Methane Dehydroaromatization by Mo/HZSM-5: Mono- or Bifunctional Catalysis?

Direct conversion of methane to aromatics and hydrogen via a heterogeneous trimetallic synergistic catalyst

Non-oxidative methane dehydro-aromatization reaction can co-produce hydrogen and benzene effectively on a molybdenum-zeolite based thermochemical catalyst, which is a very promising approach for natural-gas upgrading. However, the low methane conversion and aromatics selectivity and weak durability restrain the realistic application for industry. Here, a mechanism for enhancing catalysis activity on methane activation and carbon-carbon bond coupling has been found to promote conversion and selectivity simultaneously by adding platinum-bismuth alloy cluster to form a trimetallic catalyst on zeolite (Pt-Bi/Mo/ZSM-5). This bimetallic alloy cluster has synergistic interaction with molybdenum: the formed CH3* from Mo2C on the external surface of zeolite can efficiently move on for C-C coupling on the surface of Pt-Bi particle to produce C2 compounds, which are the key intermediates of oligomerization. This pathway is parallel with the catalysis on Mo inside the cage. This catalyst demonstrated 18.7% methane conversion and 69.4% benzene selectivity at 710 °C. With 95% methane/5% nitrogen feedstock, it exhibited robust stability with slow deactivation rate of 9.3% after 2 h and instant recovery of 98.6% activity after regeneration in hydrogen. The enhanced catalytic activity is strongly associated with synergistic interaction with Mo and ligand effects of alloys by extensive mechanism studies and DFT calculation.

Time-, space- and energy-resolved in situ characterization of catalysts by X-ray absorption spectroscopy

A setup for dispersive X-ray absorption spectroscopy (XAS) with spatial, temporal and energy resolution is presented. Through investigation of a Mo/HZSM-5 catalyst during the dehydroaromatization of methane we observed a reduction gradient along the packed bed. Our new method represents an unprecedented addition to the analytical toolbox for in situ characterizations.

Methane dehydroaromatization catalyzed by Mo/ZSM-5: location-steered activity and mechanism

This work examined the location-steered catalytic behavior of Mo/ZSM-5 catalyst for one-step methane dehydroaromatization to benzene reaction. The results indicated that α-site is the preferred location for the formation of ethylene, the main intermediate for aromatics production via the propagation pathway, while δ-site is favorable for the hydrocarbon pool aggregation reaction pathway.

Understanding W/H-ZSM-5 catalysts for the dehydroaromatization of methane

Tungsten is the most interesting and promising metal to replace molybdenum in methane dehydroaromatization (MDA) catalysis.

The Development of iDPC-STEM and Its Application in Electron Beam Sensitive Materials

The main aspects of material research: material synthesis, material structure, and material properties, are interrelated. Acquiring atomic structure information of electron beam sensitive materials by electron microscope, such as porous zeolites, organic-inorganic hybrid perovskites, metal-organic frameworks, is an important and challenging task. The difficulties in characterization of the structures will inevitably limit the optimization of their synthesis methods and further improve their performance. The emergence of integrated differential phase contrast scanning transmission electron microscopy (iDPC-STEM), a STEM characterization technique capable of obtaining images with high signal-to-noise ratio under lower doses, has made great breakthroughs in the atomic structure characterization of these materials. This article reviews the developments and applications of iDPC-STEM in electron beam sensitive materials, and provides an outlook on its capabilities and development.

Stable co-production of olefins and aromatics from ethane over Co2+-exchanged HZSM-5 zeolite

Olefins and aromatics can be stably co-produced from ethane over a Co-exchanged HZSM-5 catalyst in which isolated Co(ii) species are anchored at Brønsted acid sites and active for efficient ethane dehydrogenation.

