Fischer-Tropsch synthesis: Foregoing calcination and utilizing reduction promoters leads to improved conversion and selectivity with Co/silica
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Hydrodeoxygenation (HDO) of 2-acetylfuran (2-AF) was examined at 473 K and 33 bar over carbon-supported, bimetallic catalysts. Monodispersed, Pt-based (PtNi, PtCo, and PtCu) and Ni-based (NiCu) nanocrystals (NCs) with well-defined sizes and compositions were prepared via colloidal synthesis. Steady-state, flow-reactor measurements demonstrate that selectivities for the HDO reaction to 2-ethylfuran (2-EF) are strongly dependent on the alloy compositions. The HDO of 2-AF is shown to be sequential, where 2-EF can react further to form over-hydrogenated products. The NiCu 3 /C nanocatalyst was superior to the other bimetallics; with the optimal residence time, it was possible to achieve a selectivity of 75% 2-EF with 80% conversion of 2-AF, with good stability for up to at least 5 hours time-on-stream. Deactivation due to coking became an issue when the NCs were deposited on oxide supports with weak acidity (SiO 2 and γ-Al 2 O 3 ). Furthermore, this work provides insights into which bimetallic catalytic systems might be useful for HDO of 2-AF reaction.
We report the drastic rise in shale gas production has encouraged the quest for alternative uses of methane as a chemical feedstock in the manufacturing industry. While two-step syngas routes for methane valorization are deployed commercially, direct one-step routes for methane conversion are attracting much attention. As steam cracking installations have shifted from using oil-based naphtha to shale-based natural gas liquids, production of aromatics has dropped. Methane dehydroaromatization (MDA) is a one-step reaction capable of valorizing methane to hydrogen and benzene. Challenges with the MDA reaction are two-fold: the reaction is thermodynamically limited with low one-pass methane conversion and even the best catalytic systems, Mo/zeolites, suffer rapid deactivation from coking. A catalyst design strategy to improve stability is the use of multifunctional Mo-X/zeolite systems where X is a dopant capable of modulating the stability. In this paper we provide a complete overview of the main Mo-X/zeolite systems used in MDA and critically draw connections among the different types of dopants (X) employed, as a function of the role they play in the reaction/deactivation pathway. We have also dedicated a section to emerging trends with non-Mo based catalysts. The goal of this review article is to establish a basis that will facilitate the identification of useful multifunctional catalytic systems, and recognize gaps in the knowledge of these systems that deserve more attention. Improving MDA systems to the point to which they can be commercially deployed requires a multifaceted approach that combines optimization of the designs of both the catalyst and the reactor configuration. We therefore also provide a brief overview of the most recent advances in process intensification strategies employed with different reactor configurations.
We explore how thermocatalytic decomposition of methane (TCD) is a promising approach for producing CO 2 -free hydrogen and solid carbon co-product. In this study, a series of Al 2 O 3 - and MgAl 2 O 4 -based Ni catalysts, prepared with varying synthesis and pretreatment methods, were evaluated for methane TCD performance at 650°C and characterized before and after reaction to elucidate activity-structure relationships. We found that methane TCD turnover increases with Ni particle size. Further, large Ni particle sizes (i.e., >20 nm) are selective toward the formation of carbon nanotubes (CNTs), while small Ni particle sizes (i.e., <10 nm) are selective toward the formation of graphitic carbon layers. The formation of graphitic carbon layers block access to Ni active sites, thus rendering the catalyst inactive more quickly than when CNTs are produced. Additionally, the catalyst deactivation observed with time-on-stream is due to the fragmentation of Ni particles into smaller Ni particles followed by their encapsulation with graphitic carbon layers.
