Conversion Of Hydrocarbons Research Articles

Hydrothermally Ce modified HZSM-5 zeolite enhancing its strong acidity and Brønsted/Lewis acid ratio: Stably boosting ethylene/propylene ratio for cracking n-heptane

Modulating zeolite acidity by conventional metal impregnation is a challenge in preparing hydrocarbon cracking catalyst, which often eliminates its intrinsic strong acidity, resulting in reduced the hydrocarbon conversion capacity and low light olefins (C2=-C4=) yield. Here, the Ce/HZ5-HM and CeO2/HZ5-HM catalysts were readily prepared by hydrothermally modifying HZSM-5 zeolite (HZ5) with cerium salts (Ce3+) and cerium oxide (CeO2), respectively. Comparatively, Ce/HZ5-IW catalyst was obtained by modifying HZ5 with Ce3+ using the incipient wetness impregnation. It is revealed that, compared to HZ5, Ce/HZ5-HM and CeO2/HZ5-HM catalysts have an increased ratio of strong/weak (S/W) acid and Brønsted/Lewis (B/L) acid, while Ce/HZ5-IW sample has reduced strong acidity. Further, the Ce/HZ5-HM exhibits higher acid strength, acid density, and B/L value than that of CeO2/HZ5-HM sample. When applied to cracking n-heptane reaction, compared with HZ5 and Ce/HZ5-IW, heptane conversion and ethylene yield on Ce/HZ5-HM and CeO2/HZ5-HM catalysts increase by 6–11 % and 7–9 %, yielding the ratio of ethylene/propylene (E/P) more than 1. Moreover, Ce/HZ5-HM and CeO2/HZ5-HM catalysts perform a lifetime of 117 h and 150 h, with four-to-five times longer than that of HZ5 zeolite (∼29 h) and Ce/HZ5-IW catalyst (∼39 h). The characterization results demonstrate that, adopting hydrothermal method ensures more Ce3+ interacting with the silanol groups in Ce/HZ5-HM, generating the new Brønsted acid sites and makes CeOx species incorporating into the hydroxyl nest of zeolite, which can heal the defective sites and improve stabilization of acidity and framework structure of zeolite. Therefore, the above two catalysts can highlight the monomolecular cracking reaction, low coke deposit rate, long catalytic stability.

Integrated 1D Simulation of Aftertreatment System and Chemistry-Based Multizone RCCI Combustion for Optimal Performance with Methane Oxidation Catalyst

This paper presents a comprehensive investigation into the design of a methane oxidation catalyst aftertreatment system specifically tailored for the Wärtsilä W31DF natural gas engine which has been converted to a reactivity-controlled compression ignition NG/Diesel engine. A GT-Power model was coupled with a predictive physical base chemical kinetic multizone model (MZM) as a combustion object. In this MZM simulation, a set of 54 species and 269 reactions as chemical kinetic mechanism were used for modelling combustion and emissions. Aftertreatment simulations were conducted using a 1D air-path model in the same GT-Power model, integrated with a chemical kinetic model featuring 15 catalytic reactions, based on activation energy and species concentrations from combustion outputs. The latter offered detailed exhaust composition and exhaust thermodynamic data under specific operating conditions, effectively capturing the intricate interactions between the investigated aftertreatment system, combustion, and exhaust composition. Special emphasis was placed on the formation of intermediate hydrocarbons such as C2H4 and C2H6, despite their concentrations being lower than that of CH4. The analysis of catalytic conversion focused on key species, including H2O, CO2, CO, CH4, C2H4, and C2H6, examining their interactions. After consideration of thermal management and pressure drop, a practical choice of a 400 mm long catalyst with a density of 10 cells per cm2 was selected. Investigations of this catalyst’s specification revealed complete CO conversion and a minimum of 89% hydrocarbon conversion efficiency. Integrating the exhaust aftertreatment system into the air path resulted in a reduction in engine-indicated efficiency by up to 2.65% but did not affect in-cylinder combustion.

