Engineering topics
Ruddy, Daniel A.
Publications and source records attributed to Ruddy, Daniel A..
Multivariate Bayesian Optimization of CoO Nanoparticles for CO 2 Hydrogenation Catalysis
The hydrogenation of CO 2 holds promise for transforming the production of renewable fuels and chemicals. However, the challenge lies in developing robust and selective catalysts for this process. Transition metal oxide catalysts, particularly cobalt oxide, have shown potential for CO 2 hydrogenation, with performance heavily reliant on crystal phase and morphology. Achieving precise control over these catalyst attributes through colloidal nanoparticle synthesis could pave the way for catalyst and process advancement. Yet, navigating the complexities of colloidal nanoparticle syntheses, governed by numerous input variables, poses a significant challenge in systematically controlling resultant catalyst features. We present a multivariate Bayesian optimization, coupled with a data-driven classifier, to map the synthetic design space for colloidal CoO nanoparticles and simultaneously optimize them for multiple catalytically relevant features within a target crystalline phase. The optimized experimental conditions yielded small, phase-pure rock salt CoO nanoparticles of uniform size and shape. These optimized nanoparticles were then supported on SiO 2 and assessed for thermocatalytic CO 2 hydrogenation against larger, polydisperse CoO nanoparticles on SiO 2 and a conventionally prepared catalyst. The optimized CoO/SiO 2 catalyst consistently exhibited higher activity and CH 4 selectivity (ca. 98%) across various pretreatment reduction temperatures as compared to the other catalysts. This remarkable performance was attributed to particle stability and consistent H* surface coverage, even after undergoing the highest temperature reduction, achieving a more stable catalytic species that resists sintering and carbon occlusion.
The Overlooked Potential of Sulfated Zirconia: Reexamining Solid Superacidity Toward the Controlled Depolymerization of Polyolefins
Closed-loop recycling via an efficient chemical process can help alleviate the global plastic waste crisis. However, conventional depolymerization methods for polyolefins, which compose more than 50% of plastics, demand high temperatures and pressures, employ precious noble metals, and yield complex mixtures of products limited to single-use fuels or oils. Superacidic sulfated zirconia (SZrO) with Hammet Acidity Functions (H 0 ) = -12 (i.e., stronger than 100% H 2 SO 4 ) is an industrially deployed heterogeneous catalyst capable of activating hydrocarbons under mild conditions and is shown to decompose polyolefins at ambient pressure and temperatures near 200 °C. Additionally, confinement of active sites in porous supports is known to radically increase selectivity, coking and sintering resistance, and acid site activity, presenting a possible approach to low-energy polyolefin depolymerization. However, a critical examination of the literature on SZrO led us to a surprising conclusion: despite 40 years of catalytic study, engineering, and industrial use, the surface chemistry of SZrO is poorly understood. Ostensibly spurred by SZrO's impressive catalytic activity, the application-driven study of SZrO has resulted in deleterious ambiguity in requisite synthetic conditions and insufficient characterization of acidity, porosity, and active site structure. Here, this ambiguity has produced significant knowledge gaps surrounding the synthesis, structure, and mechanisms of hydrocarbon activation for optimized SZrO, stunting the potential of this catalyst in olefin cracking and other industrially relevant reactions, such as isomerization, esterification, and alkylation. Toward mitigating these long extant issues, we herein identify and highlight these current shortcomings and knowledge gaps, propose explicit guidelines for characterization of and reporting on characterization of solid acidity, and discuss the potential of pore-confined superacids in the efficient and selective depolymerization of polyolefins.
Modified Cu–Zn–Al mixed oxide dual function materials enable reactive carbon capture to methanol
A novel RCC process using modified CZA DFMs to produce renewable MeOH is presented. K/CZA provides exceptionally high productivity of MeOH compared to previously reported attempts of RCC to MeOH.
