Abstract background – No digital creation, made old fashioned way

A new dawn for carbon utilisation in petrochemicals

Imagine a world where the very emissions once considered a burden have become the foundation for cleaner, more efficient fuels.

The petrochemical industry is on the brink of achieving such a transformation. The landscape is shifting away from decades-old traditional processes that, while profitable, have contributed significantly to global carbon emissions. Instead, growing environmental awareness, stricter regulations and increasing demand for sustainable alternatives have created a defining moment for the industry: continue down the well-worn path of carbon-intensive production, or embrace new technologies that turn CO2 into an asset rather than a liability. Researchers and engineers have long searched for viable solutions, and recent progress in reverse water-gas shift (RWGS) catalysis and advanced diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) now promises to make that vision a reality.

This article covers emerging research that helps us understand how we might approach carbon utilisation differently, to make the manufacture of sustainable fuels and other high-value products more feasible and cost-effective.

What is the reverse water-gas shift reaction?

The water-gas shift reaction, which converts carbon monoxide (CO) and water (H2O) into carbon dioxide (CO2) and hydrogen (H2), has been a crucial source of industrial H2 production for more than a century.1 Meanwhile, the opposite process (i.e., the RWGS) has attracted growing recent attention due its potential role in carbon capture and utilisation (CCU).2 It may be used to convert CO2 and H2 into CO and water.

In particular, the RWGS reaction may be adapted to produce syngas (CO + H2) from waste CO2 via post-reaction mixing or using a high initial H2/CO2 ratio,3 thereby providing a valuable precursor for a range of petrochemical products including methanol, ammonia and synthetic fuels. However, as an endothermic process, it faces a number of recognised challenges including conversion efficiency and energy costs.2

See our new infographic on the Reverse Water-Gas Shift reaction.

Why is the RWGS important?

This process could potentially revolutionise multiple industries through:

  • Accelerated catalysis, by applying novel catalysts that improve efficiency via faster reaction rates.
  • Improved catalyst lifespan, by developing advanced formulations that reduce deactivation and therefore lower costs.
  • Positive environmental impact, by supporting CCU to convert CO2 emissions into valuable feedstocks while contributing to climate change mitigation.
  • Waste valorisation, by enabling CO2 to be used as a resource rather than a pollutant and thereby promoting a circular economy.

Recent advancements in catalyst design and in situ analysis, particularly those leveraging the Harrick Praying Mantis™ range of products, have enabled researchers to extract unprecedented catalyst surface interaction data and develop more robust, efficient and high-performing catalysts. These innovations have far-reaching implications for the petrochemical sector and beyond, as we will see through the examples below.

The RWGS reaction at the forefront of an industrial revolution

1.     Doubling catalyst lifespan for methanol synthesis

Over 100 million metric tonnes of methanol are manufactured annually, making it a cornerstone of petrochemical production. Conventional approaches rely on copper, zinc oxide and aluminium oxide (Cu/ZnO/Al₂O₃) catalysts due to their low cost and high catalytic activity, but one major disadvantage is rapid deactivation due to sintering. Barrow et al.4 recently demonstrated that incorporation of silicon as a structural promoter can extend catalyst lifespan by nearly twofold, significantly enhancing process efficiency. In addition to lowering production costs, this may facilitate increased use of CO₂ as a primary raw material to enable more cost-effective and sustainable methanol production.

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2.     Efficiency gains for syngas and Fischer–Tropsch applications

As explained above, RWGS reactions may be used to produce syngas, which is an essential feedstock for Fischer–Tropsch synthesis (FTS) of liquid hydrocarbons. Global syngas production was estimated at 230 million normal cubic metres per hour (Nm3/h) in 2023, or enough to fill over 90,000 Olympic-sized swimming pools every hour. Market projections indicate healthy growth in production to 478 million Nm3/h by 2030, corresponding to a compound annual growth rate (CAGR) of 11.3%.5 The FTS process plays a vital role in producing synthetic fuels and valuable chemicals. Its demand is on the rise due to the increasing need for alternative fuels and the use of various feedstocks, including coal, natural gas and biomass.6

Recently, Szamosvölgyi et al.7 used the Harrick Praying Mantis™ Diffuse Reflection Accessory with BaF₂ (Barium Fluoride) windows to conduct precise in situ DRIFTS measurements, investigating how catalyst composition influences CO₂ activation pathways in RWGS reactions with a high H2/CO2 ratio (4:1). This approach allowed for development of Pt–Co nanoparticle catalysts exhibiting 2.6× higher CO2 consumption than traditional platinum-based alternatives. The novel catalysts also improved CO selectivity and suppressed unwanted methane formation, promoting a more efficient carbon conversion pathway.

