Catalytic pyrolysis of harmful plastic waste to alleviate environmental impacts

Wax is a detrimental byproduct of plastic waste pyrolysis causing challenges upon its release into the environment owing to persistence and potential toxicity. In this study, the valorization of wax materials through conversion into BTEX (i.e., benzene, toluene, ethylbenzene, and xylene) was achieved via catalytic pyrolysis using zeolite-based catalysts. The potential of two types of waxes, spent wax (SW), derived from the pyrolysis of plastic waste, and commercial paraffin wax (PW), for BTEX generation, was investigated. Using HZSM-5, higher yields of oil (54.9 wt%) and BTEX (18.2 wt%) were produced from the pyrolysis of SW compared to PW (32.3 and 14.1 wt%, respectively). This is due to the improved accessibility of lighter hydrocarbons in SW to Brønsted and Lewis acid sites in HZSM-5 micropores, promoting cracking, isomerization, cyclization, Diels-Alder, and dehydrogenation reactions. Further, the use of HZSM-5 resulted in significantly larger yields of oil and BTEX from SW pyrolysis compared to Hbeta and HY. This phenomenon is ascribed to the well-balanced distribution of Brønsted and Lewis acid sites and the identical geometric structure of HZSM-5 micropores and BTEX molecules. The addition of Ga to HZSM-5 further led to 2.24% and 28.30% enhancements in oil and BTEX yields, respectively, by adjusting the acidity of the catalyst through the introduction of new Lewis acid sites. The regeneration of the Ga/HZSM-5 catalyst by removing deposited coke on the spent catalyst under air partially recovered catalytic activity. This study not only offers an efficient transformation of undesirable wax into valuable fuels but also provides an environmentally promising solution, mitigating pollution, contributing to carbon capture, and promoting a healthier and more sustainable environment. It also suggests future research directions, including catalyst optimization and deactivation management, feedstock variability exploration, and techno-economic analyses for sustainable wax conversion into BTEX via catalytic pyrolysis.

In situ hydro-deoxygenation onto nickel-doped HZSM-5 zeolite catalyst for upgrading pyrolytic oil

Global energy demand has drastically increased due to urbanization and industrialization; thus, developing alternative renewable energy sources is urgently required. In the present work, upgrading the pyrolytic oil (PO) derived from fresh palm fruit was performed by the catalytic in situ hydrodeoxygenation (in situ HDO) process. Preparation of nickel-doped HZSM-5 zeolite (SiO2/Al2O3 = 40) was achieved by incipient wetness impregnation techniques using different weight percents of nickel dopant into HZSM-5. Nickel-doped HZSM-5 zeolite (Ni-HZSM-5) was further subjected to chemical reduction for 5 h in the oxygen-free environment (10% H2 and 90% N2) at 550 °C. The structural properties showed a potential reduction of NiO-HZSM-5 to Ni-HZSM-5, enhancing the catalytic potential. The morphological characterizations showed spherical-shaped Ni agglomerated onto HZSM-5. Acidity and oxygen contents in the pyrolytic oil were achieved by catalyst-aided HDO process at 220 °C for 6 h using methanol as a hydrogen donor. The catalytically upgraded pyrolytic oil (UPO) was analyzed for density, HHV, CHNO, and TGA. The best upgrading oil was distilled following ASTM D86 to separate gasoline, kerosene, and diesel. The acidity, density, HHV, and viscosity were measured before and after the upgradation processes. The results showed the potential impact of Ni with 10% doped on HZSM-5 on HDO reaction and illustrated the lowest oxygen content in upgraded pyrolytic oil products. Considerable decrease in viscosity and density level indicated that in situ HDO not only reduced oxygen content but also cracked pyrolytic oil to small molecules. The distilled product of upgrading oil was higher than pyrolytic oil by approximately 15% in volume. The viscosity, density, and HHV were under standard specifications of kerosene and diesel, except for acidity. However, the acidity was reduced by over 60% compared with raw material.

Co- and Ni-Doped TiO2 Nanoparticles Supported on Zeolite Y with Photocatalytic Properties

Zeolite Y samples with microporous and hierarchical structures containing Ti-Ni and Ti-Co oxides were obtained as active photocatalysts. Different Ti amounts (5, 10% TiO2) were supported, followed by the loading of Ni or Co oxides (5%). X-ray diffraction evidenced the presence of TiO2 as an anatase. N2 adsorption-desorption results showed type IV isotherms for hierarchical zeolite Y samples, and a combination of type IV and I isotherms for zeolite Y samples. UV-Vis diffuse reflectance spectra showed a shift in the absorption band to visible with increasing Ti loading and especially after Co and Ni addition. A significant effect of the support was evidenced for Ti and its interaction with Co/Ni species. The zeolite Y support stabilized Ti in the 4+ oxidation state while hierarchical zeolite Y support favored the formation of Ti3+ species, Ni0 and Ni2+ and the oxidation of Co to 3+ oxidation state. Photocatalytic activity, under UV and visible light irradiation, was evaluated by the degradation of amoxicillin, used as a model test. The photocatalytic mechanism was investigated using ethanol, p-benzoquinone and KI as ·OH and ·O2- radicals and hole (h+) scavengers. The best results were obtained for the immobilized Ni-Ti species on the hierarchical zeolite Y support.

