Abstract Iron-based Fischer–Tropsch synthesis catalysts play a crucial role in coal-to-chemicals conversion, owing to their cost-effectiveness, adaptability to coal-derived syngas, and flexibility in producing olefins and oxygenates. Nevertheless, significant challenges remain, including catalyst stability issues, high CO₂ emissions, and deactivation caused by phase transformation, sintering, and coking. The objective of this review is to systematically investigate the recent progress and optimization strategies for iron-based Fischer–Tropsch synthesis catalysts within the framework of green and low-carbon goals. Multiple approaches have been explored, such as hydrophobic modification strategies like SiO₂ encapsulation and graphene coating, confinement architectures involving carbon-based materials and zeolites, promoter engineering, pure-phase carbide synthesis, and regeneration methods including H₂ reduction and oxidation–reduction. Hydrophobic modification strategies have successfully reduced CO₂ selectivity to below 5% and enhanced catalyst stability under harsh conditions. Confinement architectures physically impede particle migration. Promoter engineering improves stability and lowers CO₂ selectivity, with elements like manganese, cobalt, and boron stabilizing iron carbide phases and reducing coke formation through structural and electronic modulation, while sodium, magnesium, etc., effectively decrease CO₂ selectivity. Pure-phase carbide synthesis eliminates Fe₃O₄-related CO₂ emissions, achieving a 5% selectivity under near-industrial conditions. Regeneration methods can restore up to 53.4% of the catalyst activity, yet they face compatibility limitations in slurry-bed systems. The diverse optimization strategies presented demonstrate great potential in enhancing the performance of iron-based Fischer–Tropsch synthesis catalysts, addressing key bottlenecks and highlighting their significance for sustainable coal utilization. Future research efforts should concentrate on integrating renewable hydrogen to reduce dependence on the water–gas shift reaction, promoting operando characterization to decipher dynamic phase evolution, and formulating circular regeneration protocols that align with global decarbonization policies. These steps will help balance resource efficiency and environmental protection during the transition to low-carbon energy systems.
Li et al. (Wed,) studied this question.