3.     Nickel-based catalysts: a step change for syngas production

Noble metal catalysts like rhodium, palladium and platinum offer excellent performance but are expensive to use at scale (e.g., platinum black catalysts start at around $204 per gram8). As a result, researchers are continuously searching for more cost-effective solutions. One particular focus is nickel-based heterogeneous catalysts, in part owing to their significantly lower cost (typically $5–100 per kilogram depending on the formulation and application9). Lin et al.10 recently explored methanation-resistant nickel catalysts as an affordable and efficient option for RWGS applications. Their study employed Harrick’s Praying Mantis™ Diffuse Reflection Accessory in a DRIFTS setup to investigate CO₂ activation pathways and catalyst surface interactions in real time, and revealed that nickel-based catalysts synthesised via the molten salt method achieved an impressive 49% CO2 conversion at 500 °C with near-exclusive CO selectivity (i.e., by suppressing methanation, the competing conversion of CO2 to methane in the presence of H2).

These results emphasise the economic and practical advantages of nickel-based catalysts, showing their ability to rival noble metals in RWGS performance while drastically reducing costs. Furthermore, a 100-hour durability test confirmed that these catalysts are less prone to deactivation through coke formation,10 a common issue in industrial applications.

4.     Low-energy CO2 valorisation with iron catalysts

Traditional RWGS reactions require temperatures above 700 °C,2 making CO₂ conversion on a large scale both energy-intensive and challenging in terms of catalyst stability. However, a recent study from Yamaoka et al.11 showed that iron-based catalysts under an electric field can achieve nearly 100% CO selectivity at just 150 °C, markedly lowering energy requirements.

The study used a fixed-bed flow reactor with an applied direct current electric field and found that iron-supported catalysts could achieve enhanced CO2 conversion with reduced methanation. Interestingly, the electric field appeared to play a role beyond simple heating, by lowering the activation energy for the reaction. The most active iron-based catalyst also performed consistently over three days with start-up and shutdown operations when the RWGS reaction was run for 8.5 hours per day, highlighting the potential of this catalyst as a cost-effective, scalable alternative to noble metal-based systems.

Taken together, the above developments should pave the way for new low-energy CCU technologies, with RWGS processes at the core of sustainable syngas and synthetic fuel production.

The impact of RWGS beyond petrochemicals

RWGS catalysis is not confined to petrochemicals; it plays a pivotal role in other applications including ammonia synthesis, hydrogen economy integration and waste valorisation. As industries seek to decarbonise, RWGS reactions will drive innovation across multiple sectors by enabling access to low-carbon fertilisers, alternative fuels and many other examples.

Enabling breakthroughs with in situ catalyst analysis

The success of these innovations hinges on precise catalyst characterisation and optimisation. As illustrated by two studies introduced above,7,10 DRIFTS accessories such as the Praying Mantis™ and its range of related instruments, enable researchers to study catalyst surface interactions, active site dynamics and real-time reaction mechanisms in detail. These capabilities support:

  • Development of longer-lasting catalysts through structural stabilisation.
  • Optimisation of reaction pathways to maximise CO selectivity.
  • In-depth analysis of catalyst deactivation to improve industrial-scale performance.

Therefore, in situ analysis is enabling innovations in RWGS catalysis that will drive the transformation of petrochemical processing and beyond. From methanol production and syngas refinement to waste valorisation and hydrogen economy integration, new levels of efficiency and sustainability are being unlocked through ongoing application of advanced DRIFTS techniques.

For R&D leads and quality control managers, leveraging these tools means higher efficiency, reduced operational costs and more sustainable process footprints.

The question is: how will your industry adapt to these groundbreaking developments?

Catalytic breakthroughs start with our accessories

Related resources

Fundamental catalyst research is key to advancing the global transition from fossil fuels – Specac Ltd

How DRIFTS is transforming the petrochemical industry – Specac Ltd

Developing catalysts to drive innovation – Specac Ltd

Converting CO₂ to green methanol: a petrochemical breakthrough

Catalytic studies using FTIR reaction cells – Specac Ltd

References

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