In situ formation of ZnOx species for efficient propane dehydrogenation

Propane dehydrogenation (PDH) to propene is an important alternative to oil-based cracking processes, to produce this industrially important platform chemical(1,2). The commercial PDH technologies utilizing Cr-containing (refs. (3,4)) or Pt-containing (refs. (5-8)) catalysts suffer from the toxicity of Cr(vi) compounds or the need to use ecologically harmful chlorine for catalyst regeneration(9). Here, we introduce a method for preparation of environmentally compatible supported catalysts based on commercial ZnO. This metal oxide and a support (zeolite or common metal oxide) are used as a physical mixture or in the form of two layers with ZnO as the upstream layer. Supported ZnOx species are in situ formed through a reaction of support OH groups with Zn atoms generated from ZnO upon reductive treatment above 550 degrees C. Using different complementary characterization methods, we identify the decisive role of defective OH groups for the formation of active ZnOx species. For benchmarking purposes, the developed ZnO-silicalite-1 and an analogue of commercial K-CrOx/Al2O3 were tested in the same setup under industrially relevant conditions at close propane conversion over about 400 h on propane stream. The developed catalyst reveals about three times higher propene productivity at similar propene selectivity. Propene is obtained through propane dehydrogenation using catalysts that are toxic, expensive or demanding to regenerate with ecologically harmful compounds, but the ZnO-based alternative reported here is cheap, clean and scalable.

Automated summary

Propane dehydrogenation to propene is an important industrial process, but current commercial catalysts often suffer from toxicity or ecological concerns. A new environmentally friendly catalyst based on ZnO has been developed, showing higher propene productivity and selectivity compared to traditional catalysts.