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The CO 2 formation mechanism on Fe x C y and its structure–reactivity relationship during sintering process were systemically elucidated using the ReaxFF. [Display omitted] • Investigate the structure-activity relationship of different Fe-based nanoparticles in the sintering process. • Formation of low-coordination-number atoms may be the real reason for promoted TOF of the sintering structures. • The increased amplitude of surface area of sintered Fe x C y varies with its content of carbon. • The main CO 2 formation varies with the Fe x C y : Eley-Rideal VS. Langmuir-Hinshelwood mechanism. The sintering of nanostructured catalysts poses a grand challenge in understanding the complex mechanism in the experimental phenomena, as well as the structure-activity relationship. Here, we systematically investigate the structure-activity relationship of sintered Fe-based catalysts, including Fe 2 C, Fe 5 C 2 , Fe 3 C and pure Fe, in the CO activation by reactive molecular dynamics simulations. The results show that the sintering structures can promote the turn-over frequency of Fe 3 C compared with its un-sintered near-size structures, which might be attributed to the formation of low-coordination-number atoms. The change of surface area shows a similar trend for Fe x C y and pure Fe, and its increased magnitude varies with the content of carbon in the Fe x C y bulk. For size effect, the Fe 2 C displays the largest turn-over frequency for the 4.34 nm particle. The CO 2 formation mechanism has also been compared for different Fe x C y , which may provide critical theoretical insights for industrial reduction of CO 2 emission. [ABSTRACT FROM AUTHOR]