Promoters for Improvement of the Catalyst Performance in Methane Valorization Processes

In this work, the introduction of modifying additives in the composition of catalysts is considered as an effective mode of improving functional characteristics of materials for two processes of methane conversion into valuable products – methane dehydroaromatization (DHA of CH4) into benzene and hydrogen and autothermal reforming of methane (ATR of CH4) into synthesis gas. The effect of type and content of promoters on the structural and electronic state of the active component as well as catalyst activity and stability against deactivation is discussed. For DHA of CH4 the operation mode of additives M = Ag, Ni, Fe in the composition of Mo-M/ZSM-5 catalysts was elucidated and correlated with the product yield and coke content. It was shown that when Ag serves as a promoter, the duration of the catalyst stable operation is enhanced due to a decrease in the rate of the coke formation. In the case of Ni and Fe additives, the Ni-Мо and Fe-Mo alloys are formed that retain the catalytic activity for a long time in spite of the carbon accumulation. For ATR of CH4, the influence of M = Pd, Pt, Re, Mo, Sn in the composition of Ni-M catalysts supported on La2O3 or Ce0.5Zr0.5O2/Al2O3 was elucidated. It was demonstrated that for Ni-M/La2O3 catalysts, Pd is a more efficient promoter that improves the reducibility of Ni cations and increases the content of active Nio centers. In the case of Ni-M/Ce0.5Zr0.5O2/Al2O3 samples, Re is considered the best promoter due to the formation of an alloy with anti-coking and anti-sintering properties. The use of catalysts with optimal promoter type and its content provides high efficiency of methane valorization processes.

Recent advances in heterogeneous catalysis for the nonoxidative conversion of methane

The direct conversion of methane to high-value chemicals is an attractive process that efficiently uses abundant natural/shale gas to provide an energy supply. The direct conversion of methane to high-value chemicals is an attractive process that efficiently uses abundant natural/shale gas to provide an energy supply. Among all the routes used for methane transformation, nonoxidative conversion of methane is noteworthy owing to its highly economic selectivity to bulk chemicals such as aromatics and olefins. Innovations in catalysts for selective C-H activation and controllable C-C coupling thus play a key role in this process and have been intensively investigated in recent years. In this review, we briefly summarize the recent advances in conventional metal/zeolite catalysts in the nonoxidative coupling of methane to aromatics, as well as the newly emerging single-atom based catalysts for the conversion of methane to olefins. The emphasis is primarily the experimental findings and the theoretical understanding of the active sites and reaction mechanisms. We also present our perspectives on the design of catalysts for C-H activation and C-C coupling of methane, to shed some light on improving the potential industrial applications of the nonoxidative conversion of methane into chemicals.

Activation and conversion of alkanes in the confined space of zeolite-type materials

Microporous zeolite-type materials, with crystalline porous structures formed by well-defined channels and cages of molecular dimensions, have been widely employed as heterogeneous catalysts since the early 1960s, due to their wide variety of framework topologies, compositional flexibility and hydrothermal stability. The possible selection of the microporous structure and of the elements located in framework and extraframework positions enables the design of highly selective catalysts with well-defined active sites of acidic, basic or redox character, opening the path to their application in a wide range of catalytic processes. This versatility and high catalytic efficiency is the key factor enabling their use in the activation and conversion of different alkanes, ranging from methane to long chain n-paraffins. Alkanes are highly stable molecules, but their abundance and low cost have been two main driving forces for the development of processes directed to their upgrading over the last 50 years. However, the availability of advanced characterization tools combined with molecular modelling has enabled a more fundamental approach to the activation and conversion of alkanes, with most of the recent research being focused on the functionalization of methane and light alkanes, where their selective transformation at reasonable conversions remains, even nowadays, an important challenge. In this review, we will cover the use of microporous zeolite-type materials as components of mono- and bifunctional catalysts in the catalytic activation and conversion of C₁⁺ alkanes under non-oxidative or oxidative conditions. In each case, the alkane activation will be approached from a fundamental perspective, with the aim of understanding, at the molecular level, the role of the active sites involved in the activation and transformation of the different molecules and the contribution of shape-selective or confinement effects imposed by the microporous structure.

Dual Active Sites on Molybdenum/ZSM-5 Catalyst for Methane Dehydroaromatization: Insights from Solid-State NMR Spectroscopy

Methane dehydroaromatization (MDA) on Mo/ZSM-5 zeolite catalyst is promising for direct transformation of natural gas. Understanding the nature of active sites on Mo/ZSM-5 is a challenge for applications. Herein, using 1 H{95 Mo} double-resonance solid-state NMR spectroscopy, we identify proximate dual active sites on Mo/ZSM-5 catalyst by direct observation of internuclear spatial interaction between Brønsted acid site and Mo species in zeolite channels. The acidic proton-Mo spatial interaction is correlated with methane conversion and aromatics formation in the MDA process, an important factor in determining the catalyst activity and lifetime. The evolution of olefins and aromatics in Mo/ZSM-5 channels is monitored by detecting their host-guest interactions with both active Mo sites and Brønsted acid sites via 1 H{95 Mo} double-resonance and two-dimensional 1 H-1 H correlation NMR spectroscopy, revealing the intermediate role of olefins in hydrocarbon pool process during the MDA reaction.