Efficacy of initiators on fuel conversion, heat sink, and coke propensity of hydrocarbon fuel under supercritical environment

The investigation includes the cracking characteristics of a multi-component hydrocarbon fuel with a boiling range of 149–224 °C under supercritical environments. The impact of reactor pressure and the influence of initiators on cracking characteristics, such as fuel conversion, coke deposition, gas and liquid product distribution pattern, and heat sink capacities, of the fuel are examined explicitly. The fuel conversion improved by 70.8% as the reactor pressure increased from 2.5 MPa to 5.5 MPa at 650 °C. However, the coke deposition also increased by 55% for the corresponding pressure range. A decrease in the olefin-to-alkane ratio with pressure signifies the possibility of a reduction in unimolecular decomposition reactions and an increase in bimolecular reactions. The efficacy of two initiators, namely triethylamine (TEA) and di-tert-butyl peroxide (DTBP), on heat sinks and coke deposition was also examined. Between the two initiators, the nitrogen-based TEA initiator showed better performance in terms of fuel conversion and coke deposition rate, and the oxygen-based DTBP offered better heat sink capacity. About 22% increment in endothermicity was obtained with 1 wt% DTBP loading at 650 °C under 5.5 MPa pressure.

Ni and Ru bimetal nanoparticles-anchored porous Mo2C nanorods used as an internal reforming catalyst layer for hydrocarbon-fueled solid oxide fuel cells

Solid oxide fuel cells (SOFCs) are considered the most efficient technology for the direct conversion of hydrocarbons to electrical energy. Although the commonly used Ni/YSZ cermet materials in SOFCs show excellent electrocatalytic properties in H2 fuel, they suffer from carbon deposition problem when hydrocarbon fuels are used. In this work, we study the use of Ni0·05Ru0.05-Mo2C with a porous nanorod-shaped morphology as an internal reforming catalyst layer for methane-fueled SOFCs to solve the degradation of cell performance due to carbon deposition. The electrochemical performance and coking tolerance of two types of cells with and without the catalyst layer were systematically studied using methane and hydrogen as fuels. With the catalyst layer, the single cell using methane as fuel exhibits an improvement in peak power density by 24%, increasing from 297 to 367 mW cm−2 and there was no diffusion barrier for fuel gases within the cell. Furthermore, the cell can stably run for 100 h in methane at 700 °C. The improvement of electrochemical performance is attributed to the synergistic effect of Ni and Ru sites anchored on the porous Mo2C nanorods catalyst based on strong metal-support interactions, promoting the effective catalytic conversion of CH4 to CO and H2. This study demonstrates that the integration of a catalyst layer for internal reforming is an effective strategy for the direct use of methane in SOFCs.

Preparation of monocyclic aromatic hydrocarbons from industrial lignin residue and polyethylene co-pyrolysis by microwave-assisted in fluidized bed based on bimetal-loaded HZSM-5/MCM-41 core-shell catalyst

Enzymatic hydrolysis lignin (EHL), lignosulfonate (LS), alkali lignin (AL), and hydrolysis lignin (HL) residues are mostly burned for heating in industrial production, which greatly wastes resources and pollutes the environment. In this study, we investigated the effects of different temperatures and catalyst-to-biomass mass (C/B) ratios on the relative content of hydrocarbons in the products by microwave-assisted pyrolysis in a fluidized bed. Co and Ni bimetal-loaded molecular sieve with core-shell structure (Co-Ni@H/M) was used as the catalyst. The main component of waste plastic, polyethylene (PE), was pyrolyzed with these four lignin residues to prepare monocyclic aromatic hydrocarbons (MAHs), and the mechanism of synergistic interaction in co-pyrolysis was investigated. It was shown that the maximum liquid phase yield and hydrocarbons relative content were obtained at 550 °C when lignin residues were pyrolyzed alone. Compared with the pyrolysis of lignin residues alone, the liquid phase and gas phase yields of co-pyrolysis were improved, while the solid phase yield decreased. Moreover, the temperature for maximum liquid phase yield and hydrocarbons relative content were reduced to 500 °C. Further exploration of the liquid phase products revealed that the relative contents of hydrocarbons in the four lignin residues and PE (EHL-PE, LS-PE, AL-PE, and HL-PE) co-pyrolysis products at 500 °C were 49.6 %, 33.1 %, 37.7 %, and 43.2 %, respectively, with MAHs as the main components. The results of the effect of different C/B ratios on the distribution of pyrolysis products showed that Co-Ni@H/M promoted the deoxygenation of oxygenated compounds, especially phenolic compounds, and the conversion of aliphatic hydrocarbons into MAHs by cyclization and aromatization.

