New development in Fe/Co catalysts: Structure modulation and performance optimization for syngas conversion

Abstract

C1 chemistry is the essence of coal chemistry and natural gas chemistry. Catalytic methods to efficiently convert C1 molecules into fuels and chemicals have been extensively studied. Syngas (CO + H2) conversion is the most important industrial reaction system in C1 chemistry, and Fe and Co catalysts, two major industrial catalysts, have been the focus of fundamental research and industrial application. In the last decade, considerable research efforts have been devoted to discoveries concerning catalyst structure and increasing market demands for olefins and oxygenates. Since the development of efficient catalysts would strongly benefit from catalyst design and the establishment of a new reaction system, this review comprehensively overviews syngas conversion in three main reactions, highlights the advances recently made and the challenges that remain open, and will stimulate future research activities. The first part of the review summarizes the breakthroughs in Fischer-Tropsch synthesis regarding the optimization of activity and stability, determination of the active phase, and mechanistic studies. The second part overviews the modulation of catalytic structure and product selectivity for Fischer-Tropsch to olefins (FTO). Catalysts designed to produce higher alcohols, as well as to tune product selectivity in C1 chemistry, are described in the third section. Finally, present challenges in syngas conversion are proposed, and the solutions and prospects are discussed from the viewpoint of fundamental research and practical application. This review summarizes the latest advances in the design, preparation, and application of Fe/Co-based catalysts toward syngas conversion and presents the challenges and future directions in producing value-added fuels.