Diesel fuel properties of renewable polyoxymethylene ethers with structural diversity
Polyoxymethylene ethers (POMEs) are a class of low-soot and high-cetane oxygenate oligomers of structure RO-(CH 2 O-) $n$ -R, with different chain lengths ($n$) and end-groups (R) that determine their diesel-like fuel properties. Commercial POMEs with methyl end-groups (MM-POME 3-6 ) exhibit undesirably low energy density and high-water solubility. A previous computational assessment indicated that the lower heating value (LHV) and water solubility for MM-POME 3-6 both improve upon end-group exchange with larger butyl, $iso$-butyl and $iso$-pentyl end-groups. Here, we expanded upon our initial trans-acetalization reaction that employed 1-butanol to install butyl end-groups to also include branched, higher carbon-number end-groups using $iso$-butanol and fusel oil as reagents. Additionally, these new products are termed $i$B*POME 1-6 , and FOil*POME 1-5 , respectively, and collectively referred to as R*POMEs. They possess the advantaged properties of the parent MM-POME 3-6 while exhibiting higher LHV (31 MJ kg -1 and 28 MJ kg -1 for $i$B*POME 1-6 , and FOil*POME 1-5 , respectively) and much reduced water solubility (2.7 g L -1 and 1 g L -1 for $i$B*POME 1-6 , and FOil*POME 1-5 , respectively). Additional fuel property analyses were performed using 20 vol% blends of the R*POMEs with a base diesel fuel. Overall, the greater energy density and decreased water solubility of the R*POMEs, as well as their synergistic blending with diesel at moderate blend levels, provide the greatest benefits to consumers and position this group of products as an environmentally friendlier blendstock alternative to the commercially available MM-POME 3-6 .
Compositional dependence of hydrodeoxygenation pathway selectivity for Ni 2− x Rh x P nanoparticle catalysts
Controlled synthesis of Ni 2− x Rh x P nanoparticle catalysts enables an understanding of composition-dependent selectivity for the hydrodeoxygenation reaction of phenolic molecules.
Direct synthesis of branched hydrocarbons from CO 2 over composite catalysts in a single reactor
The thermocatalytic hydrogenation of CO 2 to hydrocarbons using a composite catalyst system in a single reactor under mild reaction conditions was investigated, by combining methanol synthesis, methanol dehydration and dimethyl ether homologation catalysts. High selectivity to isoparaffins, which are versatile precursors to sustainable aviation fuels, was achieved. The use of Cu/BEA significantly improved both the conversion of oxygenates and the hydrocarbon yield compared to HBEA by facilitating H-incorporation in the C-chain growth during the homologation reaction. A study of catalyst composition and reaction conditions revealed that nearly complete conversion of oxygenates was achieved using a stacked-bed configuration, providing high C-selectivity to C 4+ hydrocarbons (34.1% among all products and 95.5% in products excluding CO). The ability to completely convert oxygenates to hydrocarbons and achieve high CO-free selectivity to desired hydrocarbon products is unprecedented in CO 2 -to-hydrocarbon reports, and advantageous for downstream separation, as CO can be easily separated and recycled to improve overall hydrocarbon production in an integrated process.
Activating Molybdenum Carbide Nanoparticle Catalysts under Mild Conditions Using Thermally Labile Ligands
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Connecting cation site location to alkane dehydrogenation activity in Ni/BEA catalysts
Ni-modified beta zeolite (Ni/BEA) catalysts activate carbon-hydrogen bonds in light alkanes, as demonstrated through isobutane reaction testing. Controlled synthesis of Ni/BEA allows for efficient introduction of ion-exchanged Ni sites at varying Ni loadings (0.43% - 1.8%). These catalysts exhibit site time yields (STY) for H2 production that increase with increasing Ni loading. A detailed analysis of secondary reactions and carbon deposition based on the relative molar flowrates of product C and H indicates that the observed increase in H2 STY with increasing Ni loading is likely attributed to both increasing alkane activation activity and increasing formation of hydrogen-deficient aromatic products retained within the catalyst pores. In situ diffuse-reflectance UV-visible-NIR absorbance and X-ray absorption spectroscopies indicate isolated, 4-coordinate Ni(2+) species for all loadings. Quantum mechanics/molecular mechanics modeling identifies two distinct Ni(2+) sites consistent with the structural characterization, but with differing relative stabilities due to their coordination environment. Computed reaction energetics for isobutane dehydrogenation demonstrate that the more stable Ni(2+) species at a six-membered 4Si-2Al ring, Ni-6MR, is less active for isobutane dehydrogenation than the less stable Ni(2+) at the five-membered 3Si-2Al ring, Ni-5MR. The differing local structure of the isolated cationic Ni sites in Ni/BEA offers a possible rationalization for the increased H2 STY observed at greater Ni loadings.
