Tubular Inorganic catalytic membrane reactors: advantages and performance in multiphase hydrogenation reactions

Performance of Pd catalyst supported on trimetallic nanohybrid Zr–Al–La in hydrogenation of ethylanthraquinone

In light of the recent COVID-19 pandemic, the demand for hydrogen peroxide has increased significantly due to its widespread use in disinfectant formulations. The present study aims to develop an efficient nanohybrid material as catalyst support for the successful hydrogenation of ethylanthraquinone for the production of hydrogen peroxide. Co-precipitation and wet impregnation methods were used to prepare nanohybrid Zr–Al–La supported Pd catalyst (Pd/Zr–Al–La). The high surface area (146.56 m2/g) of Zr–Al–La makes it suitable to use as support and causes to lower the mass transfer resistance and dispersion of active metal. XRF, BET, FTIR, and TGA were used to characterize the developed catalyst. The catalytic activity of the developed catalyst was studied using a high-pressure autoclave reactor to obtain a notable yield of H2O2 as 93.8% at 75 °C, 0.3 MPa, and 0.5 g of catalyst dose, a significant enhancement over the traditional Pd catalyst with Al2O3 support (63%) with the loss of active quinone compound. The mass transfer limitation of the reaction is high using only a Pd catalyst. The calculated mass transfer resistance of the reaction over Pd/Zr–Al–La catalyst was found to be moderate with a diffusion coefficient of the reactant (H2) as 0.0133 × 10−6 m2/s at 75 °C. It was also verified and confirmed with the Thiele modulus (calculated as 0.0314), no mass transfer resistance. The effectiveness factor (η s ) was found to be 1.0, indicating the negligible mass transfer resistance in the hydrogenation reaction using Pd/Zr–Al–La catalyst.

A computational model for the catalytic hydrogel membrane reactor

The catalytic hydrogel membrane reactor (CHMR) is a promising new technology for hydrogenation of aqueous contaminants in drinking water. It offers numerous benefits over conventional three-phase reactors, including immobilization of nano-catalysts, high reactivity, and control over the hydrogen (H₂) supply concentration. In this study, a computational model of the CHMR was developed using AQUASIM and calibrated with 32 experimental datasets for a nitrite (NO₂^-)-reducing CHMR using palladium (Pd) nano-catalysts (~4.6 nm). The model was then used to identify key factors impacting the behavior of the CHMR, including hydrogel catalyst density, H₂ supply pressure, influent and bulk NO₂^- concentrations, and hydrogel thickness. Based on the model calibration, the reaction rate constants for the NO₂^- steady-state adsorption Hinshelwood reaction equation, k₁ and k₂, were 0.0039 m³ mole-Pd^-1 s^-1 and 0.027 (mole-H₂ m³)^1/2 mole-Pd^-1 s^-1, respectively. The reactant flux, which is the overall NO₂^- removal rate for the CHMR, is affected by the NO₂^- reduction rate at each catalyst site, which is in turn controlled by the available NO₂^- and H₂ concentrations that are regulated by their mass transport behavior. Reactant transport in the CHMR is counter-diffusional. So for thick hydrogels, the concurrent concentrations of NO₂^- and H₂ are limiting in the middle region along the x-y plane of the hydrogel, which results in a low overall NO₂^- removal rate (i.e., flux). Thinner hydrogels provide higher concurrent reactant concentrations throughout the hydrogel, resulting in higher fluxes. However, if the hydrogel is too thin, the flux becomes limited by the amount of Pd that can be loaded, and unused H₂ can diffuse into the bulk and promote biofilm growth. The hydrogel thickness that maximized the NO₂^- flux ranged between 30 and 150 μm for the conditions tested. The computational model is the first to describe CHMR behavior, and it is an important tool for the further development of the CHMR. It also can be adapted to assess CHMR behavior for other contaminants or catalysts or used for other types of interfacial catalytic membrane reactors.

Activity and stability of the catalytic hydrogel membrane reactor for treating oxidized contaminants

The catalytic hydrogel membrane reactor (CHMR) is an interfacial membrane process that uses nano-sized catalysts for the hydrogenation of oxidized contaminants in drinking water. In this study, the CHMR was operated as a continuous-flow reactor using nitrite (NO₂^-) as a model contaminant and palladium (Pd) as a model catalyst. Using the overall bulk reaction rate for NO₂^- reduction as a metric for catalytic activity, we evaluated the effect of the hydrogen gas (H₂) delivery method to the CHMR, the initial H₂ and NO₂^- concentrations, Pd density in the hydrogel, and the presence of Pd-deactivating species. The chemical stability of the catalytic hydrogel was evaluated in the presence of aqueous cations (H⁺, Na⁺, Ca²⁺) and a mixture of ions in a hard groundwater. Delivering H₂ to the CHMR lumens using a vented operation mode, where the reactor is sealed and the lumens are periodically flushed to the atmosphere, allowed for a combination of a high H₂ consumption efficiency and catalytic activity. The overall reaction rate of NO₂^- was dependent on relative concentrations of H₂ and NO₂^- at catalytic sites, which was governed by both the chemical reaction and mass transport rates. The intrinsic catalytic reaction rate was combined with a counter-diffusional mass transport component in a 1-D computational model to describe the CHMR. Common Pd-deactivating species [sulfite, bisulfide, natural organic matter] hindered the reaction rate, but the hydrogel afforded some protection from deactivation compared to a batch suspension. No chemical degradation of the hydrogel structure was observed for a model water (pH > 4, Na⁺, Ca²⁺) and a hard groundwater after 21 days of exposure, attesting to its stability under natural water conditions.

