonstrated that metal or metal oxide nanoparticles confined inside carbon nanotubes (CNTs) exhibit different catalytic activities with respect to the same metals deposited on the CNT exterior walls, with some reactions enhanced and others hindered. In this article, we describe the concept of confinement energy, which enables prediction of confinement effects on catalytic activities in different reactions. Combining density functional theory calculations and experiments by taking typical transition metals such as Fe, FeCo, RhMn, and Ru as models, we observed stronger strains and deformations within the CNT channels due to different electronic structures and spatial confinement. This leads to downshifted d-band states, and consequently the adsorption of molecules such as CO, N2, and O2 is weakened. Thus, the confined space of CNTs provides essentially a unique microenvironment due to the electronic effects, which shifts the volcano curve of the catalytic activities toward the metals with higher binding energies. The extent of the shift depends on the specific metals and the CNT diameters. This concept generalizes the diverse effects observed in experiments for different reactions, and it is anticipated to be applicable to an even broader range of reactions other than redox of metal species, CO hydrogenation, ammonia synthesis and decomposition discussed here.

Visualizing electronic interactions between iron and carbon by X-ray chemical imaging and spectroscopy.

The electronic interaction of a catalyst and its support is of vital importance to its catalytic performance. However, it is still a great challenge to directly probe the interaction due to the lack of well-defined models and efficient technical means. In this study, we report that pod-like carbon nanotubes with encapsulated iron particles (Pod-Fe) and scanning transmission X-ray microscopy (STXM) can be used as an ideal model and technique to study the electronic interaction between carbon shells and iron particles. The chemical imaging and spectroscopy of Pod-Fe by STXM show that the local electronic structures at C K-edge near edge (π*) of carbon shells can be significantly modified by the encapsulated iron particles, which promotes the adsorption of oxygen-containing species, and thereby further modifies the electronic structure (π* and σ*) of the carbon shells. Moreover, computed X-ray absorption near edge structure spectra (XANES) confirmed the electronic modifications of carbon shells by the encapsulated iron particles. The present study provides a direct evidence of electronic interactions with simultaneously collected images and spectra, which can promote the understanding towards the nature of active sites and supports.