Bimetallic and Trimetallic Catalysts Advancements in the Conventional and MW-Assisted Propane Dehydrogenation Process

A huge variety of chemical commodities are built from propylene molecules, and its conventional production technologies (naphtha steam cracking and fluid catalytic cracking) are unable to satisfy C3H6’s increasing requirements. In this scenario, Direct Propane Dehydrogenation (PDH) provides a practical and reliable route for supplying this short demand due to the economic availability of the raw material (C3H8) and the high propylene selectivities. The main challenges of propane dehydrogenation technology are related to the design of very active catalysts with negligible byproduct formation. In particular, the issue of catalyst deactivation by coke deposition still requires further development. In addition, PDH is a considerable endothermic reaction, and the efficiency of this technology is strictly related to heat transfer management. Thus, this current review specifically discusses the recent advances in highly dispersed bimetallic and trimetallic catalysts proposed for the PDH reaction in both conventional-heated and microwave-heated reactors. From the point of view of catalyst development, the recent research is mainly addressed to obtain nanometric and single-atom catalysts and core–shell alloys: atomically dispersed metal atoms promote the desorption of surface-bonded propylene and inhibit its further dehydrogenation. The discussion is focused on the alternative formulations proposed in the last few years, employing active species and supports different from the classical Pt-Sn/Al2O3 catalyst. Concerning the conventional route of energy-supply to the catalytic bed, the advantage of using a membrane as well as fluidized bed reactors is highlighted. Recent developments in alternative microwave-assisted dehydrogenation (PDH) employing innovative catalytic systems based on silicon carbide (SiC) facilitate selective heating of the catalyst. This advancement leads to improved catalytic activity and propylene selectivity while effectively reducing coke formation. Additionally, it promotes environmental sustainability in the ongoing electrification of chemical processes.