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

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 CO 2 intensity (up to 2 tons CO 2 /ton C 2 H 4 ), 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.% Na 2 WO 4 to SrMnO 3 and CaMnO 3 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. Na 2 WO 4 /CaMnO 3 demonstrated significantly higher olefin yield (55–58%) when compared to that from thermal cracking (34%) at 725 °C and 4500 h −1 . CO x yield as low as 1.7% was achieved along with complete combustion of H 2 over 25 cycles. Similarly, Na 2 WO 4 /SrMnO 3 achieved 41% olefin yield, 0.4% CO x yield, and 73% H 2 combustion at this condition. Oxygen-temperature-programmed desorption (O 2 -TPD) indicated that Na 2 WO 4 hindered gaseous oxygen release from CaMnO 3 . Low-energy ion scattering (LEIS) and X-ray photoelectron spectroscopy (XPS) revealed an outermost perovskite surface layer covered by Na 2 WO 4 , 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 SrMnO 3 with Na 2 WO 4 suppressed surface Sr species by 90%, with a similar effect also observed on CaMnO 3 . These findings point to the promoting effect of Na 2 WO 4 and the potential of promoted SrMnO 3 and CaMnO 3 as selective redox catalysts for efficient production of light olefins from naphtha via the ROC process.