Real-time multi-length scale chemical tomography of fixed bed reactors during the oxidative coupling of methane reaction

Probing Particle-Carbon/Binder Degradation Behavior in Fatigued Layered Cathode Materials through Machine Learning Aided Diffraction Tomography

Understanding how reaction heterogeneity impacts cathode materials during Li-ion battery (LIB) electrochemical cycling is pivotal for unraveling their electrochemical performance. Yet, experimentally verifying these reactions has proven to be a challenge. To address this, we employed scanning μ-XRD computed tomography to scrutinize Ni-rich layered LiNi0.6Co0.2Mn0.2O2 (NCM622) and Li-rich layered Li[Li0.2Ni0.2Mn0.6]O2 (LLNMO). By harnessing machine learning (ML) techniques, we scrutinized an extensive dataset of μ-XRD patterns, about 100,000 patterns per slice, to unveil the spatial distribution of crystalline structure and microstrain. Our experimental findings unequivocally reveal the distinct behavior of these materials. NCM622 exhibits structural degradation and lattice strain intricately linked to the size of secondary particles. Smaller particles and the surface of larger particles in contact with the carbon/binder matrix experience intensified structural fatigue after long-term cycling. Conversely, both the surface and bulk of LLNMO particles endure severe strain-induced structural degradation during high-voltage cycling, resulting in significant voltage decay and capacity fade. This work holds the potential to fine-tune the microstructure of advanced layered materials and manipulate composite electrode construction in order to enhance the performance of LIBs and beyond.

Recent developments in X-ray diffraction/scattering computed tomography for materials science

X-ray diffraction/scattering computed tomography (XDS-CT) methods are a non-destructive class of chemical imaging techniques that have the capacity to provide reconstructions of sample cross-sections with spatially resolved chemical information. While X-ray diffraction CT (XRD-CT) is the most well-established method, recent advances in instrumentation and data reconstruction have seen greater use of related techniques like small angle X-ray scattering CT and pair distribution function CT. Additionally, the adoption of machine learning techniques for tomographic reconstruction and data analysis are fundamentally disrupting how XDS-CT data is processed. The following narrative review highlights recent developments and applications of XDS-CT with a focus on studies in the last five years. This article is part of the theme issue 'Exploring the length scales, timescales and chemistry of challenging materials (Part 2)'.

Optimizing hierarchical membrane/catalyst systems for oxidative coupling of methane using additive manufacturing

The advantage of a membrane/catalyst system in the oxidative coupling of methane compared with conventional reactive systems is that by introducing oxygen into the catalytic sites through a membrane, the parasitic gas-phase reactions of O2(g)-responsible for lowering product selectivity-can be avoided. The design and fabrication of membrane/catalyst systems has, however, been hampered by low volumetric chemical conversion rates, high capital cost and difficulties in co-designing membrane and catalyst properties to optimize the performance. Here we solve these issues by developing a dual-layer additive manufacturing process, based on phase inversion, to design, fabricate and optimize a hollow-fibre membrane/catalyst system for the oxidative coupling of methane. We demonstrate the approach through a case study using BaCe0.8Gd0.2O3-δ as the basis of both catalyst and separation layers. We show that by using the manufacturing approach, we can co-design the membrane thickness and catalyst surface area so that the flux of oxygen transport through the membrane and methane activation rates in the catalyst layer match each other. We demonstrate that this 'rate matching' is critical for maximizing the performance, with the membrane/catalyst system substantially overperforming conventional reactor designs under identical conditions.

Catalytic reactor for operando spatially resolved structure-activity profiling using high-energy X-ray diffraction

In heterogeneous catalysis, operando measurements probe catalysts in their active state and are essential for revealing complex catalyst structure-activity relationships. The development of appropriate operando sample environments for spatially resolved studies has come strongly into focus in recent years, particularly when coupled to the powerful and multimodal characterization tools available at synchrotron light sources. However, most catalysis studies at synchrotron facilities only measure structural information about the catalyst in a spatially resolved manner, whereas gas analysis is restricted to the reactor outlet. Here, a fully automated and integrated catalytic profile reactor setup is shown for the combined measurement of temperature, gas composition and high-energy X-ray diffraction (XRD) profiles, using the oxidative dehydrogenation of C₂H₆ to C₂H₄ over MoO₃/γ-Al₂O₃ as a test system. The profile reactor methodology was previously developed for X-ray absorption spectroscopy and is here extended for operando XRD. The profile reactor is a versatile and accessible research tool for combined spatially resolved structure-activity profiling, enabling the use of multiple synchrotron-based characterization methods to promote a knowledge-based optimization of a wide range of catalytic systems in a time- and resource-efficient way.

