Cost-Effective Synthesis of Gamma Alumina for Propane Dehydrogenation: A Study of Raw Materials, Process Optimization, and Catalyst Performance

The high cost of catalyst production poses a major challenge in industrial processes like propane dehydrogenation (PDH), where γ-alumina (γ- Al۲O۳) is a key support. Over the past two decades, efforts have focused on lowering costs by optimizing raw materials and synthesis techniques. This study introduces a cost-effective, scalable method to synthesize γ-Al۲O۳ with high surface area, narrow pore size distribution, and optimal pore diameter to improve PDH performance. Gibbsite, an economical and abundant precursor, was used with methanol and ethanol to enhance textural properties. The synthesis involved precipitation followed by spray drying to produce uniform macro-spherical particles. Optimization via Box-Behnken response surface methodology (RSM) maximized surface area and pore features. Characterization using BET, FT-IR, TGA, XRD, SEM-EDX, and zeta potential confirmed the high thermal stability and structural integrity of the material, achieving a surface area of ۱۸۴.۹۵ m²/g. A Pt-Sn/γ- Al۲O۳ catalyst was then prepared and tested in PDH, showing propane conversion over ۳۷% and propylene selectivity around ۸۲%. This work demonstrates the potential of using low-cost raw materials and simplified synthesis routes to produce high-performance catalyst supports efficiently. The approach reduces production costs while maintaining catalytic activity, presenting a practical solution for industrial applications. Overall, the findings support ongoing efforts to make heterogeneous catalysis more economical without compromising performance in petrochemical processes.

کلیدواژه ها:

Alumina ، Pt-Sn catalyst ، propane dehydrogenation ، Response surface methodology Catalyst carrier ، Heterogeneous catalysis