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Conversion of Syngas to Light Olefins and Oxygenates using Multi-Functional Catalysts
This report describes our effort in developing catalysts for the conversion of syngas to light olefins and oxygenates. We have developed a series of metal/zeolite catalysts and tested their activity towards the conversion of syngas to light olefins. Light olefins produced in our case mostly comprised of C 2 /C 3 . A series of multimetallic catalyst also synthesized and their performance was evaluated for the conversion of syngas to the production of oxygenates. In case of oxygenates, our specific focus was to maximize the selectivity of C 2+ oxygenates which is a precursor for fuel or can be used as high value chemicals. In this direction, we have identified several Rh based catalysts that are specifically shows superior activity towards oxygenates formation.
The role of catalyst acidity and microstructure on light olefin selectivity in polyethylene deconstruction in short contact time pulse Joule-heated reactors
The growing volume of plastics waste, compounded with a low recycling rate, has led to an alarming amount of plastics ending up in landfills or being incinerated. While pyrolysis offers a route for plastic waste deconstruction, its product distribution is often broad and poorly controlled due to unselective radical chemistry at high temperatures. We recently demonstrated that rapid pulse Joule-heated catalytic cracking over HZSM-5, combined with small fractions of steam, can achieve high selectivity (>80 %) toward C 2 -C 4 olefins, while significantly reducing coking compared to continuous Joule heating. Here, we investigate how acid catalyst properties, such as silica/alumina ratio, zeolite topology, and catalyst porosity, influence light olefin selectivity during polyethylene deconstruction via rapid pulse Joule heating. We demonstrate that silica-to-alumina ratios of ∼30 yield high light olefin selectivity, and small-pore zeolites favor light olefins at the expense of increased coke formation. To mitigate coking, we synthesize HZSM-5 nanosheets and hierarchical zeolites (MFI, FAU, and CHA). Furthermore, these catalysts achieve an ethylene selectivity of approximately 35 %, a twofold increase over prior catalytic pyrolysis. Additionally, co-feeding steam and incorporating hierarchical porosity reduce coke formation and enhance catalyst stability.
Upcycling Real‐World Post‐Consumer Polyolefins Plastics Into Light Olefins Via Microwave‐Assisted Processing
The rapid accumulation of plastic waste, particularly post-consumer polyolefins (POs) pose severe environmental and economic challenges worldwide. Recycling of post-consumer POs remains inefficient due to difficulties in separating mixed plastics, complex additives compositions, and high processing costs, resulting in recycling rates of less than 9%. To address these critical issues, this study utilized an innovative microwave-assisted catalytic upcycling approach for the efficient upcycling of complex post-consumer POs mixtures into valuable light olefins. Using the microwave-assisted catalytic upcycling approach, gas yields reached up to 80 wt.% from post-consumer POs mixtures, accompanied by a high selectivity (>70 wt.%) toward valuable light olefins. The upcycling of POs under microwave conditions is fully invested, including additives in real-word plastics, mixtures of different POs, reusability of catalyst, and more. The microwave-assisted catalytic upcycling approach offers an efficient, scalable, and cost-effective solution for upcycling post-consumer plastic mixtures, thereby advancing the principles of a circular economy.
Promotional Effect of ZnO and ZrO 2 in K-Doped Fe Catalysts for CO 2 Hydrogenation to Light Olefins
Promoters play a critical role in tuning the activity and selectivity of Fe catalysts in CO 2 hydrogenation to produce light olefins, which are key building blocks in the petrochemical industry. Herein, by a combined experimental and theoretical approach, we show that high and stable performance of Fe catalysts could be achieved by taking advantage of the promotional effect of both Zn and Zr. Structural characterization indicates that ZnO could improve the dispersion and reducibility of Fe oxides and facilitate the formation of active Fe carbide species, whereas ZrO 2 could stabilize the structure and catalytic performance, especially the selectivity of hydrocarbon products. In situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) experiments suggest that carbonate, bicarbonate, formate, and methoxy are essential intermediates in the CO 2 hydrogenation to hydrocarbon products, including paraffins and olefins. The conversion kinetics of each intermediate species are dependent on the type of promoters as well as the phase structure of the active Fe species. DFT calculations revealed a strong correlation between the formation energy of surface oxygen vacancies and that of Fe carbide species in promoted Fe oxides, in accordance with experimental results. Moreover, the calculated energy profiles of CO 2 hydrogenation over different catalysts indicate that Zn could promote the activation of CO 2 and its transformation to the oxygenate intermediates, while Zr could facilitate the conversion of oxygenates to hydrocarbon precursors. Finally, the discrepancies in the evolution trend of various intermediate species on promoted Fe catalysts in the transient DRIFTS experiments can be rationalized by the differences in energy barriers of elementary or rate limiting steps.
