The
selective production of C3+ olefins from renewable
feedstocks, especially via C1 and C2 platform
chemicals, is a critical challenge for obtaining economically viable
low-carbon middle-distillate transportation fuels (i.e., jet and diesel).
Here, we report a multifunctional catalyst system composed of Zn–Y/Beta
and “single-atom” alloy (SAA) Pt–Cu/Al2O3, which selectively catalyzes ethanol-to-olefin (C3+, ETO) valorization in the absence of cofed hydrogen, forming
butenes as the primary olefin products. Beta zeolites containing predominately
isolated Zn and Y metal sites catalyze ethanol upgrading steps (588
K, 3.1 kPa ethanol, ambient pressure) regardless of cofed hydrogen
partial pressure (0–98.3 kPa H2), forming butadiene
as the primary product (60% selectivity at an 87% conversion). The
Zn–Y/Beta catalyst possesses site-isolated Zn and Y Lewis acid
sites (at ∼7 wt % Y) and Brønsted acidic Y sites, the
latter of which have been previously uncharacterized. A secondary
bed of SAA Pt–Cu/Al2O3 selectively hydrogenates
butadiene to butene isomers at a consistent reaction temperature using
hydrogen generated in situ from ethanol to butadiene
(ETB) conversion. This unique hydrogenation reactivity at near-stoichiometric
hydrogen and butadiene partial pressures is not observed over monometallic
Pt or Cu catalysts, highlighting these operating conditions as a critical
SAA catalyst application area for conjugated diene selective hydrogenation
at high reaction temperatures (>573 K) and low H2/diene
ratios (e.g., 1:1). Single-bed steady-state selective hydrogenation
rates, associated apparent hydrogen and butadiene reaction orders,
and density functional theory (DFT) calculations of the Horiuti–Polanyi
reaction mechanisms indicate that the unique butadiene selective hydrogenation
reactivity over SAA Pt–Cu/Al2O3 reflects
lower hydrogen scission barriers relative to monometallic Cu surfaces
and limited butene binding energies relative to monometallic Pt surfaces.
DFT calculations further indicate the preferential desorption of butene
isomers over SAA Pt–Cu(111) and Cu(111) surfaces, while Pt(111)
surfaces favor subsequent butene hydrogenation reactions to form butane
over butene desorption events. Under operating conditions without
hydrogen cofeeding, this combination of Zn–Y/Beta and SAA Pt–Cu
catalysts can selectively form butenes (65% butenes, 78% C3+ selectivity at 94% conversion) and avoid butane formation using
only in situ-generated hydrogen, avoiding costly
hydrogen cofeeding requirements that hinder many renewable energy
processes.