Sponsored by Specac LtdReviewed by Maria OsipovaMar 5 2025
2024 was predicted to be the hottest year on record, with global temperatures exceeding 1.5 °C above pre-industrial levels for the first time.
Numerous organizations, industries, and nations have pledged to reach net-zero carbon emissions in the coming decades to help curb rising temperatures. However, achieving these ambitious goals will require technological advancements that improve efficiency and sustainability in industrial processes.
The petrochemical industry, which derives chemical products from oil and natural gas, will be pivotal in this transition.
According to ING Research and the International Energy Agency, carbon dioxide emissions from this sector increased by 41 % in the decade leading up to 2020.1 However, emissions from the industry must be 12 % lower than 2020 levels by 2030, followed by more rapid reductions to meet net-zero targets by 2050.1
To continue producing high-value chemicals such as ammonia and methanol, the petrochemical industry must innovate to achieve these objectives.
BloombergNEF estimates that the sector will require an additional $759 billion investment to reach net zero by 2050.2 Investment in the development and optimization of catalyst technology will be crucial in reducing emissions across a wide array of processes.
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Applications of Catalysts in Petrochemicals
The utilization of catalysts to enhance industrial processes is well-established. For example, fluid catalytic cracking employs zeolite catalysts to refine heavy oil into gasoline and various petrochemical raw materials.3
Enhanced catalysts can decrease the temperatures necessary for breaking down heavy hydrocarbons, thereby reducing energy consumption, costs, and emissions.
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As the energy transition moves away from fossil fuel dependence, the role of catalysts will become increasingly important in developing innovative methods to satisfy our energy demands.
Catalysts are essential for efficiently converting basic starting materials into synthetic fuels and biofuels, such as transforming vegetable oils into biodiesel.
In addition to decreasing reliance on fossil fuel resources, catalysts can also facilitate carbon capture, utilization and storage (CCUS). This process involves sequestering residual emissions and potentially converting them into valuable products. CCUS has been deemed "critical" by the UK’s National Audit Office for meeting the country's legally binding climate goals.4
This strategy could also create economic incentives for carbon capture. Catalysts involved in these processes can generate chemicals such as methanol, establishing a closed carbon loop that promotes sustainability.
Research in this domain has identified nanoparticle organic hybrid materials capable of capturing and converting CO2.5 By transforming emissions into valuable products, these catalysts not only provide potential revenue streams but also bolster the case for investment in this technology.
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Enhancing Catalyst Performance through Research and Development
The significance of catalysts in promoting sustainability within the petrochemical sector necessitates a comprehensive understanding and analysis of these materials.
Among the analytical techniques needed for such analysis, Fourier Transform Infrared (FTIR) spectroscopy can provide valuable insights into the underlying reactions. By probing the molecular vibrations of a sample, researchers can observe reactions in real-time. With appropriate setup, this can be conducted under conditions closely resembling real-world scenarios.
For instance, in research involving nanoparticle organic hybrid materials, the team at Columbia University employed FTIR to monitor the evolution of bond formations and structural changes over time.5
These critical insights enabled the identification of the most effective materials under varying conditions and confirmed that the catalyst maintains its integrity after multiple cycles of capture and conversion.
The Role of Infrared Spectroscopy in Catalyst Optimization
There are several approaches to characterising catalysts with infrared spectroscopy, including via transmission spectroscopy or by diffuse reflectance, more commonly known as Diffuse Reflectance Infrared Fourier Transform Spectroscopy (DRIFTS).
Transmission IR is one of the most prevalent techniques for infrared studies due to its straightforward analysis. However, it necessitates pelletising the sample, which limits the surface area available for interaction between the solid sample and the reactant gases.
In contrast, DRIFTS facilitates the examination of powdered catalysts with high surface areas. The broader applicability of DRIFTS reduces sample preparation requirements by allowing researchers to work directly with any powder sample. It closely resembles the design of fixed-bed reactors, where gas flows over a heated catalyst sample, making it particularly suitable for petrochemical research and development.
DRIFTS is driving advanced research into catalysis in promising areas such as non-thermal plasma.6 This presents a potential pathway to electrify the production of valuable chemicals by energizing electrons to enable otherwise thermodynamically unfavorable reactions.
Techniques like DRIFTS provide an opportunity to explore the complex interactions between plasma and heterogeneous catalysts. With further advancements, this could enhance the cost and energy efficiency of these processes, contributing to the decarbonization of certain industrial sectors.
