Chinese Journal of Catalysis ›› 2026, Vol. 85: 394-411.DOI: 10.1016/S1872-2067(26)65033-4

• Articles • Previous Articles    

Turning methanation into chain growth: Na-induced mechanistic bifurcation on Co-ZrOx catalyst

Syeda Sidra Bibia, Sheraz Ahmedb, Heuntae Job, Jaehoon Kima,b,c,d()   

  1. a School of Chemical Engineering, Sungkyunkwan University, Suwon, Gyeonggi-do 16419, Republic of Korea
    b School of Mechanical Engineering, Sungkyunkwan University, Suwon, Gyeonggi-do 16419, Republic of Korea
    c SKKU Advanced Institute of Nano Technology (SAINT), Suwon, Gyeonggi-do 16419, Republic of Korea
    d Department of Low-Carbon Energy Engineering, Sungkyunkwan University, Suwon, Gyeonggi-do 16419, Republic of Korea
  • Received:2025-10-14 Accepted:2025-12-09 Online:2026-06-18 Published:2026-05-18
  • Contact: *E-mail: jaehoonkim@skku.edu (J. Kim).
  • About author:

    Syeda Sidra Bibi: Conceptualization, methodology, formal analysis, data curation, and writing - original draft. Sheraz Ahmed: Methodology, Validation, formal analysis, and investigation. Heuntae Jo: Methodology, formal analysis, and investigation. Jaehoon Kim: Supervision, project administration, resources, writing - review and editing, and funding acquisition.

Abstract:

Direct hydrogenation of CO2 to long-chain hydrocarbons represents a promising route for carbon-neutral fuel production, yet achieving high selectivity and catalyst stability remains a formidable challenge. In this study, we systematically investigate the promotional effect of alkali metals (Li, Na, K) on cobalt-zirconia catalysts, revealing that the nature of the alkali promoter governs both redox stability and product distribution. While unpromoted and K-promoted catalysts undergo extensive surface reoxidation during CO2 hydrogenation, suppressing C-C coupling and favoring methane formation, the Na-promoted catalyst preserves the metallic Co0 phase and achieves exceptional C5+ hydrocarbon selectivity (39.4%) and yield (22.4%) under industrially relevant conditions. Mechanistic investigations reveal that Na uniquely facilitates the formation of hydroxyl and formyl intermediates conducive to C-C bond formation, while avoiding carbonate passivation observed in the Li-promoted catalyst. This work highlights a previously unrecognized role of Na in simultaneously stabilizing active sites and directing reaction pathways, offering a rational strategy for designing robust, selective cobalt-based catalysts for CO2 conversion to liquid hydrocarbons that can be used as sustainable transportation fuel.

Key words: CO2 hydrogenation, Alkali metal -promotion, Cobalt redox behavior, C5+ hydrocarbons