Conversion of Syngas and CO2 to Light Olefins using Multi-Functional Catalysts
This report describes our effort in developing a novel zeolite encapsulated metal nanoparticle catalyst for the conversion of syngas to light olefins. We have adopted a ligand assisted synthesis protocol in which first metal-amine was prepared using metal salts and suitable amine ligands. The stable metal-amine complex thus prepared was then used as the seed for the growth of zeolite in alkaline solution. We have optimized the synthesis condition as well as different amine ligand to identify the condition to obtain stable metal-amine complex. Upon synthesis of zeolite, metal particles are encapsulated inside the zeolite in a confined space. We have synthesized both Fe and Co catalyst inside silicalite and chabazite zeolite. Catalytic activity of these catalysts were evaluated for syngas conversion reaction and compared with a baseline catalyst. The activity trend of zeolite encapsulated catalyst show very different activity trend compared to the baseline catalyst. While a distribution of products with different carbon number was obtained with baseline catalyst, zeolite encapsulated catalyst show ethylene as the major product. While ~73% selectivity to C 2 -C 6 products were obtained with cahabazite encapsulated Fe catalyst, only 53% selectivity was obtained for the corresponding products with silica-alumina supported Fe catalyst. Not only higher selectivity, Fe-chabazite also produces only C 2 products (ethylene/ethane) while a distribution of products was obtained with Fe-SiAl catalyst. The significantly different reactivity associated with the chabazite encapsulated Fe catalyst was attributed to the confinement effect. We hypothesized that due to the small size of the pore, only ethylene was obtained as the product.
Thermal Oxo-degradation and Catalytic Upgrading of Plastic Waste to Light Olefins for a Circular Economy
The commercialization of conventional pyrolysis of plastic in an inert atmosphere has been hindered by large thermal requirements stemming from long reaction rates. The rate of thermal depolymerization of waste plastics can be accelerated by the addition of oxygen in a process known as thermal oxo-degradation (TOD). This study offers the prospect of TOD to upcycle postconsumer waste rapidly and efficiently. Using moderate temperatures and small amounts of air in a fluidized bed reactor, we demonstrated that waste high-density polyethylene and polypropylene are rapidly deconstructed to condensable products. These condensable products were catalytically upgraded in a micropyrolysis reactor using commercially available zeolite (HZSM-5) to monomeric olefins. The olefin yields proved to be greater than those achieved through the catalytic upgrading of condensable products from (nonoxidative) the pyrolysis of the same plastic wastes. The coupling of TOD with catalytic upgrading proves to be an energy-efficient pathway in a plastics circular economy for the production of light olefins from wastes.
