Membrane reactor immobilized with palladium-loaded polymer nanogel for continuous-flow Suzuki coupling reaction

3D-Continuous Nanoporous Covalent Framework Membrane Nanoreactors with Quantitatively Loaded Ultrafine Pd Nanocatalysts

The confinement effect of catalytic nanoreactors containing metal catalysts within nanometer-sized volumes has attracted significant attention for their potential to enhance reaction rate and selectivity. Nevertheless, unregulated catalyst loading, aggregation, leaching, and limited reusability remain obstacles to achieving an efficient nanoreactor. A robust and durable catalytic membrane nanoreactor prepared by incorporating palladium nanocatalysts within a 3D-continuous nanoporous covalent framework membrane is presented. The reduction of palladium precursor occurs on the pore surface within 3D nanochannels, producing ultrafine palladium nanoparticles (Pd NPs) with their number density adjustable by varying metal precursor concentrations. The precise catalyst loading enables controlling the catalytic activity of the reactor while preventing excess metal usage. The facile preparation of Pd NP-loaded free-standing membrane materials allows hydrodechlorination in both batch and continuous flow modes. In batch mode, the catalytic activity is proportional to the loaded Pd amount and membrane area, while the membrane retains its activity upon repeated use. In continuous mode, the conversion remains above 95% for over 100 h, with the reactant solution passing through a single 50 µm-thick Pd-loaded membrane. The efficient nanoporous film-type catalytic nanoreactor may find applications in catalytic reactions for small chemical devices as well as in conventional chemistry and processes.

Flow-Through Catalytic Reactors Based on Metal Nanoparticles Immobilized within Porous Polymeric Gels and Surfaces/Hollows of Polymeric Membranes

State-of-the-art of flow-through catalytic reactors based on metal nanoparticles immobilized within the pores of nano-, micro- and macrosized polymeric gels and in the surface or hollow of polymeric membranes is discussed in this mini-review. The unique advantages of continuous flow-through nanocatalysis over the traditional batch-type analog are high activity, selectivity, productivity, recyclability, continuous operation, and purity of reaction products etc. The methods of fabrication of polymeric carriers and immobilization technique for metal nanoparticles on the surface of porous or hollow structures are considered. Several catalytic model reactions comprising of hydrolysis, decomposition, hydrogenation, oxidation, Suzuki coupling and enzymatic reactions in the flow system are exemplified. Realization of “on-off” switching mechanism for regulation of the rate of catalytic process through controlling the mass transfers of reactants in liquid media with the help of stimuli-responsive polymers is demonstrated. Comparative analysis of the efficiency of different flow-through catalytic reactors for various reactions is also surveyed.

High Reusability of Catalytically Active Gold Nanoparticles Immobilized in Core-Shell Hydrogel Microspheres

The reusability of hybrid core-shell microgels, whose core surfaces were decorated with gold nanoparticles, was investigated in terms of catalysis activity. Hybrid core-shell microgels composed of a rigid core and water-swollen gel shell endowed the immobilized gold nanoparticles with a high dispersion stability, which resulted in excellent catalytic activity. In contrast to free Au nanoparticles and conventional hybrid microgels, where the Au nanoparticles are randomly distributed over the entire microgel templates, the hydrogel shell part of the hybrid core-shell microgels suppressed the aggregation between the microgels and Au nanoparticles in individual microgels, which improved the reusability for the catalysis reaction. The results of this study should help to develop advanced catalyst systems that require high reusability even when the chemical reactions occur in aqueous solution and external stimuli are applied.

Engineering Porous Polymer Hollow Fiber Microfluidic Reactors for Sustainable C-H Functionalization

Highly hydrophilic and solvent-stable porous polyamide-imide (PAI) hollow fibers were created by cross-linking of bare PAI hollow fibers with 3-aminopropyl trimethoxysilane (APS). The APS-grafted PAI hollow fibers were then functionalized with salicylic aldehyde for binding catalytically active Pd(II) ions through a covalent postmodification method. The catalytic activity of the composite hollow fiber microfluidic reactors (Pd(II) immobilized APS-grafted PAI hollow fibers) was tested via heterogeneous Heck coupling reaction of aryl halides under both batch and continuous-flow reactions in polar aprotic solvents at high temperature (120 °C) and low operating pressure. X-ray photoelectron spectroscopy (XPS) and inductively coupled plasma (ICP) analyses of the starting and recycled composite hollow fibers indicated that the fibers contain very similar loadings of Pd(II), implying no degree of catalyst leaching from the hollow fibers during reaction. The composite hollow fiber microfluidic reactors showed long-term stability and strong control over the leaching of Pd species.

Catalytic Membrane Reactor Immobilized with Alloy Nanoparticle-Loaded Protein Fibrils for Continuous Reduction of 4-Nitrophenol

A catalytic membrane reactor, which contains a membrane matrix and a catalytic film of alloy nanoparticle-loaded β-lactoglobulin fibrils (NPs@β-LGF), was developed for the continuous-flow reduction of 4-nitrophenol (4-NP). The Cu-Ag and Cu-Ag-Au alloy NPs were synthesized using β-LGF as a scaffold and stabilizing agent. In this process, the Cu nanoclusters were formed in the initial stage and were able to promote the synthesis of Ag⁰, which acts as a reducing agent for the rapid formation of Au⁰. Furthermore, a catalytic membrane reactor was constructed by depositing the NPs@β-LGFs on a membrane matrix. The catalytic activity of the Cu-Ag-Au alloy NPs was higher than that of the Cu-Ag alloy NPs, using the reduction of 4-NP to 4-AP as a model reaction. The observed rate constant in the continuous-flow system is also higher than that in the batch system. In addition, these catalytic membrane reactors had good operating stability and antibacterial activity.