A tailored multi-functional catalyst for ultra-efficient styrene production under a cyclic redox scheme

Xing Zhu, Yunfei Gao, Xijun Wang, Vasudev Haribal, Junchen Liu, Luke M. Neal, Zhenghong Bao, Zili Wu, Hua Wang and Fanxing Li ()
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Xing Zhu: North Carolina State University
Yunfei Gao: North Carolina State University
Xijun Wang: North Carolina State University
Vasudev Haribal: North Carolina State University
Junchen Liu: North Carolina State University
Luke M. Neal: North Carolina State University
Zhenghong Bao: Chemical Science Division and Center for Nanophase Materials Sciences
Zili Wu: Chemical Science Division and Center for Nanophase Materials Sciences
Hua Wang: Kunming University of Science and Technology
Fanxing Li: North Carolina State University

Nature Communications, 2021, vol. 12, issue 1, 1-11

Abstract: Abstract Styrene is an important commodity chemical that is highly energy and CO2 intensive to produce. We report a redox oxidative dehydrogenation (redox-ODH) strategy to efficiently produce styrene. Facilitated by a multifunctional (Ca/Mn)1−xO@KFeO2 core-shell redox catalyst which acts as (i) a heterogeneous catalyst, (ii) an oxygen separation agent, and (iii) a selective hydrogen combustion material, redox-ODH auto-thermally converts ethylbenzene to styrene with up to 97% single-pass conversion and >94% selectivity. This represents a 72% yield increase compared to commercial dehydrogenation on a relative basis, leading to 82% energy savings and 79% CO2 emission reduction. The redox catalyst is composed of a catalytically active KFeO2 shell and a (Ca/Mn)1−xO core for reversible lattice oxygen storage and donation. The lattice oxygen donation from (Ca/Mn)1−xO sacrificially stabilizes Fe3+ in the shell to maintain high catalytic activity and coke resistance. From a practical standpoint, the redox catalyst exhibits excellent long-term performance under industrially compatible conditions.

Date: 2021
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DOI: 10.1038/s41467-021-21374-2

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