Effect of Binders on the Physicochemical and Catalytic Properties of Extrudate-Shaped Beta Zeolite Catalysts for Cyclization of Citronellal

MOF-based heterogeneous catalysis in continuous flow via incorporation onto polymer-based spherical activated carbon supports

We present an approach to harnessing the tuneable catalytic properties of complex nanomaterials for continuous flow heterogeneous catalysis by combining them with the scalable and industrially implementable properties of carbon pelleted supports. This approach, in turn, will enable these catalytic materials, which largely currently exist in forms unsuitable for this application (e.g. powders), to be fully integrated into large scale, chemical processes. A composite heterogeneous catalyst consisting of a metal-organic framework-based Lewis acid, MIL-100(Sc), immobilised onto polymer-based spherical activated carbon (PBSAC) support has been developed. The material was characterised by focused ion beam-scanning electron microscopy-energy dispersive X-ray analysis, powder X-ray diffraction, N2 adsorption, thermogravimetric analysis, atomic absorption spectroscopy, light scattering and crush testing with the catalytic activity studied in continuous flow. The mechanically robust spherical geometry makes the composite material ideal for application in packed-bed reactors. The catalyst was observed to operate without any loss in activity at steady state for 9 hours when utilised as a Lewis acid catalyst for the intramolecular cyclisation of (±)-citronellal as a model reaction. This work paves the way for further development into the exploitation of MOF-based continuous flow heterogeneous catalysis.

Effect of binder on CO2, CH4, and N2 adsorption behavior, structural properties, and diffusion coefficients on extruded zeolite 13X

The effect of inorganic binder-based extrusion (Silica sol, Bentonite, Attapulgite, and SB1) in the selective adsorption of CO₂, CH₄, and N₂ on zeolite 13X in the context of flue gas carbon capture and natural gas purification has been studied to reduce CO₂ emissions. The effect of extrusion with binders was examined by adding 20 wt% of the mentioned binders to pristine zeolite and the results were analyzed by four approaches; (i) the effect on structural properties was analyzed by XRD patterns followed by Williamson-Hall (W-H) plot, FESEM images, and BET surface area. In addition, the mechanical strength of the shaped zeolites was measured by crush resistance testing; (ii) the effect on the adsorption capacity for CO₂, CH₄, and N₂ were measured by volumetric apparatus up to 100 kPa; (iii) the impact on binary separation (CO₂/CH₄ and CO₂/N₂) were investigated; (iv) the influence on diffusion coefficients were estimated by micropore and macropore kinetic model. The results showed that the presence of a binder can cause reductions in BET surface area and pore volume, indicating partial pore blockage. It was found that the Sips model had the best adaptability to the experimental isotherms data. The trend of CO₂ adsorption was 13X > pseudo-boehmite > bentonite > attapulgite > silica, in which the adsorption capacity reached 6.02, 5.60, 5.24, 5.00, and 4.71 mmol/g, respectively. Among all samples, silica was found the most suitable binder for CO₂ capture in terms of selectivity, mechanical stability, and diffusion coefficients.

One-Pot Transformation of Citronellal to Menthol Over H-Beta Zeolite Supported Ni Catalyst: Effect of Catalyst Support Acidity and Ni Loading

Citronellal was converted to menthol in a one-pot approach using H-Beta zeolite-based Ni catalyst in a batch reactor at 80 °C, under 20 bar of total pressure. The effects of H-Beta acidity (H-Beta-25 with the molar ratio SiO2/Al2O3 = 25 and H-Beta-300 with SiO2/Al2O3 = 300) and Ni loading (5, 10 and 15 wt %) on the catalytic performance were investigated. Ni was impregnated on H-Beta support using the evaporation-impregnation method. The physico-chemical properties of the catalysts were characterized by XRD, SEM, TEM, ICP-OES, N2 physisorption, TPR, and pyridine adsorption–desorption FTIR techniques. Activity and selectivity of catalysts were strongly affected by the Brønsted and Lewis acid sites concentration and strength, Ni loading, its particle size and dispersion. A synergetic effect of appropriate acidity and suitable Ni loading in 15 wt.% Ni/H-Beta-25 catalyst led to the best performance giving 36% yield of menthols and 77% stereoselectivity to ( ±)-menthol isomer at 93% citronellal conversion. Moreover, the catalyst was successfully regenerated and reused giving similar activity, selectivity and stereoselectivity to the desired ( ±)-menthol isomer as the fresh one.