Unravelling the reactivity of metastable molybdenum carbide nanoclusters in the C-H bond activation of methane, ethane and ethylene

C-H bond activation steps in non-oxidative methane dehydroaromatization (MDA), constitute a key functionalization of the reactant and adsorbed species to form aromatics. Previous studies have focused on studying the energetics of these steps at the most stable active sites involving molybdenum carbide species. Herein, a different paradigm is presented via studying the reactivity of a metastable molybdenum carbide (Mo₂C₆) nanocluster for the C-H bond activation of methane, ethane, and ethylene and comparing it with the reactivity of the lowest energy Mo₂C₆ nanocluster. Interestingly, the metastable nanocluster is observed to result in a consistent reduction (by half) in the C-H bond activation barrier of the respective alkane and alkene molecules compared to the global minimum isomer. This specific metastable form of the nanocluster is identified from a cascade genetic algorithm search, which facilitated a rigorous scan of the potential energy surface. We attribute this significant lowering of the C-H bond activation barrier to unique co-planar orbital overlap between the reactant molecule and active centers on the metastable nanocluster. Based on geometrical and orbital analysis of the transition states arising during the C-H bond activation of methane, ethane, and ethylene, a proton-coupled electron transfer mechanism is proposed that facilitated C-H bond cleavage. Motivated by the high reactivity for C-H bond activation observed on the metastable species, a contrasting framework to analyze the elementary-step rate contributions is presented. This is based on the statistical ensemble analysis of nanocluster isomers, where the calculated rates on respective isomers are normalized with respect to the Boltzmann probability distribution. From this framework, the metastable isomer is observed to provide significant contributions to the ensemble average representations of the rate constants calculated for C-H bond activation during the MDA reaction.

Ultrasound-Assisted Preparation of Mo/ZSM-5 Zeolite Catalyst for Non-Oxidative Methane Dehydroaromatization

The activity and selectivity of Mo/ZSM-5, benchmarking catalyst for the non-oxidative dehydroaromatization of methane, strongly depend on the cluster size, spatial distribution, and chemical environment of the Mo-based active sites. This study discloses the use of an ultrasound-assisted ion-exchange (US-IE) technique as an alternative Mo/ZSM-5 synthesis procedure in order to promote metal dispersion along the zeolite framework. For this purpose, a plate transducer (91.8 kHz) is employed to transmit the ultrasonic irradiation (US) into the ion-exchange reactor. The physico-chemical properties and catalytic activity of samples prepared under the said irradiation procedure and traditional impregnation (IWI) method are critically evaluated. Characterization results suggest that US neither affects the crystalline structure nor the particle size of the parent zeolite. However, US-IE promotes molybdenum species dispersion, avoids clustering at the external fresh zeolite surface and enhances molybdate species anchoring to the zeolite framework with respect to IWI. Despite the improved metal dispersion, the catalytic activity between catalysts synthesized by US-IE and IWI is comparable. This suggests that the sole initial dispersion enhancement does not suffice to boost the catalyst productivity and further actions such ZSM-5 support and catalyst pre-conditioning are required. Nevertheless, the successful implementation of US-IE and the resulting metal dispersion enhancement pave the way toward the application of this technique to the synthesis of other dispersed catalysts and materials of interest.

