Monolithic SiC supports with tailored hierarchical porosity for molecularly selective membranes and supported liquid-phase catalysis

A Model for the Flow Distribution in Dual Cell Density Monoliths

Monoliths are promising as catalytic structured supports due to their many operational advantages. Compared to pellets, monoliths offer low backpressure and good heat distribution, even at high flow rates. There is interest in the industry for improving temperature control in highly exothermic systems, such as the catalytic hydrogenation of CO2 for e-fuels synthesis. In this context, novel substrate shapes, such as non-homogeneous cell density monoliths, show good potential; however, to date, they have only been sparsely described. This work focuses on a dual cell density substrate and uses a computational model of a straight-channel monolith with two concentric regions to analyze its flow distribution. The central (core) and peripheral (ring) regions of the substrate differ in cell density in order to obtain a non-homogeneous cross-section. The model is validated against classical data in the literature and theoretical equations. Then, the flow fraction passing through each region of the substrate is registered. Several flow rates, core sizes and combinations of apparent permeabilities are tested. According to the results, the flow distribution depends only on the monolith geometrical features and not on the flow rate. A model for this phenomenon is proposed. The model accurately predicted the flow fraction passing through each region of the monolith for all the cases analyzed.

Influence of Support Structure on Catalytic Performance of Supported Liquid-Phase (SLP) Catalysts in Hydroformylation of 1-Butene

Several supported liquid-phase (SLP) catalysts with immobilized Rh-biphephos complexes on monolithic supports were prepared and applied for continuous gas-phase hydroformylation (HyFo) of 1-butene. The support comprised macroporous monolithic silicon carbide (SiC) with deposited silica nanoparticles (NPs) in order to provide mesopores with enhanced capillary forces to retain the liquid-phase. Variable parameters were examined for the monolithic SiC supports, including size and loading of deposited silica NPs and intermediate calcination between silica deposition steps to obtain the most efficient support configuration for the SLP system. The SLP catalysts with larger deposited silica NPs gave higher catalytic activity (i.e. 1-butene conversion and turnover frequency) compared to the supports with smaller sized silica NPs. However, the selectivity towards the preferred linear aldehyde was higher in the SLP catalysts with supports containing less silica with small silica NPs. Importantly, the prepared SLP catalyst systems showed long-term stability in HyFo with negligible formation of high boiling aldol condensation products.

Porous Silicon Carbide (SiC): A Chance for Improving Catalysts or Just Another Active-Phase Carrier?

There is an obvious gap between efforts dedicated to the control of chemicophysical and morphological properties of catalyst active phases and the attention paid to the search of new materials to be employed as functional carriers in the upgrading of heterogeneous catalysts. Economic constraints and common habits in preparing heterogeneous catalysts have narrowed the selection of active-phase carriers to a handful of materials: oxide-based ceramics (e.g. Al₂O₃, SiO₂, TiO₂, and aluminosilicates-zeolites) and carbon. However, these carriers occasionally face chemicophysical constraints that limit their application in catalysis. For instance, oxides are easily corroded by acids or bases, and carbon is not resistant to oxidation. Therefore, these carriers cannot be recycled. Moreover, the poor thermal conductivity of metal oxide carriers often translates into permanent alterations of the catalyst active sites (i.e. metal active-phase sintering) that compromise the catalyst performance and its lifetime on run. Therefore, the development of new carriers for the design and synthesis of advanced functional catalytic materials and processes is an urgent priority for the heterogeneous catalysis of the future. Silicon carbide (SiC) is a non-oxide semiconductor with unique chemicophysical properties that make it highly attractive in several branches of catalysis. Accordingly, the past decade has witnessed a large increase of reports dedicated to the design of SiC-based catalysts, also in light of a steadily growing portfolio of porous SiC materials covering a wide range of well-controlled pore structure and surface properties. This review article provides a comprehensive overview on the synthesis and use of macro/mesoporous SiC materials in catalysis, stressing their unique features for the design of efficient, cost-effective, and easy to scale-up heterogeneous catalysts, outlining their success where other and more classical oxide-based supports failed. All applications of SiC in catalysis will be reviewed from the perspective of a given chemical reaction, highlighting all improvements rising from the use of SiC in terms of activity, selectivity, and process sustainability. We feel that the experienced viewpoint of SiC-based catalyst producers and end users (these authors) and their critical presentation of a comprehensive overview on the applications of SiC in catalysis will help the readership to create its own opinion on the central role of SiC for the future of heterogeneous catalysis.

Tailored monolith supports for improved ultra-low temperature water-gas shift reaction

A monolithic γ-Al2O3 support is developed to scale up the WGS process using the supported ionic liquid-phase concept in a structured reactor. The support-ionic liquid-catalyst system maximizes loading and mechanical resistance while achieving high activity and selectivity.