Propylene is an important chemical feedstock that is largely produced via cracking of oil-derived naphtha. Direct conversion of propane into propylene may be a more attractive alternative. Specifically, propane dehydrogenation (DH) and oxidative dehydrogenation (ODH) are promising for this transformation, albeit only DH has been industrially implemented. However, even the best DH catalysts (Pt-based) still suffer from deactivation. VO x - and BO x -based ODH catalysts result in significant over-oxidation and lack a mechanistic understanding. A common challenge in developing these catalysts is the broad distribution of surface species caused by the use of non-ordered catalyst supports. This hampers clear structure-performance correlations. Recent progress in the preparation of well-defined active sites on ordered supports has brought about improved catalysts, as well as fundamental insight into the working mechanism. This review will highlight recent advancements in the development of these catalysts and provide direction on the use of ordered supports for propane upgrading.
The effect of olefin addition to a stream of dimethyl ether on the methanol homologation reaction is investigated using iron-substituted zeolites Fe-beta and Fe-ZSM-5. The reaction was investigated using plug-flow microreactors in the temperature range of 240–400 °C, at a total pressure of 0.239 MPa and a WHSV of 6.12 (g DME/ gcat -hr). For Fe-beta (Si/Fe= 9.2) catalysts, isobutene co-feeding almost doubles dimethyl ether (DME) consumption rate and shifts selectivity towards larger olefins with carbon numbers from 5 to 7. Addition of isobutene above 6.3%, however, resulted in a reduction of DME consumption rates, an effect assigned to the replacement of surface methoxy groups for adsorbed olefins in the zeolite pores. Below a temperature of 340 °C hydride-transfer rates are negligible; reaction rates are stable for over 5.5 h and the products consist almost exclusively of olefins and a small amount of methane. Above 360 °C the onset of catalytic hydride transfer processes is observed leading to fast catalyst deactivation rates and an increase in the concentration of aromatic species. Iron ZSM-5 (Si/Fe = 21.4) catalysts under similar reaction conditions consumes methanol faster than Fe-beta at approximately three times the TOF (on a per iron basis). The Fe-ZSM-5 catalyst was selective to a distribution of products (C5 to C8) as compared to Fe-beta which was selective to primarily C5 and C7. Co-feeding larger olefins (2-methyl-2-butene, 2,3-dimethyl-2-butene, 2,3,3-trimethyl-1-butene, and 2,4,4-trimethyl-2-pentene) at a 3.9% olefin concentration over Fe-beta changed selectivity towards cracking products (C4 compounds such as isobutene). As the size of the olefin increases, a reduction of DME consumption rate is also observed. Here these results show that co-feeding olefins with DME over Fe-zeolites is a promising route to increase methylation rates at relatively low temperatures producing larger branched olefins and that the product distribution is highly dependent on the zeolite pore size and structure of the olefin.
Supported bimetallic catalysts are widely used for carbon nanotube (CNT) synthesis, yet the effects of impregnation procedure remain underexplored. Here, we investigated how the sequence of metal impregnation affects CNT synthesis. We prepared cobalt-molybdenum (Co-Mo) bimetallic catalysts on alumina supports via co- and stepwise impregnation, then compared their CNT synthesis performance under identical conditions. Stepwise-impregnated catalysts exhibited higher carbon yields than those prepared by co-impregnation. Notably, impregnating Mo after Co achieved the highest yield despite the lowest BET surface area. Synchrotron X-ray diffraction and visible/UV-Raman spectroscopy revealed that only this catalyst contained Al 2 (MoO 4 ) 3 with a MoO 4 structure. X-ray photoelectron spectroscopy clarified the surface chemistry: the catalyst with the highest CNT productivity exposed Mo entirely as Mo 6+ in Al 2 (MoO 4 ) 3 and CoMoO 4 , whereas the others contained both Mo 4+ and Mo 6+ . The MoO x species like Al 2 (MoO 4 ) 3 is known to suppress Co sintering during CNT synthesis, delaying catalyst deactivation and enhancing the carbon yield. Moreover, an inverse relationship was observed between carbon yield and the CoMoO 4 content. This is attributed to the consumption of catalytically active Co during CoMoO 4 formation, which reduces active sites for CNT growth. ICP-OES further confirmed higher Co and Mo loadings for stepwise catalysts, contributing to superior catalyst performance. The extent of CoMoO 4 formation strongly depended on the metal introduction sequence. In conclusion, this trend is illustrated by considering the relationship between the point of zero charge of support and the pH of the metal precursor solutions.