Kinetic and Mechanistic Understanding of Boron-Containing Catalysts for the Production of Light Olefins through Selective Oxidation
In recent years, an abundance of natural gas obtained from shale deposits has created opportunities for the US chemical industry to establish new and more efficient processes for the production of chemical intermediates and polymers. For example, the replacement of petroleum-derived naphtha as a to shale-derived ethane as feedstocks has made the production of ethylene/polyethylene less costly. However, this shift in feedstock has led to lower production of propylene from steam crackers, and new “on-purpose” light olefin production technologies have been implemented to bridge the gap between propylene supply and demand. The most important of these processes is direct propane dehydrogenation (PDH), but catalyst deactivation and high temperatures lead to high capital and operating costs. Oxidative dehydrogenation of propane (ODHP) is an efficient alternative to PDH, but high selectivity to CO2 from previous metal oxide catalyst prevents implementation. Hexagonal boron nitride (hBN) and other boron-containing materials have been recently developed as highly selective catalysts for both ODHP and oxidative cracking, surpassing previous systems. Much is still unknown in regard to the mechanism and the dynamic surface changes that occur under reaction conditions. This research project aims to combine in situ/operando spectroscopic investigation and kinetic studies to elucidate the interplay between the proposed gas-phase mechanism and the surface structures on the working catalyst. These insights will be leveraged to create a framework for optimizing reaction conditions and material synthesis for the next generation of boron-containing selective oxidation catalysts.
Selective and Stable In-Promoted Fe Catalyst for Syngas Conversion to Light Olefins
A selective and stable alumina-supported In-promoted Fe catalyst (10 mol % In based on Fe) was discovered for converting syngas (2:1 H 2 /CO ratio) to olefins with high selectivity (45% with CO 2 included) and a remarkable stability (72 h run) at a CO conversion of 10% at 400 °C and 5 bar. The X-ray photoelectron spectroscopy results indicated that incorporating In into Fe catalysts changed the chemical bonding state of Fe and Fe/In composition near the surface layers, which affected the catalytic reactivity. Steady-state isotopic transient kinetic analysis showed that more stable CHx fragments are present on the catalyst surface when incorporating In into Fe, which can promote C–C coupling reaction toward olefins. Our study demonstrates that introducing In into Fe catalysts on Al 2 O 3 support can lower CO activation abilities. It has more impacts on lowering hydrogenation activity, which permits more C–C couplings and like of “ene” hydrogenation. Furthermore, weakening CO adsorption both in terms of sites and strength encouraged CO toward hydrocarbons rather than CO 2 .
ChemPren: a new and economical technology for conversion of waste plastics to light olefins
With the ever-increasing demand for plastics, sustainable recycling methods are key necessities. Here, the current plastics industry can manage to recycle only 10% of the 400 million metric tons of plastic produced globally. Waste plastics, in the current infrastructure, land up mostly in landfills. Although a lot of research efforts have been spent on processing and recycling co-mingled mixed plastics, energy-efficient sustainable and scalable routes for plastic upcycling are still lacking. Catalytic valorization of waste plastic feedstock is one of the potential scalable routes for plastic upcycling. Silica-alumina based materials, and zeolites have shown a lot of promise. A major interest lies in restricting catalyst deactivation, and refining product selectivity and yield for such catalytic processes. This article highlights ChemPren technology as a clean energy solution to waste plastic recycling. Co-mingled, mixed plastic feedstock along with spray dried, attrition resistant, ZSM-5 containing catalysts is preprocessed with an extruder to form optimally sized particles and fed into a fluidized bed reactor for short contact times to produce selectively and in high yields ethylenes, propylenes and butylenes. This techno-economic perspective indicates that the ChemPren technology can produce propylene at $\$$0.16 per lb, whereas the current selling price of virgin propylene is $0.54 per lb. This technology can serve as a platform for mixed plastic upcycling, with more advancements necessary in the form of robust and resilient catalysts and reactor operation strategies for tuning product selectivity.
Conversion of syngas into light olefins in one step for process-intensified production of sustainable aviation fuels
Here, we report on a preliminary investigation for direct conversion of syngas into olefins. This technology combines alcohol(s) production and olefin(s) production into a single unit operation to improve process efficiencies due to the overcoming of equilibrium limitations and also to offer capital savings relative to current synthesis approaches including Fischer-Tropsch synthesis, methanol-to-olefins followed by olefins to gasoline/distillate process and alcohol-to-jet process.