Photocatalytic aerobic oxidation of C(sp3)-H bonds

In modern industries, the aerobic oxidation of C(sp3)-H bonds to achieve the value-added conversion of hydrocarbons requires high temperatures and pressures, which significantly increases energy consumption and capital investment. The development of a light-driven strategy, even under natural sunlight and ambient air, is therefore of great significance. Here we develop a series of hetero-motif molecular junction photocatalysts containing two bifunctional motifs. With these materials, the reduction of O2 and oxidation of C(sp3)-H bonds can be effectively accomplished, thus realizing efficient aerobic oxidation of C(sp3)-H bonds in e.g., toluene and ethylbenzene. Especially for ethylbenzene oxidation reactions, excellent catalytic capacity (861 mmol g cat−1) is observed. In addition to the direct oxidation of C(sp3)-H bonds, CeBTTD-A can also be applied to other types of aerobic oxidation reactions highlighting their potential for industrial applications.

A five-lump coupled kinetic model for residue hydrodesulfurization in an ebullated bed based on hydrocracking model

Extensive attention is usually paid to sulfur removal in the residue hydrodesulfurization (HDS) process, however, the sulfur transfer (sulfur compounds are cracked into the low molecular weight sulfur compounds) is always neglected. In order to solve above problems, a five-lump coupled kinetic model for residue HDS based on hydrocracking model was proposed. A residue hydrocracking model with an absolute average error of less than 5 % was established firstly. Then the correlation between hydrocarbon conversion and sulfur transfer was established and the kinetics of sulfur transfer was described by employing this correlation. Subsequently, a coupled model for residue HDS was developed and the results showed the heavier the components were, the greater the amount of sulfur transfer would be. Compared to the conventional HDS model, the coupled model could calculate sulfur transfer and sulfur removal synchronously. For example, for components with boiling point above 600 °C, 52.4 % sulfur was converted into the hydrogen sulfide and 22.4 % sulfur was transferred within 4 h at 400 °C. The developed coupled model could provide a deep insight into the understanding of residue HDS.

Pioneering the Future: A Trailblazing Review of the Fusion of Computational Fluid Dynamics and Machine Learning Revolutionizing Plasma Catalysis and Non-Thermal Plasma Reactor Design

The advancement of plasma technology is intricately linked with the utilization of computational fluid dynamics (CFD) models, which play a pivotal role in the design and optimization of industrial-scale plasma reactors. This comprehensive compilation encapsulates the evolving landscape of plasma reactor design, encompassing fluid dynamics, chemical kinetics, heat transfer, and radiation energy. By employing diverse tools such as FLUENT, Python, MATLAB, and Abaqus, CFD techniques unravel the complexities of turbulence, multiphase flow, and species transport. The spectrum of plasma behavior equations, including ion and electron densities, electric fields, and recombination reactions, is presented in a holistic manner. The modeling of non-thermal plasma reactors, underpinned by precise mathematical formulations and computational strategies, is further empowered by the integration of machine learning algorithms for predictive modeling and optimization. From biomass gasification to intricate chemical reactions, this work underscores the versatile potential of plasma hybrid modeling in reshaping various industrial processes. Within the sphere of plasma catalysis, modeling and simulation methodologies have paved the way for transformative progress. Encompassing reactor configurations, kinetic pathways, hydrogen production, waste valorization, and beyond, this compilation offers a panoramic view of the multifaceted dimensions of plasma catalysis. Microkinetic modeling and catalyst design emerge as focal points for optimizing CO2 conversion, while the intricate interplay between plasma and catalysts illuminates insights into ammonia synthesis, methane reforming, and hydrocarbon conversion. Leveraging neural networks and advanced modeling techniques enables predictive prowess in the optimization of plasma-catalytic processes. The integration of plasma and catalysts for diverse applications, from waste valorization to syngas production and direct CO2/CH4 conversion, exemplifies the wide-reaching potential of plasma catalysis in sustainable practices. Ultimately, this anthology underscores the transformative influence of modeling and simulation in shaping the forefront of plasma-catalytic processes, fostering innovation and sustainable applications.

Silica as support and binder in bifunctional catalysts with ultralow Pt loadings for the hydroconversion of n-alkanes