Methane activation by ZSM-5-supported transition metal centers

This review focuses on recent fundamental insights about methane dehydroaromatization (MDA) to benzene over ZSM-5-supported transition metal oxide-based catalysts (MO_x/ZSM-5, where M = V, Cr, Mo, W, Re, Fe). Benzene is an important organic intermediate, used for the synthesis of chemicals like ethylbenzene, cumene, cyclohexane, nitrobenzene and alkylbenzene. Current production of benzene is primarily from crude oil processing, but due to the abundant availability of natural gas, there is much recent interest in developing direct processes to convert CH₄ to liquid chemicals. Among the various gas-to-liquid methods, the thermodynamically-limited Methane DehydroAromatization (MDA) to benzene under non-oxidative conditions appears very promising as it circumvents deep oxidation of CH₄ to CO₂ and does not require the use of a co-reactant. The findings from the MDA catalysis literature is critically analyzed with emphasis on in situ and operando spectroscopic characterization to understand the molecular level details regarding the catalytic sites before and during the MDA reaction. Specifically, this review discusses the anchoring sites of the supported MO_x species on the ZSM-5 support, molecular structures of the initial dispersed surface MO_x sites, nature of the active sites during MDA, reaction mechanisms, rate-determining step, kinetics and catalyst activity of the MDA reaction. Finally, suggestions are given regarding future experimental investigations to fill the information gaps currently found in the literature.

Al-ZSM-5 Nanocrystal Catalysts Grown from Silicalite-1 Seeds for Methane Conversion

This study evaluated Al-ZSM-5 nanocrystals grown from silicalite-1 seed crystals as catalysts for the methane dehydroaromatization (MDA) reaction. Silicalite-1 seed crystals sized between 30 and 40 nm were used to grow Al-ZSM-5 under various synthesis conditions. The size of Al-ZSM-5 was significantly affected by the Si/Al ratio (SAR), synthesis time, and silica nutrients/seed crystal ratio (NSR). Larger crystals were obtained with an increased SAR in the synthesis sols. Gradual growth of Al-ZSM-5 occurred with synthesis time, although the growth in crystal size ceased at 5 h of synthesis at 120 °C, indicating the rapid growth of Al-ZSM-5 aided by the silicalite-1 seeds. Precise tuning of Al-ZSM-5 size was possible by changing the nutrient/silicalite-1 seed ratio; a higher NSR led to larger crystals. Two representative Al-ZSM-5 crystals with SARs of 35 and 140 were prepared for catalyst testing, and the crystal sizes were tailored to <100 nm by controlling NSR. The MDA reaction was conducted in the presence of the prepared Al-ZSM-5. The catalyst size exhibited distinct differences in catalyst stability, while the SAR of catalysts did not produce noticeable changes in the catalyst stability of the Al-ZSM-5 crystals and commercial zeolites in this reaction system.

Mo-Modified ZSM-5 zeolite with intergrowth crystals for high-efficiency catalytic xylene isomerization

Mo/ZSM-5 catalysts of xylene isomerization were prepared on the intergrowth ZSM-5 support by an impregnation–calcination–reduction procedure.

Status and prospects of the decentralised valorisation of natural gas into energy and energy carriers

We critically review the recent advances in process, reactor, and catalyst design that enable process miniaturisation for decentralised natural gas upgrading into electricity, liquefied natural gas, fuels and chemicals.

Elucidating the nature of Mo species on ZSM-5 and its role in the methane aromatization reaction

The valorization of methane is one of the most important goals during the transition period to the general use of renewable energies.

Reactivity, Selectivity, and Stability of Zeolite-Based Catalysts for Methane Dehydroaromatization

Non-oxidative dehydroaromatization is arguably the most promising process for the direct upgrading of cheap and abundant methane to liquid hydrocarbons. This reaction has not been commercialized yet because of the suboptimal activity and swift deactivation of benchmark Mo-zeolite catalysts. This progress report represents an elaboration on the recent developments in understanding of zeolite-based catalytic materials for high-temperature non-oxidative dehydroaromatization of methane. It is specifically focused on recent studies, relevant to the materials chemistry and elucidating i) the structure of active species in working catalysts; ii) the complex molecular pathways underlying the mechanism of selective conversion of methane to benzene; iii) structure, evolution and role of coke species; and iv) process intensification strategies to improve the deactivation resistance and overall performance of the catalysts. Finally, unsolved challenges in this field of research are outlined and an outlook is provided on promising directions toward improving the activity, stability, and selectivity of methane dehydroaromatization catalysts.