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The non-oxidative dehydrogenation of ethanol to acetaldehyde has long been considered as an important method to produce acetaldehyde and clean hydrogen gas. Although monometallic Cu nanoparticles have high activity in the non-oxidative dehydrogenation of ethanol, they quickly deactivate due to sintering of Cu. In this paper, we show that adding a small amount of Ni (Ni 0.01 Cu - Ni 0.001 Cu) into Cu to form highly dilute NiCu alloys dramatically increases the catalytic activity and increases their long-term stability. The kinetic studies show that the apparent activation energy decreases from ~70 kJ/mol over Cu to ~45 kJ/mol over the dilute NiCu alloys. The improved performance is observed both for nanoparticles and nanoporous NiCu alloys. The improvement in the long-term stability of the catalysts is attributed to the stabilization of Cu against sintering. Our characterization data show that Ni is atomically dispersed in Cu. The comparison of the catalytic performance of highly dilute alloy nanoparticles with nanoporous materials is useful to guide the design of novel mesoporous catalyst architectures for selective dehydrogenation reactions.
The co-aromatization of methane with olefins is investigated using Ag-Ga/HZSM-5 as the catalyst at 400 degrees C. The presence of methane has a pronounced effect on the product distribution in terms of increased average carbon number and substitution index and decreased aromatic carbon fraction compared with its N2 environment counterpart. The participation of methane during the co-aromatization over the Ag-Ga/HZSM-5 catalyst diminishes as the co-fed olefin feedstock molecule becomes larger, from 1-hexene to 1-octene and 1-decene, in diameter. The effect of suppressed methane participation with larger olefinic molecules is not as significant when Ag-Ga/HY is employed as the catalyst, which might be attributed to the larger pore size of HY that gives more room to hold olefin and methane molecules within the inner pores and reduces the diffusion limitation of olefin molecules. The effect of olefin feedstock on the methane participation during the co-aromatization over Ag-Ga/HZSM-5 is experimentally evidenced by 13C and 2D NMR. The incorporation of the methane carbon atoms into the phenyl ring of product molecules is reduced significantly with larger co-fed olefins, whereas its incorporation into the substitution groups of the formed aromatic molecules is not notably affected, suggesting that the methane participation in the phenyl ring formation might preferably occur within inner pores, while its incorporation into substitution groups may mainly take place on external catalytic sites. This hypothesis is well supported by the product selectivity obtained over Ag-Ga/HZSM-5 catalysts prepared using conventional ZSM-5, ZSM-5 with the external catalytic sites deactivated, nanosize ZSM-5, ZSM-5 with a micro/meso pore structure and ZSM-5 with the inner pores blocked, and further confirmed by the isotopic labeling studies.
Gas-phase dehydration of tetrahydrofurfuryl alcohol (THFA) to 3,4-2H-dihydropyran (DHP) was investigated over solid acid catalysts. A γ-Al 2 O 3 catalyst resulted in 90% DHP yield from THFA. The γ-Al 2 O 3 deactivated due to solid coke formation but was nearly fully re-generable upon a high temperature calcination step (only 2.5% activity loss after 3 rd regeneration). The high catalytic activity and selectivity of γ-Al 2 O 3 was correlated to its high Lewis to Brønsted acid site ratio, as confirmed by ammonia temperature-programmed desorption (NH 3 -TPD) and isopropylamine temperature-programmed desorption (IPA-TPD). According to isotopic-labelling studies, a reaction mechanism was proposed in which THFA initially dehydrates into a carbenium intermediate prior to Wagner-Meerwien rearrangement into DHP. A kinetic model of THFA dehydration over γ-Al 2 O 3 was developed according to kinetic experimental data. The best-fit model implied the rate-determining step was the surface reaction of adsorbed THFA dissociating into adsorbed DHP and water.