Hydroconversion is a key step in the production of ultraclean fuels from renewable sources. This reaction is carried out using a bifunctional catalyst consisting of a base metal sulfide or a noble metal and a solid acid. Recently, we have shown that for Pt/Al2O3/ZSM-22 catalysts with low Pt loadings (≤0.01 wt%) it is advantageous – to both the activity as well as the isomer selectivity - to emplace the Pt on the zeolite crystallites instead of on the Al2O3 binder. When these low loadings of Pt were on the alumina binder, small clusters or even single atoms were present which were hard to reduce leading to inactivity of the catalysts. Herein, we explore the replacement of alumina by silica, and the performance of catalysts with ultralow Pt loadings on the conversion of longer-chain hydrocarbons. A series of Pt/SiO2/ZSM-22 catalysts with varying Pt weight loadings (0.001, 0.005, 0.01, 0.05, 0.1 and 0.5 wt%) and location (on silica or on ZSM-22) was prepared and characterized using ICP, NH3-TPD, HAADF-STEM and XAS. Their hydroconversion performance was evaluated using n-heptane and n-hexadecane as model feedstocks. As for the Pt/Al2O3/ZSM-22 catalysts systems, for Pt/SiO2/ZSM-22 catalysts with low Pt loadings (≤0.01 wt% for n-heptane conversion) it was beneficial to have the Pt nanoparticles on the ZSM-22 crystals. Hydroconversion of n-hexadecane over Pt/SiO2/ZSM-22 and Pt/Al2O3/ZSM-22 catalysts showed that for feedstocks with a higher molecular weight, higher Pt loadings (≥0.05 wt%) are required for sufficient catalytic performance. For the conversion of n-hexadecane it was beneficial to locate these higher amounts of Pt on the binder.

Hollow Zeolite Nanoreactor with Double Shells for Methanol Aromatization: Explicit Recognition on Catalytic Function of Inverse Elemental Zone and Shell-Cavity.

Core@shell catalyst composited of dual aluminosilicate zeolite can effectively regulate the distribution of acid sites to control hydrocarbon conversion process for the stable formation of target product. However, the diffusion restriction reduces the accessibility of inner active sites and affects synergy between core and shell. Herein, hollow ZSM-5 zeolite nanoreactor with inverse aluminum distribution and double shells are prepared and employed for methanol aromatization. It is demonstrated that the intershell cavity alleviated the steric hindrance from zeolites channel and provided more paths and pore entrance for guest molecule. Correspondingly, olefin intermediates generated from methanol over the external shell are easier to adsorb at internal acid sites for further reactions. Importantly, the diffusion of generated aromatic macromolecules to the external surface is also promoted, which slows down the formation of internal coke, and ensures the use of internal acid sites for aromatization. The aromatics selectivity of the nanoreactor remained at 8% after 154h, while that of solid core@shell catalyst decreased to 2% after 75h. This finding promises broader insight to improve internal active site utilization of core@shell catalyst at the diffusion level and can be great aid in the flexible design of multifunctional nanoreactors to enhance the relay efficiency.

Dominant role of zeolite in coordination between metal and acid sites on an industrial catalyst for tetralin hydrocracking

An effective approach for upgrading light cycle oil (LCO) is the targeted conversion of poly-aromatic hydrocarbons to valuable monoaromatic hydrocarbons.

Morphological effect of MnO2 promoter on iron-based Fischer-Tropsch synthesis catalysts

In this work, flower-like spherical, sea urchin-like and tubular MnO2 are prepared via hydrothermal synthesis and used as promoters of iron-based Fischer-Tropsch synthesis (FTS) catalysts to investigate their morphological effects. It is found that the different morphology of MnO2 exhibits observably distinct promotion functions on iron-based FTS catalysts. Tubular MnO2 contains moderate amount of surface oxygen vacancies accompany with weak Fe-Mn electronical interaction, as a result, tubular MnO2 promotes the formation of long-chain hydrocarbon and olefins, and restrains the generation of CH4. Flower-like spherical MnO2 presents negative roles in the CO conversion and formation of long-chain hydrocarbon, due to its insufficient oxygen vacancies and moderate Fe-Mn electronical interaction. With the most abundance of oxygen vacancies and strongest Fe-Mn interaction, sea urchin-like MnO2 modified catalysts exhibits the highest initial CO conversion, but deactivates rapidly. Besides, the sea urchin-like MnO2 enhances the formation of long-chain paraffins. This work presents new insights of the promotion roles of Mn additive, which is beneficial for the rational design of efficient iron-based FTS catalysts.

The evolutions of Pt with different initial sizes during propane oxidation over Pt-CeO2 catalysts

Pt-based catalysts are widely used in catalytic combustion of hydrocarbons and play an important role in emission control. However, developing a Pt catalyst for efficient conversion of hydrocarbons at low...

Selectivity descriptors of the catalytic n-hexane cracking process over 10-membered ring zeolites.