Hydrogen production from hazardous petroleum sludge gasification over nickel-loaded porous ZSM-5 and Al2O3 catalysts under air condition

In this study, the potential of petroleum sludge (PS) for hydrogen production via the gasification process was evaluated. For this purpose, nickel (Ni)-loaded ZSM-5 and γ-Al₂O₃ (Ni-ZS and Ni-Al) catalysts were prepared and employed for PS gasification in air condition. The effects of different supports, Ni loading content, and reaction temperatures on the production of hydrogen-rich syngas along with the stability and reusability of the best catalyst were investigated. Applying 5%Ni-ZS obtained more gas yield (68.09 wt%) and hydrogen selectivity (25.04 vol%) compared to those obtained by 5%Ni-Al mostly owing to weak metal-support interactions which led to the dominance of well-dispersed metallic Ni. At various Ni loading percentages, 10%Ni-ZS showed the highest catalytic efficiency, which increased both gas yield (70.92 wt%) and hydrogen selectivity (30.74 vol%). However, excessive Ni content (especially 20%) significantly reduced the gas yield and hydrogen selectivity because of limited accessibility of support's active sites, poor dispersion of Ni, and inappropriate acidity. Increasing the temperature promoted the gas yield and produced hydrogen, where the highest gas yield (73.18 wt%) and hydrogen selectivity (33.15 vol%) were obtained at 850 °C due to the endothermic nature of gasification reactions. The 10%Ni-ZS catalyst showed proper stability during three consecutive experiments at 850 °C. The spent catalyst was successfully regenerated without a significant reduction in activity or selectivity.

Thermocatalytic conversion of wood-plastic composite over HZSM-5 catalysts

Air gasification of the Wood-Plastic Composite (WPC) was performed over Ni-loaded HZSM-5 catalysts to generate H₂-rich gas. Increasing SiO₂/Al₂O₃ ratio (SAR) of HZSM-5 adversely affected catalytic activity, where the highest gas yield (51.38 wt%) and H₂ selectivity (27.01 vol%) were acquired using 20 %Ni/HZSM-5(30) than those produced over 20 %Ni/HZSM-5(80) and 20 %Ni/HZSM-5(280). Reducing SAR was also favorably conducive to increasing the acyclic at the expense of cyclic compounds in oil products. These phenomena are attributed to enhanced acid strength and Ni dispersion of 20 %Ni/HZSM-5(30) catalyst. Moreover, catalytic activity in the terms of gas yield and H₂ selectivity enhanced with growing Ni loading to 20 %. Also, the addition of promoters (Cu and Ca) to 20 %Ni/HZSM-5(30) boosted the catalytic efficiency for H₂-rich gas generation. Raising temperature indicated a positive relevance with the gas yield and H₂ selectivity. WPC valorization via gasification technology would be an outstanding outlook in the terms of a waste-to-energy platform.

Hydrogenation of Carboxylic Acids, Esters, and Related Compounds over Heterogeneous Catalysts: A Step toward Sustainable and Carbon-Neutral Processes

The catalytic hydrogenation of esters and carboxylic acids represents a fundamental and important class of organic transformations, which is widely applied in energy, environmental, agricultural, and pharmaceutical industries. Due to the low reactivity of the carbonyl group in carboxylic acids and esters, this type of reaction is, however, rather challenging. Hence, specifically active catalysts are required to achieve a satisfactory yield. Nevertheless, in recent years, remarkable progress has been made on the development of catalysts for this type of reaction, especially heterogeneous catalysts, which are generally dominating in industry. Here in this review, we discuss the recent breakthroughs as well as milestone achievements for the hydrogenation of industrially important carboxylic acids and esters utilizing heterogeneous catalysts. In addition, related catalytic hydrogenations that are considered of importance for the development of cleaner energy technologies and a circular chemical industry will be discussed in detail. Special attention is paid to the insights into the structure-activity relationship, which will help the readers to develop rational design strategies for the synthesis of more efficient heterogeneous catalysts.