M-WO x /TiO 2 (M = Pt-, Rh-, Pd-, and Ru) catalysts were prepared and studied for tetrahydrofuran-dimethanol (THFDM) hydrogenolysis. All catalysts have a small metal particle size (< 2 nm) but show catalytic activities that differ by two orders of magnitude. From a combination of CO chemisorption and STEM, we conclude that this wide gap in activity is primarily due to overgrowth of WO x /TiO 2 covering the metal particle of the less-active catalysts. This overgrowth decreases the number of exposed hydrogenation sites in these catalysts, lowering the overall reaction rate. The catalyst with the highest activity (Pt-WO x /TiO 2 ) was studied at various pressures of H 2 , with catalytic activity passing through a maximum with increasing pressure. This is likely due to changes in the oxidation state of W δ+ on the catalyst surface, which changes from W 6+ to W 5+ and W 4+ with increasing hydrogen pressure. Moreover, H 2 can strongly adsorb on the catalyst surface and inhibit the activity at high hydrogen pressure. The apparent activation energy of THFDM conversion over Pt-WO x /TiO 2 is 47 kJ·mol -1 . Pt-WO x /TiO 2 showed a decrease in conversion from 45% to 23% over 46 h on stream in a continuous flow reactor. Catalyst deactivation is likely due to leaching of W. THFDM can be efficiently converted to 1,2,6-hexanetriol (HTO) in the presence of Pt/TiO 2 and homogeneous W salts.
Designing high–performance catalysts that can stabilize catalytic active sites against sintering to deactivation at temperature higher than 900°C is significant but challenging. In this work, we report a new strategy to obtain a transition metal oxide catalyst with high temperature stability for CO oxidation. This is achieved through a synergistic interfacial interaction at the interface of a heterostructure between high– entropy oxides (HEO, high temperature stability) and CuCeO x (catalytic site). The catalytic site (CuCeO x ) for CO oxidation is realized by dissolving an amount of Cu species in HEO into CeO 2 via an entropy–driven mechanochemical process. In situ XRD and HAADF–STEM have confirmed the high temperature stability of the heterostructure CuCeO x –HEO, which can remain its CO oxidation catalytic activity at elevated temperatures. It should be expected that this innovative will offer the potential to the synthesis of catalysts with high temperature stability in industry.
Moderately strong BAS and spacious microporous environments (i.e., large-pore acidic zeolites HBEA and HY) are important criteria for efficient alkylation of phenols with cyclic alcohols and alkenes, while very strong BAS appear to be responsible for catalyst deactivation. BAS confined in HBEA and HY pores show substantially higher turnover frequencies compared to solids without molecularly sized pore constraints. HBEA favors the formation of mono-alkylates, while enhanced formation of di-alkylates is observed on HY. Dehydration of alcohols always dominates over the alkylation at the onset of the reaction. Carbenium ions, the direct electrophile for aromatic oxygenates, are produced mainly from the adsorption and protonation of olefins. The present study shows that for the alkylation of phenols and cyclic alcohols in apolar liquids, the alcohol concentration should be kept low to avoid the formation of unreactive surface dimers and mitigate their inhibitory effects on olefin adsorption and protonation.
