Perovskite oxides for redox oxidative cracking of n-hexane under a cyclic redox scheme

Abstract

Steam cracking of naphtha is a commercially proven technology for light olefin production and the primary source of ethylene in the Europe and Asia-Pacific markets. However, its significant energy consumption and high CO2 intensity (up to 2 tons CO2/ton C2H4), stemming from endothermic cracking reactions and complex product separations, make this state-of-the-art process increasingly undesirable from an environmental standpoint. We propose a redox oxidative cracking (ROC) approach as an alternative pathway for naphtha conversion. Enabled by perovskite oxide-based redox catalysts, the ROC process converts naphtha (represented by n-hexane) in an auto-thermal, cyclic redox mode. The addition of 20 wt.% Na2WO4 to SrMnO3 and CaMnO3 created highly selective redox catalysts capable of achieving enhanced olefin yields from n-hexane oxy-cracking. This was largely attributed to the redox catalysts’ high activity, selectivity, and stability towards selective hydrogen combustion (SHC) under a redox mode. Na2WO4/CaMnO3 demonstrated significantly higher olefin yield (55–58%) when compared to that from thermal cracking (34%) at 725 °C and 4500 h−1. COx yield as low as 1.7% was achieved along with complete combustion of H2 over 25 cycles. Similarly, Na2WO4/SrMnO3 achieved 41% olefin yield, 0.4% COx yield, and 73% H2 combustion at this condition. Oxygen-temperature-programmed desorption (O2-TPD) indicated that Na2WO4 hindered gaseous oxygen release from CaMnO3. Low-energy ion scattering (LEIS) and X-ray photoelectron spectroscopy (XPS) revealed an outermost perovskite surface layer covered by Na2WO4, which suppressed near-surface Mn and alkaline earth metal cations. The formation of non-selective surface oxygen species was also inhibited. XPS analysis further confirmed that promotion of SrMnO3 with Na2WO4 suppressed surface Sr species by 90%, with a similar effect also observed on CaMnO3. These findings point to the promoting effect of Na2WO4 and the potential of promoted SrMnO3 and CaMnO3 as selective redox catalysts for efficient production of light olefins from naphtha via the ROC process.