Low-Temperature Light-off MnOx-Na2WO4-Based Catalysts: A Step Forward to OCM Process Industrialization

Oxidative coupling of methane (OCM) catalyzed by MnOx-Na2WO4-based catalysts has great industrial potential to convert CH4 directly to C2-3 products, but the high light-off temperature is a big challenge to OCM commercialization. The reaction mechanism studies disclosed that O2/CH4-activation relevant "Mn2+↔Mn3+" redox cycle is tightly linked with the catalyst light-off. One concept is thus put forward that the OCM light-off temperature could be lowered once a "Mn2+↔Mn3+" redox cycle was established to be triggered at low temperature over MnOx-Na2WO4-based catalysts. The relevant studies in recent years are reviewed, showing that the establishment of low-temperature light-off "Mn2+↔Mn3+" redox cycle over the MnOx-Na2WO4-based catalysts indeed works effectively toward a low-temperature light-off OCM process. Moreover, three perspectives for the OCM industrialization are discussed based on this concept, including monolithic catalyst, fluidized-bed method and chemical-looping process.

A combined computational and experimental study of methane activation during oxidative coupling of methane (OCM) by surface metal oxide catalysts

The experimentally validated computational models developed herein, for the first time, show that Mn-promotion does not enhance the activity of the surface Na2WO4 catalytic active sites for CH4 heterolytic dissociation during OCM. Contrary to previous understanding, it is demonstrated that Mn-promotion poisons the surface WO4 catalytic active sites resulting in surface WO5 sites with retarded kinetics for C-H scission. On the other hand, dimeric Mn2O5 surface sites, identified and studied via ab initio molecular dynamics and thermodynamics, were found to be more efficient in activating CH4 than the poisoned surface WO5 sites or the original WO4 sites. However, the surface reaction intermediates formed from CH4 activation over the Mn2O5 surface sites are more stable than those formed over the Na2WO4 surface sites. The higher stability of the surface intermediates makes their desorption unfavorable, increasing the likelihood of over-oxidation to CO x , in agreement with the experimental findings in the literature on Mn-promoted catalysts. Consequently, the Mn-promoter does not appear to have an essential positive role in synergistically tuning the structure of the Na2WO4 surface sites towards CH4 activation but can yield MnO x surface sites that activate CH4 faster than Na2WO4 surface sites, but unselectively.

New Mechanistic and Reaction Pathway Insights for Oxidative Coupling of Methane (OCM) over Supported Na2 WO4 /SiO2 Catalysts

The complex structure of the catalytic active phase, and surface-gas reaction networks have hindered understanding of the oxidative coupling of methane (OCM) reaction mechanism by supported Na₂ WO₄ /SiO₂ catalysts. The present study demonstrates, with the aid of in situ Raman spectroscopy and chemical probe (H₂ -TPR, TAP and steady-state kinetics) experiments, that the long speculated crystalline Na₂ WO₄ active phase is unstable and melts under OCM reaction conditions, partially transforming to thermally stable surface Na-WO_x sites. Kinetic analysis via temporal analysis of products (TAP) and steady-state OCM reaction studies demonstrate that (i) surface Na-WO_x sites are responsible for selectively activating CH₄ to C₂ H_x and over-oxidizing CH_y to CO and (ii) molten Na₂ WO₄ phase is mainly responsible for over-oxidation of CH₄ to CO₂ and also assists in oxidative dehydrogenation of C₂ H₆ to C₂ H₄ . These new insights reveal the nature of catalytic active sites and resolve the OCM reaction mechanism over supported Na₂ WO₄ /SiO₂ catalysts.

Heterogeneity in the Fragmentation of Ziegler Catalyst Particles during Ethylene Polymerization Quantified by X-ray Nanotomography

Ziegler-type catalysts are the grand old workhorse of the polyolefin industry, yet their hierarchically complex nature complicates polymerization activity-catalyst structure relationships. In this work, the degree of catalyst framework fragmentation of a high-density polyethylene (HDPE) Ziegler-type catalyst was studied using ptychography X-ray-computed nanotomography (PXCT) in the early stages of ethylene polymerization under mild reaction conditions. An ensemble consisting of 434 fully reconstructed ethylene prepolymerized Ziegler catalyst particles prepared at a polymer yield of 3.4 g HDPE/g catalyst was imaged. This enabled a statistical route to study the heterogeneity in the degree of particle fragmentation and therefore local polymerization activity at an achieved 3-D spatial resolution of 74 nm without requiring invasive imaging tools. To study the degree of catalyst fragmentation within the ensemble, a fragmentation parameter was constructed based on a k-means clustering algorithm that relates the quantity of polyethylene formed to the average size of the spatially resolved catalyst fragments. With this classification method, we have identified particles that exhibit weak, moderate, and strong degrees of catalyst fragmentation, showing that there is a strong heterogeneity in the overall catalyst particle fragmentation and thus polymerization activity within the entire ensemble. This hints toward local mass transfer limitations or other deactivation phenomena. The methodology used here can be applied to all polyolefin catalysts, including metallocene and the Phillips catalysts to gain statistically relevant fundamental insights in the fragmentation behavior of an ensemble of catalyst particles.