Precision Equipment for DRIFTS Experiments
The spectra produced by DRIFTS result from intricate interactions between light and the sample, making analysis more complex than in transmission mode. However, appropriate equipment can simplify this process.
Powdered catalyst materials scatter incoming infrared light in multiple directions, and this diffuse reflectance contains essential information about the chemical bonds being formed. Nonetheless, this diffuse scattering can be overshadowed by mirror-like specular reflection, complicating spectrum interpretation.
The Praying Mantis™ diffuse reflection accessory employs a sophisticated optical design with off-axis collection geometry to optimize the capture of diffuse reflected light. This results in higher-quality data that is easier to analyze.
Additionally, larger ellipsoidal mirrors enhance illumination and radiation collection, achieving superior optical efficiency and sensitivity.
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Researchers have utilized the Praying Mantis in the study of innovative catalysts known as supported catalytically active liquid metal solutions, which may facilitate more efficient production of light olefins through dehydrogenation.7
The Praying Mantis enabled the team to use CO as a probe molecule to investigate the behavior of active platinum species during propane conversion. This yielded valuable insights into atomic structure and catalyst poisoning, which is crucial for designing catalysts with enhanced efficiency and longevity, thus reducing the environmental impact of industrial chemical processes.
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These experiments can be conducted in a specialized reaction chamber that enables the meticulous examination of in situ catalyst activity, even under extreme conditions. The reaction chambers are capable of controlling temperatures ranging from -150 °C to 910 °C and pressures up to 34 bar.
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This high-pressure/high-temperature reaction cell has recently been utilized in research to elucidate the chemical intermediates generated during the catalytic hydrogenation of CO2.8
This research could enhance this critical process, which utilizes captured CO2 to produce lower olefins and higher hydrocarbons, thereby facilitating a more sustainable approach to meet industrial demand while reducing carbon emissions and dependence on fossil fuels.
Characterizing Catalysts to Drive Innovation and Sustainability
The transition towards net zero will necessitate numerous efficiency improvements and groundbreaking developments within the petrochemical industry.
Advances in catalysis have been instrumental in industrial processes for decades; however, this innovation in research and development will be significantly accelerated in the forthcoming era.
Catalyst characterization technologies, such as DRIFTS, can assist researchers in gaining a comprehensive understanding of the activity, structure, and durability of novel catalysts. This enhanced understanding will yield increased R&D productivity, resulting in more cost-effective and sustainable methodologies.
References
- ING (2023). Decarbonisation of petrochemicals needs more cross-sector effort. (online) ING.com. Available at: https://www.ing.com/Newsroom/News/Decarbonisation-of-petrochemicals-needs-more-cross-sector-effort.htm (Accessed 27 Feb. 2025).
- BloombergNEF. (2022). $759 Billion Required for a Net-Zero Petrochemicals Sector by 2050 | BloombergNEF. (online) Available at: https://about.bnef.com/blog/759-billion-required-for-a-net-zero-petrochemicals-sector-by-2050/ (Accessed 27 Feb. 2025).
- Vogt, E.T.C. and Weckhuysen, B.M. (2015). Fluid catalytic cracking: recent developments on the grand old lady of zeolite catalysis. Chemical Society Reviews, 44(20), pp.7342–7370. https://doi.org/10.1039/c5cs00376h.
- National Audit Office (NAO). (2024). Carbon Capture, Usage and Storage programme - NAO report. (online) Available at: https://www.nao.org.uk/reports/carbon-capture-usage-and-storage-programme/.
- SelectScience. (2018). Novel Material Offers Solution for Renewable Energy. (online) Available at: https://www.selectscience.net/article/novel-material-offers-solution-for-renewable-energy (Accessed 27 Feb. 2025).
- Stefano Dell’Orco, Leick, N., et al. (2024). Exploring opportunities in operando DRIFTS and complementary techniques for advancing plasma catalysis. EES Catalysis, (online) 2(5), pp.1059–1071. https://doi.org/10.1039/d4ey00088a.
- Bauer, T., et al (2019). Operando DRIFTS and DFT Study of Propane Dehydrogenation over Solid- and Liquid-Supported GaxPty Catalysts. ACS Catalysis, 9(4), pp.2842–2853. https://doi.org/10.1021/acscatal.8b04578.
- Fedorova, E.A., et al. (2024). Operando DRIFTS Investigations on Surface Intermediates and Effects of Potassium in CO2 Hydrogenation over a K−Fe/YZrOx Catalyst. ChemCatChem, 16(10). https://doi.org/10.1002/cctc.202301697.
This information has been sourced, reviewed and adapted from materials provided by Specac Ltd.
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