Bypassing In Situ CO Poisoning in Furfural Conversion: Electron-Deficient Pd Single-Atom Alloys Enable One-Step Selective Synthesis of Tetrahydrofuran.

The one-step conversion of biomass-derived furfural (FUR) to tetrahydrofuran (THF) via combining decarbonylation and hydrogenation offers a sustainable alternative to the industrial Reppe process, while the selectivity control remains a significant challenge. Herein, we identify carbon monoxide (CO), in situ generated during FUR decarbonylation, as a major hindrance, significantly inhibiting subsequent furan hydrogenation. To overcome this limitation, a zeolite-encapsulated PtPd single-atom alloy (SAA) catalyst, namely PtPd@S-1, is designed, which effectively mitigates CO poisoning and enables efficient FUR conversion to THF, achieving 100% FUR conversion and >93% THF selectivity with good long-term stability (∼100 h)-among the highest values reported to date. Mechanistic studies reveal that electron-deficient Pd species adjacent to single Pt atoms in PtPd@S-1 significantly enhance H activation and furan adsorption, enabling efficient hydrogenation at both the C and C positions of furan despite CO poisoning. Furthermore, the one-step process is economically viable with a minimum selling price (MSP) of USD 1701 per tonne of THF, and a life cycle assessment shows a CO equivalent emission of 1.29 tonnes per tonne of THF-less than 25% of that of the traditional Reppe process. This work represents a transformative advancement in sustainable THF production, with the potential to revolutionize industrial THF production.