Ultra-thin (~1 μm) Pd–Cu membrane reactor for coupling CO2 hydrogenation and propane dehydrogenation applications

Electrocatalytic Hydrogenation Using Palladium Membrane Reactors

Hydrogenation is a crucial chemical process employed in a myriad of industries, often facilitated by metals such as Pd, Pt, and Ni as catalysts. Traditional thermocatalytic hydrogenation usually necessitates high temperature and elevated pressure, making the process energy intensive. Electrocatalytic hydrogenation offers an alternative but suffers from issues such as competing H2 evolution, electrolyte separation, and limited solvent selection. This Perspective introduces the evolution and advantages of the electrocatalytic Pd membrane reactor (ePMR) as a solution to these challenges. ePMR utilizes a Pd membrane to physically separate the electrochemical chamber from the hydrogenation chamber, permitting the use of water as the hydrogen source and eliminating the need for H2 gas. This setup allows for greater control over reaction conditions, such as solvent and electrolyte selection, while mitigating issues such as low Faradaic efficiency and complex product separation. Several representative hydrogenation reactions (e.g., hydrogenation of C=C, C≡C, C=O, C≡N, and O=O bonds) achieved via ePMR over the past 30 years were concisely discussed to highlight the unique advantages of ePMR. Promising research directions along with the advancement of ePMR for more challenging hydrogenation reactions are also proposed. Finally, we provide a prospect for future development of this distinctive hydrogenation strategy using hydrogen-permeable membrane electrodes.

Hydrogen Permeability of Composite Pd-Au/Pd-Cu Membranes and Methods for Their Preparation

Thin Pd-40%Cu films were obtained via the classical melting and rolling method, magnetron sputtering, and modified with nanostructured functional coatings to intensify the process of hydrogen transportation. The films were modified by electrodeposition, according to the classical method of obtaining palladium black and "Pd-Au nanoflowers" with spherical and pentagonal particles, respectively. The experiment results demonstrated the highest catalytic activity (89.47 mA cm^-2), good resistance to CO poisoning and long-term stability of Pd-40%Cu films with a pentagonal structured coating. The investigation of the developed membranes in the hydrogen transport processes in the temperature range of 25-300 °C also demonstrated high and stable fluxes of up to 475.28 mmol s^-1 m^-2 (deposited membranes) and 59.41 mmol s^-1 m^-2 (dense metal membranes), which were up to 1.5 higher, compared with membrane materials with classic niello. For all-metal modified membranes, the increase in flux was up to sevenfold, compared with a smooth membrane made of pure palladium, and for deposited films, this difference was manyfold. The membrane materials' selectivity was also high, up to 4419. The developed strategy for modifying membrane materials with functional coatings of a fundamentally new complex geometry can shed new light on the development and fabrication of durable and highly selective palladium-based membranes for gas steam reformers.

Simultaneous Production of Aromatics and COx-Free Hydrogen via Methane Dehydroaromatization in Membrane Reactors: A Simulation Study

As an alternative route for aromatics and hydrogen production, methane dehydroaromatization (MDA) is of significant academic and industrial interest due to the abundance of natural gas resources and the intensive demand for aromatics and CO_x-free hydrogen. In the present work, a simulation study on MDA in membrane reactors (MRs) was performed with the aim of co-producing aromatics and CO_x-free hydrogen with a highly improved efficiency. The effects of various parameters, including catalytic activity, membrane flux and selectivity, as well as the operating conditions on the MR performance were discussed with respect to methane conversion, hydrogen yield, and hydrogen purity. The results show that catalytic activity and membrane flux and selectivity have significant impacts on CH₄ conversion and H₂ yield, whereas H₂ purity is mainly dominated by membrane selectivity. A highly improved MDA is confirmed to be feasible at a relatively low temperature and a high feed pressure because of the hydrogen extraction effect. To further improve MDA in MRs by intensifying H₂ extraction, a simple configuration combining a fixed-bed reactor (FBR) and an MR together is proposed for MDA, which demonstrates good potential for the high-efficiency co-production of aromatics and CO_x-free hydrogen.

Dielectric Barrier Discharge Plasma-Assisted Catalytic CO2 Hydrogenation: Synergy of Catalyst and Plasma

CO2 hydrogenation is an effective way to convert CO2 to value-added chemicals (e.g., CH4 and CH3OH). As a thermal catalytic process, it suffers from dissatisfactory catalytic performances (low conversion/selectivity and poor stability) and high energy input. By utilizing the dielectric barrier discharge (DBD) technology, the catalyst and plasma could generate a synergy, activating the whole process in a mild condition, and enhancing the conversion efficiency of CO2 and selectivity of targeted product. In this review, a comprehensive summary of the applications of DBD plasma in catalytic CO2 hydrogenation is provided in detail. Moreover, the state-of-the-art design of the reactor and optimization of reaction parameters are discussed. Furthermore, several mechanisms based on simulations and experiments are provided. In the end, the existing challenges of this hybrid system and corresponding solutions are proposed.

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.

Tuning the selectivity of CO2 hydrogenation using ceramic hollow fiber catalytic modules

The unique structural features and advantageous pore distributions of alumina hollow fibers can be exploited to tune the selectivity in heterogeneous catalysis.

Smart Designs of Anti-Coking and Anti-Sintering Ni-Based Catalysts for Dry Reforming of Methane: A Recent Review

Dry reforming of methane (DRM) reaction has drawn much interest due to the reduction of greenhouse gases and production of syngas. Coking and sintering have hindered the large-scale operations of Ni-based catalysts in DRM reactions at high temperatures. Smart designs of Ni-based catalysts are comprehensively summarized in fourth aspects: surface regulation, oxygen defects, interfacial engineering, and structural optimization. In each part, details of the designs and anti-deactivation mechanisms are elucidated, followed by a summary of the main points and the recommended strategies to improve the catalytic performance, energy efficiency, and utilization rate.

Synthesizing High-Volume Chemicals from CO2 without Direct H2 Input

Decarbonizing the chemical industry will eventually entail using CO₂ as a feedstock for chemical synthesis. However, many chemical syntheses involve CO₂ reduction using inputs such as renewable hydrogen. In this review, chemical processes are discussed that use CO₂ as an oxidant for upgrading hydrocarbon feedstocks. The captured CO₂ is inherently reduced by the hydrocarbon co-reactants without consuming molecular hydrogen or renewable electricity. This CO₂ utilization approach can be potentially applied to synthesize eight emission-intensive molecules, including olefins and epoxides. Catalytic systems and reactor concepts are discussed that can overcome practical challenges, such as thermodynamic limitations, over-oxidation, coking, and heat management. Under the best-case scenario, these hydrogen-free CO₂ reduction processes have a combined CO₂ abatement potential of approximately 1 gigatons per year and avoid the consumption of 1.24 PWh renewable electricity, based on current market demand and supply.