Catalyst design based on microkinetic models: Oxidative coupling of methane

Oxidative Coupling of Methane over Pt/Al2O3 at High Temperature: Multiscale Modeling of the Catalytic Monolith

At high temperatures, the oxidative coupling of methane (OCM) is an attractive approach for catalytic conversion of methane into value-added chemicals. Experiments with a Pt/Al2O3-coated catalytic honeycomb monolith were conducted with varying CH4/O2 ratios, N2 dilution at atmospheric pressure, and very short contact times. The reactor was modeled by a multiscale approach using a parabolic two-dimensional flow field description in the monolithic channels coupled with a heat balance of the monolithic structure, and multistep surface reaction mechanisms as well as elementary-step, gas phase reaction mechanisms. The contribution of heterogeneous and homogeneous reactions, both of which are important for the optimization of C2 products, is investigated using a combination of experimental and computational methods. The oxidation of methane, which takes place over the platinum catalyst, causes the adiabatic temperature increase required for the generation of CH3 radicals in the gas phase, which are essential for the formation of C2 species. Lower CH4/O2 ratios result in higher C2 selectivity. However, the presence of OH radicals at high temperatures facilitates subsequent conversion of C2H2 at a CH4/O2 ratio of 1.4. Thereby, C2 species selectivity of 7% was achieved at CH4/O2 ratio of 1.6, with 35% N2 dilution.

On the Potential of Gallium- and Indium-Based Liquid Metal Membranes for Hydrogen Separation

The concept of liquid metal membranes for hydrogen separation, based on gallium or indium, was recently introduced as an alternative to conventional palladium-based membranes. The potential of this class of gas separation materials was mainly attributed to the promise of higher hydrogen diffusivity. The postulated improvements are only beneficial to the flux if diffusion through the membrane is the rate-determining step in the permeation sequence. Whilst this is a valid assumption for hydrogen transport through palladium-based membranes, the relatively low adsorption energy of hydrogen on both liquid metals suggests that other phenomena may be relevant. In the current study, a microkinetic modeling approach is used to enable simulations based on a five-step permeation mechanism. The calculation results show that for the liquid metal membranes, the flux is limited by the dissociative adsorption over a large temperature range, and that the membrane flux is expected to be orders of magnitude lower compared to the membrane flux through pure palladium membranes. Even when accounting for the lower cost of the liquid metals compared to palladium, the latter still outperforms both gallium and indium in all realistic scenarios, in part due to the practical difficulties associated with making liquid metal thin films.

High-Throughput Screening and Literature Data Driven Machine Learning Assisting Investigation of Multi-component La2O3-based Catalysts for Oxidative Coupling of Methane

Multi-component La2O3-based catalysts for oxidative coupling of methane (OCM) were designed based on high-throughput screening (HTS) and literature datasets with multi-output machine learning (ML) approaches including random forest regression (RFR),...

Noncatalytic Oxidative Coupling of Methane (OCM): Gas-Phase Reactions in a Jet Stirred Reactor (JSR)

Oxidative coupling of methane (OCM) is a promising technique for converting methane to higher hydrocarbons in a single reactor. Catalytic OCM is known to proceed via both gas-phase and surface chemical reactions. It is essential to first implement an accurate gas-phase model and then to further develop comprehensive homogeneous-heterogeneous OCM reaction networks. In this work, OCM gas-phase kinetics using a jet-stirred reactor are studied in the absence of a catalyst and simulated using a 0-D reactor model. Experiments were conducted in OCM-relevant operating conditions under various temperatures, residence times, and inlet CH₄/O₂ ratios. Simulations of different gas-phase models related to methane oxidation were implemented and compared against the experimental data. Quantities of interest (QoI) and rate of production analyses on hydrocarbon products were also performed to evaluate the models. The gas-phase models taken from catalytic reaction networks could not adequately describe the experimental gas-phase performances. NUIGMech1.1 was selected as the most comprehensive model to describe the OCM gas-phase kinetics; it is recommended for further use as the gas-phase model for constructing homogeneous-heterogeneous reaction networks.

