Matthijs Ruitenbeek

Supported Iron Nanoparticles as Catalysts for Sustainable Production of Lower Olefins

From Plant to Plastic Petroleum is primarily used as fuel, but it is also used in the production of plastics. Thus, if biomass were to replace petroleum as societys carbon feedstock, a means of deriving ethylene and propylene—the principal building blocks of todays commodity plastics— would be helpful. Well-known Fischer-Tropsch (FT) catalysts can transform gasified biomass into a range of hydrocarbon derivatives, but ethylene and propylene tend to constitute a small fraction of the overall product distribution. Torres Galvis et al. (p. 835) now demonstrate a class of iron catalysts on relatively passive supports (carbon nanofibers or α-alumina) that robustly directed the FT process toward light olefins. A class of iron catalysts selectively transforms gasified biomass into the building blocks of common plastics. Lower olefins are key building blocks for the manufacture of plastics, cosmetics, and drugs. Traditionally, olefins with two to four carbons are produced by steam cracking of crude oil–derived naphtha, but there is a pressing need for alternative feedstocks and processes in view of supply limitations and of environmental issues. Although the Fischer-Tropsch synthesis has long offered a means to convert coal, biomass, and natural gas into hydrocarbon derivatives through the intermediacy of synthesis gas (a mixture of molecular hydrogen and carbon monoxide), selectivity toward lower olefins tends to be low. We report on the conversion of synthesis gas to C2 through C4 olefins with selectivity up to 60 weight percent, using catalysts that constitute iron nanoparticles (promoted by sulfur plus sodium) homogeneously dispersed on weakly interactive α-alumina or carbon nanofiber supports.

Iron Particle Size Effects for Direct Production of Lower Olefins from Synthesis Gas

The Fischer-Tropsch synthesis of lower olefins (FTO) is an alternative process for the production of key chemical building blocks from non-petroleum-based sources such as natural gas, coal, or biomass. The influence of the iron carbide particle size of promoted and unpromoted carbon nanofiber supported catalysts on the conversion of synthesis gas has been investigated at 340-350 °C, H(2)/CO = 1, and pressures of 1 and 20 bar. The surface-specific activity (apparent TOF) based on the initial activity of unpromoted catalysts at 1 bar increased 6-8-fold when the average iron carbide size decreased from 7 to 2 nm, while methane and lower olefins selectivity were not affected. The same decrease in particle size for catalysts promoted by Na plus S resulted at 20 bar in a 2-fold increase of the apparent TOF based on initial activity which was mainly caused by a higher yield of methane for the smallest particles. Presumably, methane formation takes place at highly active low coordination sites residing at corners and edges, which are more abundant on small iron carbide particles. Lower olefins are produced at promoted (stepped) terrace sites that are available and active, quite independent of size. These results demonstrate that the iron carbide particle size plays a crucial role in the design of active and selective FTO catalysts.

Metal organic framework-mediated synthesis of highly active and stable Fischer-Tropsch catalysts

Depletion of crude oil resources and environmental concerns have driven a worldwide research on alternative processes for the production of commodity chemicals. Fischer-Tropsch synthesis is a process for flexible production of key chemicals from synthesis gas originating from non-petroleum-based sources. Although the use of iron-based catalysts would be preferred over the widely used cobalt, manufacturing methods that prevent their fast deactivation because of sintering, carbon deposition and phase changes have proven challenging. Here we present a strategy to produce highly dispersed iron carbides embedded in a matrix of porous carbon. Very high iron loadings (>40 wt %) are achieved while maintaining an optimal dispersion of the active iron carbide phase when a metal organic framework is used as catalyst precursor. The unique iron spatial confinement and the absence of large iron particles in the obtained solids minimize catalyst deactivation, resulting in high active and stable operation.

Hard X-ray Nanotomography of Catalytic Solids at Work†

A closer look at catalysis: In situ hard X‐ray nanotomography has been developed (see picture) as a method to investigate an individual iron‐based Fischer–Tropsch‐to‐Olefins (FTO) catalyst particle at elevated temperatures and pressures. 3D and 2D maps of 30 nm resolution could be obtained and show heterogeneities in the pore structure and chemical composition of the catalyst particle of about 20 μm.

Suppression of carbon deposition in the iron-catalyzed production of lower olefins from synthesis gas.

Pressure leverage: A tapered-element oscillating microbalance was used to evaluate carbon deposition on a highly selective and active supported iron catalyst for the production of lower olefins. With increasing pressure, the H(2)/CO ratio had a profound effect on the carbon deposition rate and accordingly, conditions leading to minimal carbon deposition, low methane selectivity, and high olefin selectivity were identified.

A Radical Twist to the Versatile Behavior of Iron in Selective Methane Activation

Things go better without coke! The selective activation of methane and its direct conversion into light olefins and aromatic compounds remains a formidable challenge. Recent work shows that a catalyst material consisting of lattice-confined single iron atoms is very active and selective in the direct, nonoxidative conversion of methane into ethylene, benzene, and naphthalene without the formation of coke deposits.