Effect of thermal treatment on the stability of Na-Mn-W/SiO2 catalyst for the oxidative coupling of methane

In this study, we investigate the effect of thermal treatment/calcination on the stability and activity of a Na-Mn-W/SiO₂ catalyst for the oxidative coupling of methane. The catalyst performance and characterisation measurements suggest that the W species are directly involved in the catalyst active site responsible for CH₄ conversion. Under operating conditions, the active components, present in the form of a Na-W-O-Mn molten state, are highly mobile and volatile. By varying the parameters of the calcination protocol, it was shown that these molten components can be partially stabilised, resulting in a catalyst with lower activity (due to loss of surface area) but higher stability even for long duration OCM reaction experiments.

Sample Environment for Operando Hard X-ray Tomography—An Enabling Technology for Multimodal Characterization in Heterogeneous Catalysis

Structure–activity relations in heterogeneous catalysis can be revealed through in situ and operando measurements of catalysts in their active state. While hard X-ray tomography is an ideal method for non-invasive, multimodal 3D structural characterization on the micron to nm scale, performing tomography under controlled gas and temperature conditions is challenging. Here, we present a flexible sample environment for operando hard X-ray tomography at synchrotron radiation sources. The setup features are discussed, with demonstrations of operando powder X-ray diffraction tomography (XRD-CT) and energy-dispersive tomographic X-ray absorption spectroscopy (ED-XAS-CT). Catalysts for CO2 methanation and partial oxidation of methane are shown as case studies. The setup can be adapted for different hard X-ray microscopy, spectroscopy, or scattering synchrotron radiation beamlines, is compatible with absorption, diffraction, fluorescence, and phase-contrast imaging, and can operate with scanning focused beam or full-field acquisition mode. We present an accessible methodology for operando hard X-ray tomography studies, which offer a unique source of 3D spatially resolved characterization data unavailable to contemporary methods.

Multi-Scale Studies of 3D Printed Mn–Na–W/SiO2 Catalyst for Oxidative Coupling of Methane

This work presents multi-scale approaches to investigate 3D printed structured Mn–Na–W/SiO2 catalysts used for the oxidative coupling of methane (OCM) reaction. The performance of the 3D printed catalysts has been compared to their conventional analogues, packed beds of pellets and powder. The physicochemical properties of the 3D printed catalysts were investigated using scanning electron microscopy, nitrogen adsorption and X-ray diffraction (XRD). Performance and durability tests of the 3D printed catalysts were conducted in the laboratory and in a miniplant under real reaction conditions. In addition, synchrotron-based X-ray diffraction computed tomography technique (XRD-CT) was employed to obtain cross sectional maps at three different positions selected within the 3D printed catalyst body during the OCM reaction. The maps revealed the evolution of catalyst active phases and silica support on spatial and temporal scales within the interiors of the 3D printed catalyst under operating conditions. These results were accompanied with SEM-EDS analysis that indicated a homogeneous distribution of the active catalyst particles across the silica support.

DLSR: a solution to the parallax artefact in X-ray diffraction computed tomography data

A new tomographic reconstruction algorithm is presented, termed direct least-squares reconstruction (DLSR), which solves the well known parallax problem in X-ray-scattering-based experiments. The parallax artefact arises from relatively large samples where X-rays, scattered from a scattering angle 2θ, arrive at multiple detector elements. This phenomenon leads to loss of physico-chemical information associated with diffraction peak shape and position (i.e. altering the calculated crystallite size and lattice parameter values, respectively) and is currently the major barrier to investigating samples and devices at the centimetre level (scale-up problem). The accuracy of the DLSR algorithm has been tested against simulated and experimental X-ray diffraction computed tomography data using the TOPAS software.

In situ X-ray diffraction computed tomography studies examining the thermal and chemical stabilities of working Ba0.5Sr0.5Co0.8Fe0.2O3-δ membranes during oxidative coupling of methane

In this study we present the results from two in situ X-ray diffraction computed tomography experiments of catalytic membrane reactors (CMRs) using Ba0.5Sr0.5Co0.8Fe0.2O3-δ (BSCF) hollow fibre membranes and Na-Mn-W/SiO2 catalyst during the oxidative coupling of methane (OCM) reaction. The negative impact of CO2, when added to the inlet gas stream, is seen to be mainly related to the C2+ yield, while no evidence of carbonate phase(s) formation is found during the OCM experiments. The main degradation mechanism of the CMR is suggested to be primarily associated with the solid-state evolution of the BSCF phase rather than the presence of CO2. Specifically, in situ XRD-CT and post-mortem SEM/EDX measurements revealed a collapse of the cubic BSCF phase and subsequent formation of secondary phases, which include needle-like structures and hexagonal Ba6Co4O12 and formation of a BaWO4 layer, the latter being a result of chemical interaction between the membrane and catalyst materials at high temperatures.