Graphical Abstract

Diffusion measurements of hydrocarbons in H-MCM-41 extrudates with pulsed-field gradient nuclear magnetic resonance spectroscopy

Mesoporous materials are promising catalysts for production of biofuels. Herein, H-MCM-41 catalysts with different concentrations of the silica Bindzil binder (10–50 wt%) were prepared and characterized using pulsed-field gradient (PFG) NMR in the powder form and as extrudates. Effective diffusion coefficients (D_e) are measured in all cases. Diffusivities of n-hexadecane were found smaller for extrudates as compared to the powder catalysts. The estimates of diffusive tortuosity were also determined. PFG NMR data showed one major component that reveals diffusion in interconnected meso- and micropores and one other minor component (1–2%) that may correspond to more isolated pores or may represent complex effects of restricted diffusion. Therefore, several approaches including initial slope analysis of spin-echo attenuation curves, two-component fitting and Laplace inversion were used to discuss different aspects of diffusional transport in the studied H-MCM-41 materials. Correlations between D_e and the amount of Bindzil, the specific surface area, the micropore volume, the particle size, the total acid sites and the Lewis acid sites are discussed.

Diffusivities of n-hexadecane were measured using pulsed-field gradient (PFG) NMR for extrudates and powder catalysts comprising H-MCM-41′ and silica Bindzil binder.

Review on Additive Manufacturing of Catalysts and Sorbents and the Potential for Process Intensification

Additive manufacturing of catalyst and sorbent materials promises to unlock large design freedom in the structuring of these materials, and could be used to locally tune porosity, shape and resulting parameters throughout the reactor along both the axial and transverse coordinates. This contrasts catalyst structuring by conventional methods, which yields either very dense randomly packed beds or very open cellular structures. Different 3D-printing processes for catalytic and sorbent materials exist, and the selection of an appropriate process, taking into account compatible materials, porosity and resolution, may indeed enable unbounded options for geometries. In this review, recent efforts in the field of 3D-printing of catalyst and sorbent materials are discussed. It will be argued that these efforts, whilst promising, do not yet exploit the full potential of the technology, since most studies considered small structures that are very similar to structures that can be produced through conventional methods. In addition, these studies are mostly motivated by chemical and material considerations within the printing process, without explicitly striving for process intensification. To enable value-added application of 3D-printing in the chemical process industries, three crucial requirements for increased process intensification potential will be set out: i) the production of mechanically stable structures without binders; ii) the introduction of local variations throughout the structure; and iii) the use of multiple materials within one printed structure.

Binder-free hierarchical zeolite pellets and monoliths derived from ZSM-5@LDH composites for bioethanol dehydration to ethylene

The development of industrial catalysts is of crucial importance for practical uses. However, it still suffers from making extruded catalysts because of a remarkably decreased catalytic activity when combining them...

Catalytic transformations of citral in a continuous flow over bifunctional Ru-MCM-41 extrudates

The three-step reaction of citral to menthol was investigated in an autoclave and a trickle-bed reactor over Ru-MCM-41 catalysts in powder and shaped forms, respectively, with the same composition and controlled metal location.

The Potential Use of Core-Shell Structured Spheres in a Packed-Bed DBD Plasma Reactor for CO2 Conversion

This work proposes to use core-shell structured spheres to evaluate whether it allows to individually optimize bulk and surface effects of a packing material, in order to optimize conversion and energy efficiency. Different core-shell materials have been prepared by spray coating, using dense spheres (as core) and powders (as shell) of SiO2, Al2O3, and BaTiO3. The materials are investigated for their performance in CO2 dissociation and compared against a benchmark consisting of a packed-bed reactor with the pure dense spheres, as well as an empty reactor. The results in terms of CO2 conversion and energy efficiency show various interactions between the core and shell material, depending on their combination. Al2O3 was found as the best core material under the applied conditions here, followed by BaTiO3 and SiO2, in agreement with their behaviour for the pure spheres. Applying a thin shell layer on the cores showed equal performance between the different shell materials. Increasing the layer thickness shifts this behaviour, and strong combination effects were observed depending on the specific material. Therefore, this method of core-shell spheres has the potential to allow tuning of the packing properties more closely to the application by designing an optimal combination of core and shell.

Cascade transformations of (±)-citronellal to menthol over extruded Ru-MCM-41 catalysts in a continuous reactor

Catalytic cascade transformations of (±)-citronellal in a continuous mode over bifunctional ruthenium/MCM-41/binder extrudates with different metal location.

Synthesis of menthol from citronellal over supported Ru- and Pt-catalysts in continuous flow

One-pot menthol synthesis in a trickle bed reactor was investigated using Ru/H-beta-300 extrudates without any binder and Pt- and Ru/H-beta-25 extrudates containing 30 wt% bentonite binder using different methods of metal loading on the extrudates.