We successfully synthesized uniform SSZ-39 with an average crystal size of about a micron. Pd (0.7 - 3 wt%) was supported on SSZ-39 with Si/Al ratio ~12. The as-synthesized materials were characterized by FTIR, XRD, Helium Ion Microscopy, HAADF-STEM imaging, 27 Al, 29 Si and H solid state NMR spectroscopic techniques. FTIR studies with CO and NO probe molecules reveal that the 0.7 wt% Pd/SSZ-39 material with Si/Al ~12 has the majority of Pd dispersed atomically as isolated Pd(II) and Pd(II)-OH centers, and thus can be used as a low-temperature passive NOx adsorber. Pd(II)-NO, Pd(II)(OH)(NO) and Pd(II)(CO)(NO) complexes form during PNA in this material. We compare this PNA material directly with the Pd/SSZ-13 system (with Si/Al ratio ~12) and show its superior hydrothermal stability. Remarkably, Pd/SSZ-39 with Si/Al ratio ~12 survives hydrothermal aging up to 815 ºC in 10% H 2 O/Air vapor for 16 hours without significant loss in activity. The SSZ-39 crystal structure remains intact during hydrothermal aging up to 1,000 ºC as we elucidate it with XRD and HAADF-STEM imaging/EDS mapping. However, changes to the framework during such harsh hydrothermal treatment significantly change the NOx release profiles during PNA as evidenced by high-field 27 Al NMR on fresh and aged Pd/SSZ-39 samples as well as PNA performance measurements. Besides PNA application, these hydrothermally very stable materials (3 wt% Pd on SSZ-39 with Si/Al ratio ~12) can be used as a robust methane combustion catalyst under industrially relevant conditions (GHSV~600,000hr -1 ). This catalyst shows minimal deactivation after both harsh hydrothermal aging at 750 and 800 ºC, and prolonged time on stream (105 hrs) at 425 °C. In contrast, both 3wt% Pd/alumina and 3wt% SSZ-13 supported samples lose a significant portion of their activity. Our study opens new avenues to prepare the most hydrothermally stable known Pd/zeolite materials with applications for adsorption and catalytic hydrocarbon combustion under industrially relevant conditions.
Conversion of methanol and dimethyl ether (DME) to high-octane gasoline catalyzed by beta zeolite (BEA) provides an opportunity for the production of high-quality fuels from renewable carbon sources (e.g., gasified biomass). Recent research demonstrated that a Cu-modified BEA zeolite catalyst (Cu/BEA) offered advantages over the unmodified BEA catalyst due to multifunctional Cu species that enabled incorporation of co-fed H2, reactivation of light alkanes, and reduction of products from the aromatic hydrocarbon pool. The shift in hydrocarbon pool chemistry has the potential to influence the identity and relative composition of surface carbon species that are often linked to deactivation. A detailed understanding of these carbon species is important to develop an effective and efficient regeneration procedure that can enable the transition from fundamental catalyst development to commercial application. Here, we applied complementary ex situ and in situ characterization techniques to compare the structures of surface carbon species on post-reaction Cu/BEA and unmodified BEA catalysts. Both catalysts contained acyclic and aromatic hydrocarbons along with graphitic carbon species. However, the post-reaction Cu/BEA catalyst had a lower polycyclic aromatic content, and further, the graphitic species were more hydrogenated and defective. It was also found that the presence of Cu promoted carbon removal at lower temperatures than for unmodified BEA through activation of O2 by Cu oxide during thermal oxidation. The fundamental insight into the composition of surface carbon species enabled the design of an effective and efficient regeneration strategy for the DME homologation reaction over Cu/BEA, resulting in full recovery of the catalyst activity.
By doping 1%Ru/m-ZrO 2 with sodium, selectivity tuning between CO and CH 4 during CO 2 hydrogenation was achieved by controlling the relative rates of reverse water-gas shift and CO methanation. By increasing basicity through Na loading: (1) the formate C-H bond is weakened in DRIFTS of adsorbed CO, accelerating C-H bond formation of formate and promoting CO formation at the Ru/m-ZrO 2 interface; and (2) the coverage of Na increases on ensembles of Ru atoms responsible for methanation. Increasing Na content shifts selectivity from CH 4 (useful for synthetic natural gas) to CO, which can be used for Fischer-Tropsch synthesis or methanol-to-gasoline. Electronic modification of formate is likely due to enhanced basicity (strengthening bonding between catalyst and the-CO 2 function of formate and weakening C-H). In conclusion, no electron transfer from Na to Ru was detected in XANES. DRIFTS as a function of time and XPS results showed that Na exacerbates site blocking and deactivation.