Atomically tailored non-noble metal-based catalysts toward efficient propane dehydrogenation

Abstract

Propane dehydrogenation (PDH) is a key process to address the supply–demand imbalance of propylene. Commercial PtSn/Al₂O₃ and CrO_x/Al₂O₃ catalysts, however, face limitations due to high cost and environmental concerns, motivating the development of sustainable, non-noble metal alternatives. Recent studies reveal that atomically tailored single-metal oxides, bimetallic oxides, and non-noble metal alloys can achieve comparable or even superior activity and selectivity through precise control over geometric structures, electronic states, and interfacial synergy. This review systematically summarizes the rational design strategies, key structure–performance relationships, and mechanistic insights underlying these catalysts. Emphasis is placed on the role of atomic-level active site engineering and synergistic dual-metal interactions in enhancing activity, selectivity, and stability. Looking forward, multi-scale collaborative design, advanced in situ/operando characterization, and machine-learning-assisted high-throughput screening are identified as promising approaches to accelerate the development and industrial deployment of high-performance non-noble metal-based PDH catalysts. This review aims to provide a comprehensive perspective to guide the design of efficient, stable and sustainable PDH catalysts.