A Disruptive Innovation for Upgrading Methane to C3 Commodity Chemicals : Technical challenges faced by the C123 European consortium

C123 is a €6.4 million European Horizon 2020 (H2020) integrated project running from 2019 to 2023, bringing together 11 partners from seven different European countries. There are large reserves of stranded natural gas waiting for a viable solution and smaller scale biogas opportunities offering methane feedstocks rich in carbon dioxide, for which utilisation can become an innovation advantage. C123 will evaluate how to best valorise these unexploited methane resources by an efficient and selective transformation into easy-to-transport liquids such as propanol and propanal that can be transformed further into propylene and fed into the US$6 billion polypropylene market. In C123 the selective transformation of methane to C3 hydrocarbons will be realised via a combination of oxidative conversion of methane (OCoM) and hydroformylation, including thorough smart process design and integration under industrially relevant conditions. All C123 technologies exist at TRL3 (TRL = technology readiness level), and the objectives of C123 will result in the further development of this technology to TRL5 with a great focus on the efficient overall integration of not only the reaction steps but also the required purification and separation steps, incorporating the relevant state-of-the-art engineering expertise.

Microkinetic Modeling: A Tool for Rational Catalyst Design

The design of heterogeneous catalysts relies on understanding the fundamental surface kinetics that controls catalyst performance, and microkinetic modeling is a tool that can help the researcher in streamlining the process of catalyst design. Microkinetic modeling is used to identify critical reaction intermediates and rate-determining elementary reactions, thereby providing vital information for designing an improved catalyst. In this review, we summarize general procedures for developing microkinetic models using reaction kinetics parameters obtained from experimental data, theoretical correlations, and quantum chemical calculations. We examine the methods required to ensure the thermodynamic consistency of the microkinetic model. We describe procedures required for parameter adjustments to account for the heterogeneity of the catalyst and the inherent errors in parameter estimation. We discuss the analysis of microkinetic models to determine the rate-determining reactions using the degree of rate control and reversibility of each elementary reaction. We introduce incorporation of Brønsted-Evans-Polanyi relations and scaling relations in microkinetic models and the effects of these relations on catalytic performance and formation of volcano curves are discussed. We review the analysis of reaction schemes in terms of the maximum rate of elementary reactions, and we outline a procedure to identify kinetically significant transition states and adsorbed intermediates. We explore the application of generalized rate expressions for the prediction of optimal binding energies of important surface intermediates and to estimate the extent of potential rate improvement. We also explore the application of microkinetic modeling in homogeneous catalysis, electro-catalysis, and transient reaction kinetics. We conclude by highlighting the challenges and opportunities in the application of microkinetic modeling for catalyst design.

Computational design of heterogeneous catalysts and gas separation materials for advanced chemical processing

Functional materials are widely used in chemical industry in order to reduce the process cost while simultaneously increase the product quality. Considering their significant effects, systematic methods for the optimal selection and design of materials are essential. The conventional synthesis-and-test method for materials development is inefficient and costly. Additionally, the performance of the resulting materials is usually limited by the designer’s expertise. During the past few decades, computational methods have been significantly developed and they now become a very important tool for the optimal design of functional materials for various chemical processes. This article selectively focuses on two important process functional materials, namely heterogeneous catalyst and gas separation agent. Theoretical methods and representative works for computational screening and design of these materials are reviewed.

Catalyst screening for the oxidative coupling of methane: from isothermal to adiabatic operation via microkinetic simulations

OCM catalysts underperforming in typical isothermal conditions could result in above average performances in adiabatically-relevant operating conditions.

Descriptor–property relationships in heterogeneous catalysis: exploiting synergies between statistics and fundamental kinetic modelling

Combined kinetic and statistical approach to shed light on the link between kinetically-relevant descriptors and easily tuneable catalyst properties.