Benchmarking Cu/BEA and HBEA catalysts for high-octane gasoline synthesis
We distinguish rates at which carbon deposition occurs during initiation, rates at which catalytic centers are lost during deactivation, and paraffin-to-olefin ratio during propagation as benchmarks that distinguish 5 wt% Cu/H-BEA and H-BEA (Si/Al = 13.5) catalysts during dimethyl ether (DME) homologation in the presence of hydrogen. Studies that systematically vary initial DME contact time (210, 94, and 45 mol H+, initial s (mol C ) -1 ), DME pressure (4 and 22 kPa), and H 2 pressure (1, 24, and 48 kPa) reveal that Cu enables lower carbon deposition rates (on a per proton basis) in the induction period, increases the effluent paraffin-to-olefin ratio during propagation, and decreases the instantaneous site-loss yields by a factor of ~ 1.5-2x (moles of active sites lost per mole of DME) during termination sequences thus affecting the degree of product saturation and catalyst stability during DME homologation. Furthermore, these results provide mechanistic insights revealing the critical role of Cu in facilitating DME homologation to high value, high-octane gasoline-range hydrocarbons with higher cumulative turnovers than proton form H-BEA.
A separations and purification process for improving yields and meeting fuel contaminant specifications for high-octane gasoline produced from dimethyl-ether over a Cu/BEA catalyst
In this work, we have been developing a three-step conversion of biomass-derived syngas to methanol to dimethyl-ether (DME) to non-aromatic hydrocarbons for use as high-octane gasoline and sustainable aviation fuel. This process produces branched alkanes from DME using a Cu/BEA catalyst and is a promising alternative to other syngas conversion processes such as Fischer-Tropsch to linear alkanes and traditional ZSM-5 catalyzed methanol to aromatic gasoline. In this short article we describe some advances in our understanding related to separations and purification via the use of more detailed experimental speciation in an updated process model involving multiple phase equilibrium-based separation steps. Primary modeled reactor outlet constituents (and weight %) are: C3 and lighter hydrocarbon gases (11.1%), C4s (54.5%), H 2 (1.2%), CO 2 (2.9%), water (5.0%), unreacted DME (16.5%), methanol (2.3%), and C5+ hydrocarbons (6.4%). DME (the primary reactant) and H 2 recycle and reuse are important for the overall process efficiency, and the recycle of C4s is important to increase the C5+ yield via reactivation and homologation. Thus H 2 , C4s, and DME are targeted for recycle, while methanol and water need to be removed from the product to conform with fuel specifications. Model predictions from Aspen Plus using the NRTL-RK property method indicate a fuel composition with C5+ content of 97.1 wt%, with minor constituents: 2.4 wt% C4s, 0.3 wt% methanol, 0.1 wt% DME, 0.03 wt% water, and 0.01 wt% C3s. These ranges of minor components conform with fuel quality requirements, and the modeled product is amenable for unconstrained blending to boost gasoline octane ratings.