Production and Fuel properties of Iso-Olefins with Controlled Molecular Structure and Obtained from Butene Oligomerization
The ability to control the molecular structure (e.g., degree of branching) of iso-olefins produced from oligomerizing light olefins is a valuable tool for tuning the final compositions of hydrocarbon fuels and targeting specific fuel properties. In this study, we demonstrated that the degree of branching of iso-olefins obtained from butene(s) oligomerization can be controlled by tuning process conditions (i.e., temperature, weight hourly space velocity [WHSV], and nature of butene feedstock) and by choosing the proper catalyst (i.e., Amberlyst-36 vs. Y/ZSM-22). In this study, we produced three types of iso-olefin mixtures: 1) a methyl-heptenes rich (74 wt.%) mixture, 2) dimethyl-hexenes rich (80–96 wt.%) mixtures, and 3) highly branched (i.e., more than three methyl substitutions) iso-olefins rich (>50 wt.%) mixtures. While dimethyl-hexenes are preferentially formed at lower temperatures (60–100°C) and WHSV (i.e., 2 hr-1), methyl-heptenes are favorably produced at higher temperatures (>100°C) and WHSVs (i.e., 7 hr-1) over Amberlyst-36. The use of either 1-butene or 2-butene as feedstock resulted in liquid products with similar branching because facile intramolecular isomerization occurs prior to oligomerization. However, the use of isobutylene feedstock forms a significantly more branched olefin product. The formation of highly branched iso-olefins also is favored at higher temperature (140°C) over Amberlyst-36. Using Y/ZSM-22 instead of Amberlyst-36 allowed preferential formation of less-branched methyl-heptenes. For each type of iso-olefins mixture, we determined fuel properties including research octane number (RON), motor octane number (MON), and octane sensitivity (S), which is the difference between RON and MON. We found that not only RON and MON but also S values increased with the degree of branching of these complex mixtures of iso-olefins. The highest RON of 99.7 and S value of 9.3 were obtained for a mixture of highly branched iso-olefins.
Abstract for CRADA between National Energy Technology Laboratory and American Institute of Chemical Engineers dba RAPID Manufacturing Institute
NETL and RAPID Manufacturing will develop advanced electromagnetic (EM) reactors and catalysts to produce light olefins from alternative feedstocks using CO2 soft oxidation. Light olefins are the building blocks for many plastic products, in addition to synthetic fibers, rubbers, and polymers. This project has the potential to produce high-value light olefins from alternative feedstocks with reduced energy consumption (50-70%), carbon intensity (50-70%), and production cost (15-25%) compared to the traditional olefin production processes.
Production of Gaseous Olefins from Syngas over a Cobalt-HZSM-5 Catalyst
Light olefins (C2–C5) are high-value platform chemicals used to produce plastics, lubricants, coating material, and surfactants, and can be intermediates to produce transportation fuels. In this study we report on the development of a Co-based catalyst for direct conversion of fossil as well as biomass derived syngas into light olefins that enables high conversion and olefin/paraffin (O/P) product ratio, minimal selectivity to CO2 (<?1%) and wax formation (C14+ selectivity?<?1%). Over a Co/HZSM-5 bi-functional catalyst 38% CO conversion with C2–C5 olefin selectivity of 48%, and O/P ratio of 4.0 was achieved at 240 °C, 17 bar, and 1.5 L/(g–h). In addition to a gaseous olefin-rich stream a C6–C13 mixed olefin/paraffin liquid byproduct was also produced with 25% selectivity. Both Co loading and the HZSM-5 acidity levels were optimized to maintain the balance between the hydrogenation and the cracking activity to generate high levels of C2–C4 olefins. A suite of catalyst characterization tools were used to correlate the physical and chemical property of the catalyst to the performance of the catalyst towards syngas conversion and C2–C4 olefin selectivity.