Understanding the Deactivation Phenomena of Small-Pore Mo/H-SSZ-13 during Methane Dehydroaromatisation

Small pore zeolites have shown great potential in a number of catalytic reactions. While Mo-containing medium pore zeolites have been widely studied for methane dehydroaromatisation (MDA), the use of small pore supports has drawn limited attention due to the fast deactivation of the catalyst. This work investigates the structure of the small pore Mo/H-SSZ-13 during catalyst preparation and reaction by operando X-ray absorption spectroscopy (XAS), in situ synchrotron powder diffraction (SPD), and electron microscopy; then, the results are compared with the medium pore Mo/H-ZSM-5. While SPD suggests that during catalyst preparation, part of the MoO_x anchors inside the pores, Mo dispersion and subsequent ion exchange was less effective in the small pore catalyst, resulting in the formation of mesopores and Al₂(M_OO₄)₃ particles. Unlike Mo/H-ZSM-5, part of the Mo species in Mo/H-SSZ-13 undergoes full reduction to Mo⁰ during MDA, whereas characterisation of the spent catalyst indicates that differences also exist in the nature of the formed carbon deposits. Hence, the different Mo speciation and the low performance on small pore zeolites can be attributed to mesopores formation during calcination and the ineffective ion exchange into well dispersed Mo-oxo sites. The results open the scope for the optimisation of synthetic routes to explore the potential of small pore topologies.

Molybdenum carbide and oxycarbide from carbon-supported MoO3 nanosheets: phase evolution and DRM catalytic activity assessed by TEM and in situ XANES/XRD methods

Molybdenum carbide (β-Mo₂C) supported on carbon spheres was prepared via a carbothermal hydrogen reduction (CHR) method from delaminated nanosheets of molybdenum(vi) oxide (d-MoO₃/C). The carburization process was followed by combined in situ XANES/XRD analysis revealing the formation of molybdenum oxycarbide Mo₂C_xO_y as an intermediate phase during the transformation of d-MoO₃/C to β-Mo₂C/C. It was found that Mo₂C_xO_y could not be completely carburized to β-Mo₂C under a He atmosphere at 750 °C, instead a reduction in H₂ is required. The β-Mo₂C/C obtained showed activity and stability for the dry reforming of methane at 800 °C and 8 bar. In situ XANES/XRD evaluation of the catalyst under DRM reaction conditions combined with high resolution TEM analysis revealed the evolution of β-Mo₂C/C to Mo₂C_xO_y/C. Notably, the gradual oxidation of β-Mo₂C/C to Mo₂C_xO_y/C correlates directly with the increased activity of the competing reverse water gas shift reaction.

Catalytic conversion of ethane to valuable products through non-oxidative dehydrogenation and dehydroaromatization

Chemical utilization of ethane to produce valuable chemicals has become especially attractive since the expanded utilization of shale gas in the United States and associated petroleum gas in the Middle East. Catalytic conversion to ethylene and aromatic hydrocarbons through non-oxidative dehydrogenation and dehydroaromatization of ethane (EDH and EDA) are potentially beneficial technologies because of their high selectivity to products. The former represents an attractive alternative to conventional thermal cracking of ethane. The latter can produce valuable aromatic hydrocarbons from a cheap feedstock. Nevertheless, further progress in catalytic science and technology is indispensable to implement these processes beneficially. This review summarizes progress that has been achieved with non-oxidative EDH and EDA in terms of the nature of active sites and reaction mechanisms. Briefly, platinum-, chromium- and gallium-based catalysts have been introduced mainly for EDH, including effects of carbon dioxide co-feeding. Efforts to use EDA have emphasized zinc-modified MFI zeolite catalysts. Finally, some avenues for development of catalytic science and technology for ethane conversion are summarized.

High-Impact Promotional Effect of Mo Impregnation on Aluminum-Rich and Alkali-Treated Hierarchical Zeolite Catalysts on Methanol Aromatization

A systematic change of HZSM-5 (HZ5) as a catalyst of the methanol to aromatics (MTA) reaction was undertaken by employing a fixed-bed tubular-type reactor under ambient pressure, applying a weight hourly space velocity (WHSV) of 2 h^-1 at 375 °C, as the first report on the application of low-Si/Al-ratio alkaline-[Mo,Na]-HZSM-5 in the MTA process. To characterize the surface and textural properties of the catalysts, powder X-ray diffraction (PXRD), nitrogen adsorption/desorption, temperature-programmed desorption of ammonia (NH₃-TPD), pyridine-infrared spectroscopy (Py-IR), thermogravimetric analysis (TGA), and energy-dispersive X-ray (EDX) methods were employed. Gas chromatography (GC) and gas chromatography-mass spectrometry (GC-MS) measurements demonstrated a selectivity of up to 86 wt % (65.7 wt % for benzene, toluene, and xylene (BTX)) over 2[Mo]HZ5. NH₃-TPD and Py-IR results indicated a sensible decrease of strong acid sites on the impregnated samples, while the surface analyses revealed the highest Lewis acid sites (LAS) together with the largest mesopore surface area for 2[Mo]alk-HZ5, supporting the migration of Mo species to the bulk of the catalysts. Mo impregnation had a minor effect on the observed coke formation in the promoted catalyst.