Controlled Synthesis of Transition Metal Phosphide Nanoparticles to Establish Composition-Dependent Trends in Electrocatalytic Activity
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Direct Conversion of Renewable CO 2 -Rich Syngas to High-Octane Hydrocarbons in a Single Reactor
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Blended fuel property analysis of butyl-exchanged polyoxymethylene ethers as renewable diesel blendstocks
Methyl-terminated polyoxymethylene ethers (MM-POMEs), having the formula CH 3 O-(CH 2 O)n-CH 3 (n = 3-6), are a class of oxygenates with desirable diesel-like fuel properties including high cetane number and low soot formation. However, their low energy density and high water-solubility present barriers to their adoption. Both concerns were recently addressed by our research group by synthesizing a mixture of POME structures having butyl end-groups and n = 1-6, termed B*POME1-6. B*POME1-6 maintained the advantageous properties of the parent MM-POMEs, and exhibited improved energy density and most notably, dramatically decreased water solubility. For evaluation against a set of criteria for a blended diesel blendstock, a 20 vol% blend of B*POME1-6 with a base diesel fuel was investigated here. Oxidation stability, cetane number, sooting tendency, lubricity and conductivity were improved in the B*POME1-6 blend compared with the base diesel, while also maintaining the flash point, cloud point, energy density, viscosity, and boiling point requirements. The B*POME1-6 product demonstrated a synergistic blending behavior at 10 vol% and a linear blending behavior at 20-30 vol% blends, in agreement with similar POME blends at comparable blend levels. Finally, common environmental and toxicity models performed on B*POME1-6 component molecules suggested they have a greater propensity to partition into the water compartment compared to a common diesel surrogate, but with a lower tendency to bioaccumulate.
Catalytic Activation of Polyethylene Model Compounds Over Metal-Exchanged Beta Zeolites
Decomposition of polymers by heterogeneous catalysts presents a promising approach for reuse of waste plastics. Here, we demonstrated non-hydrogenative decomposition of model polyolefins over proton-form and metal (Cu, Ni) ion-exchanged beta zeolites at moderate temperatures (ca. 300 degrees C). Near complete polyolefin decomposition was observed in batch reactions monitored by thermogravimetric analysis, while decomposition at partial conversion was studied in flow reactions. Ni-exchanged zeolites produced H 2 at substantially higher rates (> 10x) than other catalysts while also uniquely resisting deactivation over time. Application of the delplot formalism offered insights into the reaction network for polyolefin decomposition over Ni/BEA, most notably that H 2 is solely a primary product. We deduce that H 2 production is catalyzed by activation of C-H bonds at ionic Ni sites, and H 2 prevents buildup of polyaromatic coke species in Ni-exchanged zeolites that deactivate Cu-exchanged and protonic zeolites.
Catalyst design to direct high-octane gasoline fuel properties for improved engine efficiency
The paraffin-to-olefin (P/O) ratio in gasoline fuel is a critical metric affecting fuel properties and engine efficiency. In the conversion of dimethyl ether (DME) to high-octane hydrocarbons over BEA zeolite catalysts, the P/O ratio can be controlled through catalyst design. Here, we report bimetallic catalysts that balance the net hydrogenation and dehydrogenation activity during DME homologation. The Cu-Zn/BEA catalyst exhibited greater relative dehydrogenation activity attributed to higher ionic site density, resulting in a lower P/O ratio (6.6) versus the benchmark Cu/BEA (9.4). The Cu-Ni/BEA catalyst exhibited increased hydrogenation due to reduced Ni species, resulting in a higher P/O ratio (19). The product fuel properties were estimated with an efficiency merit function and compared against finished gasolines and a typical alkylate blendstock. Merit values for the hydrocarbon product from all three BEA catalysts exceeded those of the comparison fuels (0–5.3), with the product from Cu-Zn/BEA exhibiting the highest merit value (9.7).
Top 13 Blendstocks Derived from Biomass for Mixing-Controlled Compression-Ignition (Diesel) Engines: Bioblendstocks with Potential for Decreased Emissions and Improved Operability
Reducing the impacts of medium- and heavy-duty (MD/HD) ground transportation can be enabled by fuel-engine combinations that use lower compression ignition liquid fuels and reduce criteria pollutant emissions. Fuels and blendstocks combined with advanced engine technologies could reduce the cost of ownership and the emission of pollutants, including soot, nitrogen oxides (NOx) and greenhouse gases (GHGs), from MD/HD vehicles. This report describes the evaluation and screening of MD/HD mixing-controlled compression ignition (MCCI) biofuel candidates for further development and commercialization. The report is aimed at 1) biofuel researchers looking to better understand options to reduce criteria pollutant and GHG emissions while maintaining efficiency and meeting requirements for engine operability and 2) engine researchers who want to evaluate biofuels that meet diesel fuel properties for their impact on conventional and advanced diesel combustion strategies.