Production and Catalytic Upgrading of 2,3-Butanediol Fermentation Broth into Sustainable Aviation Fuel Blendstock and Fuel Properties Measurement
With the increasing demand for sustainable supplies of aviation fuel and need to address climate change, new conversion technologies are needed to efficiently process biomass, produce high quality jet fuel blendstock, and meet carbon emission targets. This study demonstrates the synthesis, conditioning, and catalytic upgrading of 2,3-butanediol (BDO) fermentation broth into a jet fuel blendstock candidate. A high-titer 2,3-BDO fermentation broth (i.e., ~90 g/L) was produced at a 100-L scale and pretreated via nanofiltration to decrease the impurities level in the broth from 4.6 to 0.6 wt%. A novel process for catalytic upgrading of aqueous 2,3-BDO into a jet fuel blendstock candidate was developed, and each step was efficiently demonstrated. The catalytic steps include 1) 2,3-BDO dehydration into methyl ethyl ketone (MEK) over AlPO4, 2) MEK conversion into olefins over Zn1Zr10Ox, 3) oligomerization of olefins over a zeolite beta, and 4) hydrogenation over platinum/carbon. Both the model feed and real 2,3-BDO fermentation broth were tested for upgrading 2,3-BDO to MEK. With the real feed, a continuous loss of conversion (i.e., >50% loss over ~140 h time-on-stream [TOS]) was partly attributed to reversible deactivation from coking species. However, the conversion remained stable with the model feed, which demonstrates the efficiency of the first step for converting aqueous 2,3-BDO (10 wt% in water). For upgrading MEK to olefins, high selectivity to olefins (i.e., 82.5%) was obtained at high conversion levels (i.e., 93-98%) with stable conditions being achieved for > 70-hours TOS. Oligomerization of light olefins, which was demonstrated for > 270 h TOS, mainly led to the formation of dimers (C8-10) and trimers (C13-14). The oligomerized product was hydrogenated and distilled to recover the jet fraction (35 mass% or 40.9% carbon based yield), which consists mostly of desired isoalkanes (31.7 wt%), n-alkanes (24.5 wt%), and cycloalkanes (29.6 wt%). While some improvement is still needed to meet ASTM D7566 specifications for viscosity and final boiling point temperature, freezing point, density, aromatics content, and sulfur content of the jet blendstock candidate were within acceptable ranges, thus highlighting the potential of this process for production of jet fuel blendstock.
Recycling polyolefin plastic waste at short contact times via rapid joule heating
Abstract The chemical deconstruction of polyolefins to fuels, lubricants, and waxes offers a promising strategy for mitigating their accumulation in landfills and the environment. Yet, achieving true recyclability of polyolefins into C 2 -C 4 monomers with high yields, low energy demand, and low carbon dioxide emissions under realistic polymer-to-catalyst ratios remains elusive. Here, we demonstrate a single-step electrified approach utilizing Rapid Joule Heating over an H-ZSM-5 catalyst to efficiently deconstruct polyolefin plastic waste into light olefins (C 2 -C 4 ) in milliseconds, with high productivity at much higher polymer-to-catalyst ratio than prior work. The catalyst is essential in producing a narrow distribution of light olefins. Pulsed operation and steam co-feeding enable highly selective deconstruction (product fraction of >90% towards C 2 -C 4 hydrocarbons) with minimal catalyst deactivation compared to Continuous Joule Heating. This laboratory-scale approach demonstrates effective deconstruction of real-life waste materials, resilience to additives and impurities, and versatility for circular polyolefin plastic waste management.
Selective hydrogenation of CO 2 and CO over potassium promoted Co/ZSM-5
The utilization of CO 2 as a C 1 feedstock for synthesis of value-added chemicals and fuels could both mitigate the negative effects associated with increasing CO 2 emissions and decrease dependence on fossil fuels as part of a future circular carbon economy. Co-based catalysts have been well-developed for Fischer-Tropsch synthesis (FTS), but replacing the CO reactant with CO 2 (CO 2 -FTS) typically results in low selectivity toward desirable light olefins. To better understand the structure-property relationships of Co-based catalysts, and extend promising FTS results to CO 2 -FTS, we have studied the effect of a potassium promoter and acidic properties of ZSM-5 on catalytic performance. The selectivity of FTS and CO 2 -FTS is shown to be a strong function of Si/Al ratio in co-impregnated catalysts, with findings supported by in situ XAFS and FTIR, demonstrating light olefin selectivity can be tuned by Si/Al ratio and the method of introducing the K promoter.