Sustainable catalytic conversion of ethanol: catalyst design and modification strategies for dehydration and petrochemical applications

Ethanol has emerged as a promising renewable feedstock for chemicals and sustainable fuel production. Its conversion into ethylene, diethyl ether, and higher-value chemicals through dehydration over catalysts relies on carefully designed catalysts to enhance activity, selectivity, and stability. This review critically examines the catalytic transformation pathways leading to key petrochemical intermediates such as ethylene, propylene, and 1,3-butadiene. It places special emphasis on solid acid catalysts, modified oxides, zeolites, and heteropoly acids, highlighting recent advances in catalyst design, including surface modification, morphology control, and nanostructuring. The review also discusses mechanistic insights, reactor engineering, and strategies to overcome coke formation and catalyst deactivation. Finally, it explores future perspectives on integrating bioethanol into petrochemical supply chains, focusing on challenges related to catalyst performance, process scalability, and sustainable chemical production.