γ-Valerolactone Production from Levulinic Acid Hydrogenation Using Ni Supported Nanoparticles: Influence of Tungsten Loading and pH of Synthesis

γ-Valerolactone (GVL) has been considered an alternative as biofuel in the production of carbon-based chemicals; however, the use of noble metals and corrosive solvents has been a problem. In this work, Ni supported nanocatalysts were prepared to produce γ-Valerolactone from levulinic acid using methanol as solvent at a temperature of 170 °C utilizing 4 MPa of H₂. Supports were modified at pH 3 using acetic acid (CH₃COOH) and pH 9 using ammonium hydroxide (NH₄OH) with different tungsten (W) loadings (1%, 3%, and 5%) by the Sol-gel method. Ni was deposited by the suspension impregnation method. The catalysts were characterized by various techniques including XRD, N₂ physisorption, UV-Vis, SEM, TEM, XPS, H₂-TPR, and Pyridine FTIR. Based on the study of acidity and activity relation, Ni dispersion due to the Lewis acid sites contributed by W at pH 9, producing nanoparticles smaller than 10 nm of Ni, and could be responsible for the high esterification activity of levulinic acid (LA) to Methyl levulinate being more selective to catalytic hydrogenation. Products and by-products were analyzed by ¹H NMR. Optimum catalytic activity was obtained with 5% W at pH 9, with 80% yield after 24 h of reaction. The higher catalytic activity was attributed to the particle size and the amount of Lewis acid sites generated by modifying the pH of synthesis and the amount of W in the support due to the spillover effect.

Conversion of Oxygenates on H-ZSM-5 Zeolites—Effects of Feed Structure and Si/Al Ratio on the Product Quality

The conversion of different biogenic feedstocks to hydrocarbons is a major challenge when ensuring hydrocarbon and fuel supply in spite of the heterogeneity of this feed. Flexible adaptation to changing compositions is mandatory for the respective processes. In this study, different oxygenate model feeds, such as alcohols, aldehydes, carboxylic acids and esters, were converted at 500 °C and 5 barg H2 using H-ZSM-5 zeolite catalysts with various Si/Al ratios to identify the relationship between the feed structure and the final product distribution. As the main outcome, the product distribution becomes increasingly independent of the feed structure for Al-rich H-ZSM-5 catalyst samples at low Time on Stream (ToS). Some minor exceptions are the increased formation of aromatics during ToS for carbonyl oxygenates compared to primary alcohols and the dominance of initial deoxygenation products for Si-rich H-ZSM-5 samples. This is interpreted by a multi-stage reaction sequence, which involves the initial deoxygenation of the feed and the subsequent integration of the olefin intermediates into a reaction network. The results pave the way towards the achievement of a desired product distribution in the conversion of different oxygenates simply by the adaption of the Al content of H-ZSM-5.

Zeolite-Supported Ni Catalysts for CO2 Methanation: Effect of Zeolite Structure and Si/Al Ratio

The urgent need to reduce CO2 emissions requires the development of efficient catalysts for the conversion of CO2 into chemicals and fuels. In this study, a series of nickel catalysts supported on ITQ-2 and ZSM-5 zeolites have been prepared, characterized and tested in the hydrogenation reaction of CO2 towards methane. Specifically, two ITQ-2 and two ZSM 5 zeolites with different aluminum content have been studied. For both types, the higher Si/Al ratio of the material, the more active the catalyst due probably to its higher hydrophobicity. The largest difference was found for the ITQ-2 samples, being the CO2 conversion for the sample with a greater Si/Al ratio 50 points higher at 350 °C. Comparing both zeolite structures, while similar catalytic results were obtained with the samples with lower Si/Al ratio, a distinctly higher activity was found for the ITQ-2 zeolite without aluminum, pure silica. Therefore, this result suggests that the presence of aluminum is of particular relevance. Among the studied materials, the catalyst supported on the delaminated ITQ-2 zeolite without Al was the most active catalyst. Its higher activity was mainly attributed to the smaller crystallite size of nickel supported on the large external surface area presented by this zeolite.

Continuous Flow Upgrading of Selected C2-C6 Platform Chemicals Derived from Biomass

The ever increasing industrial production of commodity and specialty chemicals inexorably depletes the finite primary fossil resources available on Earth. The forecast of population growth over the next 3 decades is a very strong incentive for the identification of alternative primary resources other than petro-based ones. In contrast with fossil resources, renewable biomass is a virtually inexhaustible reservoir of chemical building blocks. Shifting the current industrial paradigm from almost exclusively petro-based resources to alternative bio-based raw materials requires more than vibrant political messages; it requires a profound revision of the concepts and technologies on which industrial chemical processes rely. Only a small fraction of molecules extracted from biomass bears significant chemical and commercial potentials to be considered as ubiquitous chemical platforms upon which a new, bio-based industry can thrive. Owing to its inherent assets in terms of unique process experience, scalability, and reduced environmental footprint, flow chemistry arguably has a major role to play in this context. This review covers a selection of C₂ to C₆ bio-based chemical platforms with existing commercial markets including polyols (ethylene glycol, 1,2-propanediol, 1,3-propanediol, glycerol, 1,4-butanediol, xylitol, and sorbitol), furanoids (furfural and 5-hydroxymethylfurfural) and carboxylic acids (lactic acid, succinic acid, fumaric acid, malic acid, itaconic acid, and levulinic acid). The aim of this review is to illustrate the various aspects of upgrading bio-based platform molecules toward commodity or specialty chemicals using new process concepts that fall under the umbrella of continuous flow technology and that could change the future perspectives of biorefineries.

