(57f) Electrifying Propane Dehydrogenation Via Radio Frequency Heating for Sustainable Catalysis

The transition to electrified chemical manufacturing is gaining traction as industries seek to reduce reliance on fossil fuels and lower greenhouse gas emissions. Propane dehydrogenation (PDH), a key process for on-purpose propylene production, is highly endothermic and traditionally relies on fossil fuel-fired heaters to achieve the required high temperatures. This work explores radio frequency (RF) heating as an electrified alternative, capable of delivering selective, volumetric heating to Pt-Sn/Al₂O₃ catalysts supported on washcoated cordierite monoliths.

This study integrates RF-responsive materials into catalyst structures to enable rapid, localized heating and improve thermal control and energy efficiency in PDH reactions. To achieve this, we developed RF-responsive catalyst hybrids incorporating multi-walled carbon nanotubes (MWCNTs) as susceptors to facilitate direct RF energy absorption. A fixed-bed reactor was employed to compare the performance of conventional heating and RF heating. Catalytic experiments at temperatures around 500 °C using Pt/Al₂O₃ demonstrated that RF heating enables comparable propane conversion while allowing for localized heating, potentially reducing overall energy losses. The addition of Sn to the Pt-based catalyst further improved selectivity toward propylene, with a notable suppression of methane formation as the Sn/Pt ratio increased. Additionally, early results of RF heating suggest that precise susceptor control may allow for in-situ regeneration of the catalyst, supporting sustained reactor performance.

This work highlights the potential of RF heating as an electrified alternative for high-temperature catalytic processes. The integration of RF-responsive materials into reactor systems enables more efficient heat management, faster thermal response, and reduced dependence on fossil fuel-derived energy. Ongoing efforts aim to optimize RF absorption characteristics, enhance regeneration capabilities, and extend this approach to other endothermic catalytic reactions relevant to sustainable chemical manufacturing.