Zeolite-mediated catalytic cracking of alkanes is pivotal in the petrochemical and refining industry, breaking down heavier hydrocarbon feedstocks into fuels and chemicals. Its relevance also extends to emerging technologies such as biomass and plastic valorization. Zeolite catalysts, with shape selectivity and selective adsorption capabilities, enhance efficiency and sustainability due to their well-defined network of pores, dimensionality, cages/cavities, and channels. This study focuses on the alkane cracking over 10-membered ring (10-MR) zeolites under industrially relevant conditions. Through a series of characterizations, including operando UV-vis spectroscopy and solid-state NMR spectroscopy, we intend to address mechanistic debates about the alkane cracking mechanism, aiming to understand the dependence of product selectivity on zeolite topologies. The findings highlight topology-dependent mechanisms, particularly the role of intersectional void spaces in zeolite ZSM-5, influencing aromatic-based product selectivity. This work provides a unique understanding of zeolite-catalyzed hydrocarbon conversion, linking alkane activation steps to the traditional hydrocarbon pool mechanism, contributing to the fundamental knowledge of this crucial industrial process.

Strategies for Sustainable Fuel Production Via Photoelectrochemical Synthesis

Developing sustainable energy is highly imperative for humankind owing to the drastic rise in world population and the proportional rise in energy demand at the expense of energy consumption. Various efforts have been made to explore, generate, store, and utilize renewable energy to replace fossil fuels. Among them, solar energy is considered an alternative to fossil fuels because it is inexhaustible, clean, cost-effective, and versatile. Interestingly, this prime source provides massive energy that is high enough (1.9 × 108 TWh/yr) to counterattack global energy consumption (1.3 × 105 TWh/yr).Photoelectrochemistry has been considered a promising route to harness this incredible energy by producing sustainable energy fuels and carriers such as hydrogen, hydrocarbon, and ammonia. PEC systems have the great advantages of simple process steps and very low environmental burdens. However, this technology must overcome many challenges regarding commercial applications, particularly in fabricating electrode materials for PEC water splitting.One of the most important challenges to overcome this problem is discovering efficient catalysts for implementing photoelectrochemical (PEC) fuel production. A critical requirement for outstanding catalysts is an ability to boost the kinetics of a chemical reaction and durability against electrochemical and photo-induced degradation. Moreover, the charge-separation and transfer mechanism are the two paramount properties to consider while designing photoelectrodes. Briefly, the semiconductor materials to be used in PEC water splitting must possess a conduction band potential more negative than the reduction edge of hydrogen and a valence band potential positive to actuate water oxidation. In practice, the photocurrent density and solar-to-hydrogen (STH) efficiency of the n-type semiconductors are far behind the theoretical values.To address this critical and long-standing technical barrier, I have focused on an intense search for efficient, durable, and inexpensive alternative catalysts with moderate band gap, efficient charge excitation-separation property, and high solar energy conversion efficiency for photoelectrochemical systems of water splitting, hydrocarbon conversion, and ammonia production. Keywords : Photoelectrochemistry, Sustainable Energy, Water Splitting, Ammonia synthesis, Urea synthesis, Hydrocarbon

Рt/SAPO-11 Catalytic Systems Differing in Acidity and Secondary Pore Structure in n-Hexadecane Hydroisomerization

SAPO-11 molecular sieve samples differing in the acid properties, crystal morphology and size, and secondary pore structure characteristics were obtained by crystallization of reaction gels with the SiO2/Al2O3 molar ratios of 0.1 and 0.3, prepared using aluminum isopropoxide or boehmite as an aluminum source. Platinum (0.5 wt %) was deposited onto the molecular sieves prepared, and the catalytic properties of the resulting samples in n-hexadecane hydroisomerization were studied. The hydrocarbon conversion on these samples varies from 76.8 to 87.7 wt %, and the isoparaffin formation selectivity, from 76.7 to 91.2 wt %.

Probing the Nature of Surface Hydrides by Deuterium Quadrupolar Parameters: A Case Study on Silica‐Supported Zirconium Hydrides

AbstractSupported metal hydrides are key reactive intermediates in various catalytic processes, such as hydrogenation and dehydrogenation, but are often challenging to characterize spectroscopically. Here, deuterium solid state nuclear magnetic resonance spectroscopy is used to understand the structure of the corresponding silica‐supported zirconium hydrides after H/D exchange as an illustrative example of supported metal hydrides, which have been shown to display notable reactivity towards small molecules (e. g., CO2 and N2O) and to activate both C−H and C−C bonds, hence their use in to the conversion of hydrocarbons (alkanes, polyolefins etc.)