Imaging Beam-Sensitive Materials by Electron Microscopy

Electron microscopy allows the extraction of multidimensional spatiotemporally correlated structural information of diverse materials down to atomic resolution, which is essential for figuring out their structure-property relationships. Unfortunately, the high-energy electrons that carry this important information can cause damage by modulating the structures of the materials. This has become a significant problem concerning the recent boost in materials science applications of a wide range of beam-sensitive materials, including metal-organic frameworks, covalent-organic frameworks, organic-inorganic hybrid materials, 2D materials, and zeolites. To this end, developing electron microscopy techniques that minimize the electron beam damage for the extraction of intrinsic structural information turns out to be a compelling but challenging need. This article provides a comprehensive review on the revolutionary strategies toward the electron microscopic imaging of beam-sensitive materials and associated materials science discoveries, based on the principles of electron-matter interaction and mechanisms of electron beam damage. Finally, perspectives and future trends in this field are put forward.

Lower olefins from methane: recent advances

Modern methods for methane conversion to lower olefins having from 2 to 4 carbon atoms per molecule are generalized. Multistage processing of methane into ethylene and propylene via syngas or methyl chloride and methods for direct conversion of CH4 to ethylene are described. Direct conversion of syngas to olefins as well as indirect routes of the process via methanol or dimethyl ether are considered. Particular attention is paid to innovative methods of olefin synthesis. Recent achievements in the design of catalysts and development of new techniques for efficient implementation of oxidative coupling of methane and methanol conversion to olefins are analyzed and systematized. Advances in commercializing these processes are pointed out. Novel catalysts for Fischer – Tropsch synthesis of lower olefins from syngas and for innovative technique using oxide – zeolite hybrid catalytic systems are described. The promise of a new route to lower olefins by methane conversion via dimethyl ether is shown. Prospects for the synthesis of lower olefins via methyl chloride and using non-oxidative coupling of methane are discussed. The most efficient processes used for processing of methane to lower olefins are compared on the basis of degree of conversion of carbonaceous feed, possibility to integrate with available full-scale production, number of reaction stages and thermal load distribution.

The bibliography includes 346 references.

Boric acid treated HZSM-5 for improved catalyst activity in non-oxidative methane dehydroaromatization

The dehydroaromatization (DHA) reaction of methane under non-oxidative conditions is carried out over a molybdenum catalyst supported on HZSM-5 and boric acid (BA) treated HZSM-5 at 700 °C and atmospheric pressure.

Overcoming Stability Problems in Microwave-Assisted Heterogeneous Catalytic Processes Affected by Catalyst Coking

Microwave-assisted heterogeneous catalysis (MHC) is gaining attention due to its exciting prospects related to selective catalyst heating, enhanced energy-efficiency, and partial inhibition of detrimental side gas-phase reactions. The induced temperature difference between the catalyst and the comparatively colder surrounding reactive atmosphere is pointed as the main factor of the process selectivity enhancement towards the products of interest in a number of hydrocarbon conversion processes. However, MHC is traditionally restricted to catalytic reactions in the absence of catalyst coking. As excellent MW-susceptors, carbon deposits represent an enormous drawback of the MHC technology, being main responsible of long-term process malfunctions. This work addresses the potentials and limitations of MHC for such processes affected by coking (MHCC). It also intends to evaluate the use of different catalyst and reactor configurations to overcome heating stability problems derived from the undesired coke deposits. The concept of long-term MHCC operation has been experimentally tested/applied to for the methane non-oxidative coupling reaction at 700 °C on Mo/ZSM-5@SiC structured catalysts. Preliminary process scalability tests suggest that a 6-fold power input increases the processing of methane flow by 150 times under the same controlled temperature and spatial velocity conditions. This finding paves the way for the implementation of high-capacity MHCC processes at up-scaled facilities.