Microkinetic Analysis and Scaling Relations for Catalyst Design

Microkinetic analysis plays an important role in catalyst design because it provides insight into the fundamental surface chemistry that controls catalyst performance. In this review, we summarize the development of microkinetic models and the inclusion of scaling relationships in these models. We discuss the importance of achieving stoichiometric and thermodynamic consistency in developing microkinetic models. We also outline how analysis of the maximum rates of elementary steps can be used to determine which transition states and adsorbed intermediates are kinetically significant, allowing the derivation of general reaction kinetics rate expressions in terms of changes in binding energies of the relevant transition states and intermediates. Through these analyses, we present how to predict optimal surface coverages and binding energies of adsorbed species, as well as the extent of potential rate improvement for a catalytic system. For systems in which the extent of potential rate improvement is small because of limitations imposed by scaling relations, different approaches, including the addition of promoters and formation of catalysts containing multiple functionalities, can be used to break the scaling relations and obtain further rate enhancement.

Critical Surface Parameters for the Oxidative Coupling of Methane over the Mn-Na-W/SiO2 Catalyst

The work here presents a thorough evaluation of the effect of Mn-Na-W/SiO₂ catalyst surface parameters on its performance in the oxidative coupling of methane (OCM). To do so, we used microporous dealuminated β-zeolite (Zeo), or mesoporous SBA-15 (SBA), or macroporous fumed silica (Fum) as precursors for catalyst preparation, together with Mn nitrate, Mn acetate and Na₂WO₄. Characterizing the catalysts by inductively coupled plasma-optical emission spectroscopy, N₂ physisorption, X-ray diffraction, high-resolution scanning electron microscopy-energy-dispersive spectroscopy, X-ray photoelectron spectroscopy, and catalytic testing enabled us to identify critical surface parameters that govern the activity and C₂ selectivity of the Mn-Na-W/SiO₂ catalyst. Although the current paradigm views the phase transition of silica to α-cristobalite as the critical step in obtaining dispersed and stable metal sites, we show that the choice of precursors is equally or even more important with respect to tailoring the right surface properties. Specifically, the SBA-based catalyst, characterized by relatively closed surface porosity, demonstrated low activity and low C₂ selectivity. By contrast, for the same composition, the Zeo-based catalyst showed an open surface pore structure, which translated up to fourfold higher activity and enhanced selectivity. By varying the overall composition of the Zeo catalysts, we show that reducing the overall W concentration reduces the size of the Na₂WO₄ species and increases the catalytic activity linearly as much as fivefold higher than the SBA catalyst. This linear dependence correlates well to the number of interfaces between the Na₂WO₄ and Mn₂O₃ species. Our results combined with prior studies lead us to single out the interface between Na₂WO₄ and Mn₂O₃ as the most probable active site for OCM using this catalyst. Synergistic interactions between the various precursors used and the phase transition are discussed in detail, and the conclusions are correlated to surface properties and catalysis.

Effects of Ir-doping on the transition from oxidative coupling to partial oxidation of methane in La2O3–CeO2 nanofiber catalysts: spatial concentration and temperature profiles

The spatial profiles suggest this direct CH₄ partial oxidation to syngas may ensue by a hybrid of established kinetic mechanisms.

Methane conversion into different hydrocarbons or oxygenates: current status and future perspectives in catalyst development and reactor operation

This Perspective highlights recent developments in methane conversion into different hydrocarbons and C₁-oxygenates. Our analysis identified possible directions for further research to bring the above approaches to a commercial level.

Things go better with coke: the beneficial role of carbonaceous deposits in heterogeneous catalysis

Carbonaceous deposits on heterogeneous catalysts are traditionally associated with catalyst deactivation. However, they can play a beneficial role in many catalytic processes, e.g. dehydrogenation, hydrogenation, alkylation, isomerisation, Fischer–Tropsch, MTO etc. This review highlights the role and mechanism by which coke deposits can enhance catalytic performance.

Developing catalytic materials for the oxidative coupling of methane through statistical analysis of literature data

Accuracy of models based on literature data for predicting experimental yield of C₂ hydrocarbons over La₂O₃- and MgO-based catalysts in the oxidative coupling of methane.