High-performance catalytic perovskite hollow fiber membrane reactor for oxidative propane dehydrogenation

High-Performance Co-production of Electricity and Light Olefins Enabled by Exsolved NiFe Alloy Nanoparticles from a Double-Perovskite Oxide Anode in Solid Oxide-Ion-Conducting Fuel Cells

Light olefins (LOs) such as ethylene and propylene are critical feedstocks for many vital chemicals that support our economy and daily life. LOs are currently mass produced via steam cracking of hydrocarbons, which is highly energy intensive and carbon polluting. Efficient, low-emission, and LO-selective conversion technologies are highly desirable. Electrochemical oxidative dehydrogenation of alkanes in oxide-ion-conducting solid oxide fuel cell (SOFC) reactors has been reported in recent years as a promising approach to produce LOs with high efficiency and yield while generating electricity. We report here an electrocatalyst that excels in the co-production. The efficient catalyst is NiFe alloy nanoparticles (NPs) exsolved from a Pr- and Ni-doped double perovskite Sr2Fe1.5Mo0.5O6 (Pr0.8Sr1.2Ni0.2Fe1.3Mo0.5O6-δ, PSNFM) matrix during SOFC operation. We show evidence that Ni is first exsolved, which triggers the following Fe-exsolution, forming the NiFe NP alloy. At the same time as the NiFe exsolution, abundant oxygen vacancies are created at the NiFe/PSNFM interface, which promotes the oxygen mobility for oxidative dehydrogenation of propane (ODHP), coking resistance, and power generation. At 750 °C, the SOFC reactor with the PSNFM catalyst reaches a propane conversion of 71.40% and LO yield of 70.91% under a current density of 0.3 A cm-2 without coking. This level of performance is unmatchable by the current thermal catalytic reactors, demonstrating the great potential of electrochemical reactors for direct hydrocarbon conversion into value-added products.

Ion-Conducting Ceramic Membrane Reactors for the Conversion of Chemicals

Ion-conducting ceramic membranes, such as mixed oxygen ionic and electronic conducting (MIEC) membranes and mixed proton-electron conducting (MPEC) membranes, have the potential for absolute selectivity for specific gases at high temperatures. By utilizing these membranes in membrane reactors, it is possible to combine reaction and separation processes into one unit, leading to a reduction in by-product formation and enabling the use of thermal effects to achieve efficient and sustainable chemical production. As a result, membrane reactors show great promise in the production of various chemicals and fuels. This paper provides an overview of recent developments in dense ceramic catalytic membrane reactors and their potential for chemical production. This review covers different types of membrane reactors and their principles, advantages, disadvantages, and key issues. The paper also discusses the configuration and design of catalytic membrane reactors. Finally, the paper offers insights into the challenges of scaling up membrane reactors from experimental stages to practical applications.

Direct Conversion of Methane to C2 Hydrocarbons in Solid-State Membrane Reactors at High Temperatures

Direct conversion of methane to C₂ compounds by oxidative and nonoxidative coupling reactions has been intensively studied in the past four decades; however, because these reactions have intrinsic severe thermodynamic constraints, they have not become viable industrially. Recently, with the increasing availability of inexpensive "green electrons" coming from renewable sources, electrochemical technologies are gaining momentum for reactions that have been challenging for more conventional catalysis. Using solid-state membranes to control the reacting species and separate products in a single step is a crucial advantage. Devices using ionic or mixed ionic-electronic conductors can be explored for methane coupling reactions with great potential to increase selectivity. Although these technologies are still in the early scaling stages, they offer a sustainable path for the utilization of methane and benefit from the advances in both solid oxide fuel cells and electrolyzers. This review identifies promising developments for solid-state methane conversion reactors by assessing multifunctional layers with microstructural control; combining solid electrolytes (proton and oxygen ion conductors) with active and selective electrodes/catalysts; applying more efficient reactor designs; understanding the reaction/degradation mechanisms; defining standards for performance evaluation; and carrying techno-economic analysis.

A mini-review on recent developments in SAPO-34 zeolite membranes and membrane reactors

Schematic diagram of a SAPO-34 membrane for various gas separation.

Current status and perspectives in oxidative, non-oxidative and CO2-mediated dehydrogenation of propane and isobutane over metal oxide catalysts

Conversion of propane or isobutane from natural/shale gas into propene or isobutene, which are indispensable for the synthesis of commodity chemicals, is an important environmentally friendly alternative to oil-based cracking processes.

Catalytic mixed conducting ceramic membrane reactors for methane conversion

Schematic of catalytic mixed conducting ceramic membrane reactors for various reactions: (a) O₂ permeable ceramic membrane reactor; (b) H₂ permeable ceramic membrane reactor; (c) CO₂ permeable ceramic membrane reactor.

Highly Efficient NO Decomposition via Dual-Functional Catalytic Perovskite Hollow Fiber Membrane Reactor Coupled with Partial Oxidation of Methane at Medium-Low Temperature

A novel dual-functional catalytic perovskite hollow fiber membrane reactor was fabricated by integrating BaBi_0.05Co_0.8Nb_0.15O_3-δ (BBCN) perovskite hollow fiber membrane with Ni-phyllosilicate hollow sphere catalysts for simultaneous NO decomposition and partial oxidation of methane (POM) reaction. With this novel catalytic membrane reactor, NO could be completely converted to N₂ at a medium-low temperature (675 °C) owing to instantaneous oxygen removal from the NO decomposition reaction system. Coupled POM reaction on the other side of BBCN hollow fiber membrane not only increased the driving force for oxygen permeation but also produced valuable products (syngas). This novel membrane reactor showed high NO removal capacity at comparatively low temperatures (675-700 °C), which is 100-200 °C lower than those of other membrane reactors reported in literature. In addition, even with the presence of a 2-5% oxygen concentration in NO stream, NO could still be completely decomposed to N₂ via this catalytic BBCN membrane reactor. Evidently, the application of this novel catalytic membrane reactor could overcome the inhibition of oxygen present atmosphere for NO decomposition and achieve a remarkably high efficiency for NO removal.

Structured Monolithic Catalysts vs. Fixed Bed for the Oxidative Dehydrogenation of Propane

The deposition of V-based catalysts for the oxidative dehydrogenation of propane to propene on cordierite honeycomb monoliths was optimised as a strategy to decrease the contact time in a structured reactor with respect to a conventional fixed bed one. 10 wt% VO_x supported over SiO₂ or Al₂O₃ were used as catalysts, deposed over the monolith using silica or alumina as primer, respectively. Both the alumina supported catalyst and the bohemite primer precursor were effectively deposed by dip-coating from stable powder suspensions, whereas insufficient adhesion was obtained when loading pre-synthesised SiO₂ over the cordierite. A new method based on sol-gel production of SiO₂ from tetraethylortosilicate (TEOS) over the monolith surface was set up. A correlation was derived for the prevision of the amount of silica deposed depending on the amount of TEOS. Both primer and catalyst loading were optimised as for uniformity and stability of the coating and resulted 0.5–1 wt % primer and 0.15 wt % of catalyst. Activity testing confirmed the strong improvement of propene productivity by increasing the time factor (i.e. Ncm³ of flowing reactant/min g_cat), which ended in a one order of magnitude increase of productivity for the honeycomb-supported samples with respect to the fixed bed configuration.