Toward Green Production of Chewing Gum and Diet: Complete Hydrogenation of Xylose to Xylitol over Ruthenium Composite Catalysts under Mild Conditions

Xylitol is one of the most famous chemicals known to people as the essential ingredient of chewing gum and as the sugar alternative for diabetics. Catalytic hydrogenation of biomass-derived xylose with H₂ to produce high-value xylitol has been carried out under harsh reaction conditions. Herein, we exhibit the combination of Ru NPs with an environmentally benign MOF (ZIF-67) to afford a heterogeneous composite catalyst. Complete conversion of xylose with 100% selectivity to xylitol was achieved at 50°C and 1 atm H₂. This is the first successful attempt to produce xylitol with ambient pressure H₂ as well as the first time to achieve a 100% selectivity of xylitol for applicable catalysts. We also proved the universality of the Ru@ZIF-67 towards other hydrogenation processes. Under 1 atm H₂, we achieved 100% conversion and >99% selectivity of 1-phenylethanol at 50°C for the hydrogenation of acetophenone. This is also the first report of hydrogenating acetophenone to 1-phenylethanol under 1 atm H₂, which confirms that our result not only contributes to enhance the industrial yields of xylitol and reduces both the economical and energy costs but also provides new perspectives on the other hydrogenation process with H₂.

Transformation of Levulinic Acid to Valeric Biofuels: A Review on Heterogeneous Bifunctional Catalytic Systems

Valerate esters (VAEs) commonly derived from levulinic acid (LA), which is deemed as one of the most promising biomass platform molecules, have been hailed as "valeric biofuels" in recent years. The cascade transformation of LA to VAEs consists of a series of acid- and metal-catalyzed processes alternately, in which heterogeneous bifunctional catalysts are required for better catalytic performance. The transformation pathway from LA to VAEs is presented, and bifunctional catalytic systems for the cascade transformation of LA into valeric acid (VA) and its esters, as well as one-pot conversion processes, are reviewed. Additionally, effects of metal and acid sites on the catalytic performance are discussed in detail. Impacts of and improvements to coke deposition, which is determined to be the primary reason for the reduction in catalytic activity, are also analyzed. Finally, feasible suggestions are proposed for enhanced catalytic performance and a reduction in overall costs.

Hollow MFI Zeolite Supported Pt Catalysts for Highly Selective and Stable Hydrodeoxygenation of Guaiacol to Cycloalkanes

Hollow Silicalite-1 and ZSM-5 zeolites with hierarchical porous shells have been synthesized by using a dissolution-recrystallization method. The morphology, structure, and acidity of these zeolites supported Pt catalysts were characterized by XRD, FT-IR, MAS-SSNMR, FE-SEM, FE-TEM, N₂-BET, XPS, NH₃-TPD, and CO pulse chemisorption. Compared to the conventional ZSM-5 supported Pt catalyst, the special structure in hollow ZSM-5 zeolite significantly promotes the dispersion of metallic Pt and the synergistic effect between metal active sites and acid sites. These boost the catalytic activity, selectivity of guaiacol hydrodeoxygenation toward cycloalkanes and long-term stability over the Pt/hollow ZSM-5 catalyst combined with improved mass transfer of products and reactants derived from the hierarchical hollow porous structure. Moreover, the Pt/hollow ZSM-5 catalyst exhibits excellent low temperature catalytic activity to completely transform guaiacol into cycloalkanes with the cyclohexane selectivity of more than 93% at 220 °C, suggesting that hollow ZSM-5 zeolite is a promising support for upgrading of bio-oils.

Selective hydroconversion of levulinic acid to γ-valerolactone or 2-methyltetrahydrofuran over silica-supported cobalt catalysts

Levulinic acid can be hydrodeoxygenated either to γ-valerolactone or to 2-methyltetrahydrofuran over the Co/SiO₂ catalyst. Selectivity was controlled by the hydrogenation activity of the catalyst.

Effect of SiO2 support properties on the performance of Cu–SiO2 catalysts for the hydrogenation of levulinic acid to gamma valerolactone using formic acid as a hydrogen source

Vapor phase catalytic transfer hydrogenation of levulinic acid with formic acid was carried out over Cu–SiO₂ catalysts having different physicochemical properties.