Catalytic Palladium-Based and Iron-Based Membrane Reactors: Novel Strategies of Synthesis

Several procedures were employed in the preparation of different Pd- and Fe-based catalytic membrane reactors (CMRs) via the normal wet impregnation method, reverse filtration of a microemulsion, sputtering method, and the precipitation of a Fe complex. Depending on the chosen procedure, the metal active phase can be found on the exterior and/or interior part of the CMR or even in its pores in concentrations between 0.05 and 2 wt %. Moreover, we have managed to implement a unique systematic process to grow hydrotalcite in the pores of a Pd-CMR. To exemplify the activity of these new CMRs, we have tested them in the peroxidation of phenol and in situ epoxidation of trans-chalcone.

Membrane Technology in Catalytic Carbonylation Reactions

In this review, the recent achievements on the use of membrane technologies in catalytic carbonylation reactions are described. The review starts with a general introduction on the use and function of membranes in assisting catalytic chemical reactions with a particular emphasis on the most widespread applications including esterification, oxidation and hydrogenation reactions. An independent paragraph will be then devoted to the state of the art of membranes in carbonylation reactions for the synthesis of dimethyl carbonate (DMC). Finally, the application of a specific membrane process, such as pervaporation, for the separation/purification of products deriving from carbonylation reactions will be presented.

Catalytic Ionic-Liquid Membranes: The Convergence of Ionic-Liquid Catalysis and Ionic-Liquid Membrane Separation Technologies

Membrane technologies enable the facile separation of complex mixtures of gases, vapours, liquids and/or solids under mild conditions. Simultaneous chemical transformations can also be achieved in membranes by using catalytically active membrane materials or embedded catalysts, in so-called membrane reactors. A particular class of membranes containing or composed of ionic liquids (ILs) or polymeric ionic liquids (pILs) have recently emerged. These membranes often exhibit superior transport and separation properties to those of classical polymeric membranes. ILs and pILs have also been extensively studied as separation solvents, catalysts and co-catalysts in similar applications for which membranes are employed. In this review, after introducing ILs and their applications in catalysis, catalytic membranes and recent advances in membrane separation processes based on ILs are described. Finally, the nascent concept of catalytic IL membranes is highlighted, in which catalytically active ILs/pILs are incorporated into membrane technologies to act as a catalytic separation layer.

Nanoparticle-containing membranes for the catalytic reduction of nitroaromatic compounds

Layer-by-layer deposition of polyelectrolyte/metal nanoparticle films in porous alumina, track-etched polycarbonate, and nylon substrates yields catalytic membranes. With all three substrates, scanning electron microcopy images demonstrate a high density of well-separated nanoparticles in the membrane pores. These nanoparticles catalyze the reduction of nitroaromatic compounds by sodium borohydride with rate constants that are the same as those for nanoparticles immobilized on alumina powder. Moreover, the membranes selectively catalyze the reduction of nitro groups in compounds containing other reducible functionalities such as cyano, chloro, and styrenyl moieties. With nitrophenols and nitroanilines, the only reduction product is the corresponding amine. In contrast, nitrobenzene, nitrotoluenes, nitrobenzonitriles, chloronitrobenzenes, and m-nitrostyrene also form a nitroso product. Membrane catalysts are particularly attractive for controlling product distributions through variation of solution fluxes, as demonstrated by the formation of increased levels of nitroso compounds at high flux.

Hydrogen peroxide synthesis: an outlook beyond the anthraquinone process

Hydrogen peroxide (H2O2) is widely used in almost all industrial areas, particularly in the chemical industry and environmental protection. The only degradation product of its use is water, and thus it has played a large role in environmentally friendly methods in the chemical industry. Hydrogen peroxide is produced on an industrial scale by the anthraquinone oxidation (AO) process. However, this process can hardly be considered a green method. It involves the sequential hydrogenation and oxidation of an alkylanthraquinone precursor dissolved in a mixture of organic solvents followed by liquid-liquid extraction to recover H2O2. The AO process is a multistep method that requires significant energy input and generates waste, which has a negative effect on its sustainability and production costs. The transport, storage, and handling of bulk H2O2 involve hazards and escalating expenses. Thus, novel, cleaner methods for the production of H2O2 are being explored. The direct synthesis of H2O2 from O2 and H2 using a variety of catalysts, and the factors influencing the formation and decomposition of H2O2 are examined in detail in this Review.