Innovative zeolite-supported platinum catalysts for highly efficient propane-to-propylene conversion

Innovative zeolite-supported platinum catalysts for highly efficient propane-to-propylene conversion

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Obtaining feedstocks through catalytic processes is of fundamental importance for the chemical industry. The shale gas revolution has shifted propylene production from naphtha cracking to targeted production with propane dehydrogenation (PDH) as the dominant technology. Recent studies, conducted jointly by Chinese research teams from the Universities of Fuzhou, Quanzhou, and Dalian, in collaboration with Professor Paolo Fornasiero, Head of the URT CNR-ICCOM in Trieste, have been published in the prestigious journals Nature and Science.

These studies demonstrated that, under appropriate conditions, spontaneous dispersion of platinum into single atoms can be achieved in a zeolite containing a low germanium content. This catalyst demonstrated high activity in PDH reactions, and after prolonged use, the oxidative removal of accumulated carbon allowed the platinum clusters that had formed to be redispersed into single atoms. This self-regeneration was achieved for over 110 reaction-regeneration cycles and, unlike commercial platinum- and tin-based catalysts, did not require the addition of chlorine.

Huizhen Hong et al., A self-regenerating Pt/Ge-MFI zeolite for propane dehydrogenation with high endurance. Science 2025, 388, 497-502. https://doi.org/10.1126/science.adu6907.

Silicalite-1-supported Pt–Sn catalysts have also been developed for this class of reactions. It has been demonstrated that the migration of encapsulated Pt–Sn2 clusters can be controlled by adjusting the length of the b-axis of the S-1 crystals. Intracrystalline formation of (Pt–Sn2)2 dimers allows the conversion of pure propane to propylene at 550 °C for over 6 months with a selectivity of 98.3% at 91% equilibrium conversion. This performance surpasses that of other Pt-based PDH catalysts and approaches that of the Rh-based catalyst. This could enable the development of other noble metal-based catalysts, ensuring longer lifetimes in industrial applications.

Xu, Z., Gao, M., Wei, Y., et al. Pt migration–lockup in zeolite for stable propane dehydrogenation catalyst. Nature 2025, 643, 691–698. https://doi.org/10.1038/s41586-025-09168-8.