Reducing Pt dependency in propane dehydrogenation: rational design toward efficient and durable catalysts

Propane dehydrogenation (PDH) has emerged as a vital technology for propylene production, offering a promising alternative to conventional steam cracking and fluid catalytic cracking routes. Among various developed catalytic PDH systems, Pt-based catalysts exhibit outstanding activity and selectivity; however, the high cost and limited availability of platinum significantly constrain their large-scale and long-term industrial deployment. Although non-noble metal oxide catalysts have been investigated as cost-effective alternatives, their performance is usually inferior to Pt-based counterparts and their application remains confined to the laboratory scale. Thus, devising strategies to minimize the Pt content while preserving or even enhancing catalytic performance is of significant research interest. This review presents a systematic overview of recent advances in optimizing Pt utilization in PDH catalysts. Typically, one prominent approach is to enhance the utilization efficiency of Pt atoms by introducing promoters that improve dispersion and increase exposure of active sites. Another complementary strategy aims to boost catalyst stability with minimal Pt usage by suppressing sintering and coke formation via confinement effects or strong metal-support interactions. This review offers critical insights into the rational design of cost-effective and durable Pt-based PDH catalysts, aiming to bridge the gap between academic exploration and industrial application.