Cu-promoted Ni-LaCeOx/SBA-15 catalysts for ethanol steam reforming

Hydrogen is a globally recognized high-energy, clean, and ecofriendly fuel that is currently produced by means of electrocatalysis, biomass conversion, coal gasification, and thermal decomposition of hydrocarbons, with the steam reforming showing high potential. The present work is focused on Cu-promoted SBA-15-supported Ni-LaCeOx catalysts for ethanol steam reforming (ESR). The catalysts were prepared by incipient wetness impregnation and characterized by XRF, N2 adsorption-desorption, IR spectroscopy, SAXS, XRD, H2-TPR, Raman, and STA methods. The support features caused by the distribution of LaCeOx NPs and Cu promoter in proper ratios affect the conditions of formation of active dispersed Ni species to determine the catalyst performance and its reducibility. At 800 оС, the NiСu-LaCeOx/SBA-15 (1:1) catalyst demonstrates a 100 % ethanol conversion and 55 % hydrogen yield. Thus, the role of the Cu-containing promoter comprises both a significant decrease of carbon deposits on the catalyst surface and redirecting of the intermediate interactions towards the formation of the desired gaseous products.

Experimental investigation on gas emission characteristics of ammonia/diesel dual-fuel engine equipped with DOC + SCR aftertreatment

After-treatment device diesel oxidation catalyst (DOC) and selective catalytic reduction (SCR) were installed in the exhaust system of ammonia/diesel dual-fuel engine to remove harmful pollutants such as hydrocarbon (HC), carbon monoxide (CO), ammonia (NH3), nitrogen oxide (NOx), nitrous oxide (N2O) and other pollutants produced by the dual-fuel combustion mode. The results indicate that the HC, CO and N2O emissions of ammonia/diesel dual-fuel engine increase with the increment of ammonia fraction, whereas NOx emissions decrease. At 50 % load, the CO conversion efficiency of DOC decreases from 100 % at diesel-only mode to 18.9 % at 40 % ammonia fraction, while the HC conversion efficiency is independent of ammonia fraction. NOx can be reduced by NH3 in the exhaust, while NH3 will be oxidized to N2O and NOx in DOC. Moreover, at 50 % load, more NH3 emission is oxidized to N2O compared to 75 % load. After SCR, the NOx, N2O and NH3 emissions in the exhaust are further reduced, but due to the NH3/NOx ratio, there are still a large amount of NOx and NH3 emissions at SCR outlet. The N2O conversion efficiency of SCR is relatively low, with a maximum value of only 47.8 % at 50 % load and 30 % ammonia fraction. Owing to the high N2O emission from dual-fuel engine, the direct introduction of ammonia cannot significantly reduce greenhouse gas (GHG) emissions. Furthermore, the massive amount of unburnt ammonia in the exhaust is oxidized to N2O by DOC, leading to a sharp increase in GHG emissions after DOC + SCR aftertreatment, and the GHG emissions at 50 % load and 40 % ammonia fraction are 6.2 times higher than those before the aftertreatment, and 9.2 times higher than those of diesel-only mode.

Smart Dual-Exsolved Self-Assembled Anode Enables Efficient and Robust Methane-Fueled Solid Oxide Fuel Cells.

Perovskite oxides have emerged as alternative anode materials for hydrocarbon-fueled solid oxide fuel cells (SOFCs). Nevertheless, the sluggish kinetics for hydrocarbon conversion hinder their commercial applications. Herein, a novel dual-exsolved self-assembled anode for CH4 -fueled SOFCs is developed. The designed Ru@Ru-Sr2 Fe1.5 Mo0.5 O6-δ (SFM)/Ru-Gd0.1 Ce0.9 O2-δ (GDC) anode exhibits a unique hierarchical structure of nano-heterointerfaces exsolved on submicron skeletons. As a result, the Ru@Ru-SFM/Ru-GDC anode-based single cell achieves high peak power densities of 1.03 and 0.63Wcm-2 at 800°C under humidified H2 and CH4 , surpassing most reported perovskite-based anodes. Moreover, this anode demonstrates negligible degradation over 200h in humidified CH4 , indicating high resistance to carbon deposition. Density functional theory calculations reveal that the created metal-oxide heterointerfaces of Ru@Ru-SFM and Ru@Ru-GDC have higher intrinsic activities for CH4 conversion compared to pristine SFM. These findings highlight a viable design of the dual-exsolved self-assembled anode for efficient and robust hydrocarbon-fueled SOFCs.