Cobalt Catalyst Outperforms Platinum in Key Industrial Reaction

Cobalt Catalyst Zeolite

In a groundbreaking advancement that could redefine catalytic chemistry and industrial sustainability, researchers from the Dalian Institute of Chemical Physics at the Chinese Academy of Sciences have unveiled a new cobalt-based catalyst capable of rivaling—and even surpassing—traditional platinum catalysts for propane dehydrogenation.

This innovation, published in Nature Catalysis, introduces CoS-1, a highly stable cobaltosilicate zeolite with isolated tetrahedral cobalt sites. It achieved an impressive propylene productivity of 9.7 kgC₃H₆·kgcat⁻¹·h⁻¹, exceeding the output of standard PtSn/Al₂O₃ industrial catalysts while using an Earth-abundant metal.

The Need for Non-Precious Catalysts

Propylene is a cornerstone of the petrochemical industry, vital for manufacturing plastics, synthetic rubbers, and other essential materials. However, its conventional production relies on precious-metal catalysts like platinum, which are expensive and resource-limited. The discovery of an efficient, stable, and cost-effective cobalt catalyst could dramatically reduce industrial dependence on such rare materials.

The Science Behind CoS-1

The catalyst was synthesized via a hydrothermal method involving cobalt salts, silica precursors, and structure-directing agents, followed by calcination and acid washing. This meticulous process eliminated unstable cobalt species and ensured only tetrahedrally coordinated Co atoms remained embedded in the zeolite framework.

Advanced modeling techniques, including density functional theory (DFT) and ab initio molecular dynamics simulations, revealed why CoS-1 is so effective. The flexible zeolite architecture introduces favorable entropic effects that lower dehydrogenation barriers compared to platinum-based alloys like Pt₃Sn. Furthermore, microkinetic simulations showed that while the reaction rate was initially slightly lower due to diffusion limits, overall catalytic efficiency remained high and stable over time.

Stability and Selectivity: Industrial Viability

One of the most compelling aspects of CoS-1 is its exceptional long-term stability. Unlike conventional catalysts that suffer from coke deposition, the CoS-1 design facilitates non-bonding adsorption of propylene, which supports rapid product desorption and minimizes catalyst deactivation. This positions it as an industrially viable solution for sustainable propane-to-propylene conversion.

A Step Toward Greener Chemistry

This cobalt catalyst represents a significant stride toward green catalysis, not only reducing reliance on platinum group metals but also offering a potentially cheaper and more scalable path for industrial chemical reactions. As demand for propylene continues to rise globally, innovations like CoS-1 could be key to maintaining supply while slashing environmental and economic costs.

🔬 Original article citation: Phys.org – Cobalt catalyst rivals platinum in key industrial reaction (May 20, 2025)

📘 Full journal publication: Nature Catalysis – DOI: 10.1038/s41929-025-01320-x

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