The Fundamentals for Efficient Non-oxidative Propane Dehydrogenation over ZrO2-Based Catalysts

The activation of C–H bonds in light alkanes efficiently is a challenging yet crucial aspect of heterogeneous catalysis. This process is essential for converting abundant hydrocarbon feedstocks into valuable products. The non-oxidative propane dehydrogenation to propene (PDH) has attracted widespread attention due to the presence of cheap propane in shale and has become the basis of an important on-purpose technology to bridge the gap between propene production and demand. It is also an important model reaction for studying the fundamentals of C–H bond activation. Compared to traditional oil-based cracking processes, the PDH reaction has the following advantages: (1) abundant propane recourses, mainly from shale gas and refinery plants, (2) high selectivity to propene (above 90%), and (3) the composition of the products is simple and easy to separate. Currently, commercial PDH processes rely on the Catofin and Oleflex technologies developed by CB&I Lummus and UOP Company, which apply PtSn/γ-Al₂O₃ and K–CrO_x/γ-Al₂O₃ catalysts, respectively. However, Pt-based catalysts are expensive and Cr(VI)O_x-based catalysts are toxic, limiting their application to a certain degree. Therefore, the search for environmentally friendly and cost-effective PDH catalysts has become a key topic of ongoing research.