Turbulent Properties of Stationary Flows in Porous Media

In this study, we investigate the flow dynamics in a fixed bed of hydrogel beads using particle tracking velocimetry to compute the velocity field in the middle of the bed for moderate Reynolds numbers (Re=[124,169,203,211]). We discover that even though the flow is stationary at the larger scales, it exhibits complex multiscale spatial dynamics reminiscent of those observed in classical turbulence. We find evidence of the presence of an inertial range and a direct energy cascade, and are able to obtain a value for a "porous" Kolmogorov constant of C_{2}=3.1±0.3. This analogy with turbulence opens up new possibilities for understanding mixing and global transport properties in porous media.

3D-Printing of Hierarchical Porous Copper-Based Metal-Organic-Framework Structures for Efficient Fixed-Bed Catalysts

Metallic structures with hierarchical open pores that span several orders of magnitude are ideal candidates for various catalyst applications. However, porous metal materials prepared using alloy/dealloy methods still struggle to achieve continuous pore distribution across a broad size range. Herein, we report a printable copper (Cu)/iron (Fe) composite ink that produces a hierarchical porous Cu material with pores spanning over 4 orders of magnitude. The manufacturing process involves four steps: 3D-printing, annealing, dealloying, and reannealing. Because of the unique annealing process, the resulting hierarchical pore surface becomes coated with a layer of Cu-Fe alloy. This feature imparts remarkable catalytic ability and versatile functionality within fixed bed reactors for 4-nitrophenol (4-NP) reduction and Friedländer cyclization. Specifically, for 4-NP reduction, the porous Cu catalyst demonstrates an excellent reaction rate constant (kapp = 86.5 × 10-3 s-1) and a wide adaptability of the substrate (up to 1.26 mM), whilst for Friedländer cyclization, a conversion over 95% within a retention time of only 20 min can be achieved by metal-organic-framework-decorated porous Cu catalyst. The utilization of dual metallic particles as printable inks offers valuable insights for fabricating hierarchical porous metallic structures for applications, such as advanced fixed-bed catalysts.

Bicontinuous Interfacially Jammed Emulsion Gels (Bijels): Preparation, Control Strategies, and Derived Porous Materials

Bicontinuous interfacially jammed emulsion gels, also known as Bijels, are a new type of soft condensed matter. Over the last decade, Bijels have attracted considerable attention because of their unique morphology, property, and broad application prospects. In the present review, we summarize the preparation methods and main control strategies of Bijels, focusing on the research progress and application of Bijels as templates for porous materials preparation in recent years. The potential future directions and applications of Bijels are also envisaged.

Evolution of Hierarchically Porous Nickel Alumina Catalysts Studied by X-Ray Ptychography

The synthesis of hierarchically porous materials usually requires complex experimental procedures, often based around extensive trial and error approaches. One common synthesis strategy is the sol-gel method, although the relation between synthesis parameters, material structure and function has not been widely explored. Here, in situ 2D hard X-ray ptychography (XRP) and 3D ptychographic X-ray computed tomography (PXCT) are applied to monitor the development of hierarchical porosity in Ni/Al2 O3 and Al2 O3 catalysts with connected meso- and macropore networks. In situ XRP allows to follow textural changes of a dried gel Ni/Al2 O3 sample as a function of temperature during calcination, activation and CO2 methanation reaction. Complementary PXCT studies on dried gel particles of Ni/Al2 O3 and Al2 O3 provide quantitative information on pore structure, size distribution, and shape with 3D spatial resolution approaching 50 nm, while identical particles are imaged ex situ before and after calcination. The X-ray imaging results are correlated with N2 -sorption, Hg porosimetry and He pycnometry pore characterization. Hard X-ray nanotomography is highlighted to derive fine structural details including tortuosity, branching nodes, and closed pores, which are relevant in understanding transport phenomena during chemical reactions. XRP and PXCT are enabling technologies to understand complex synthesis pathways of porous materials.

Gold nanoparticles with tailored size through ligand modification for catalytic applications

The active sites of catalysts can be tuned by using appropriate organic moieties. Here, we describe a facile approach to synthesise gold nanoparticles (AuNPs) using various Au(I) precursors. The core size of these AuNPs can be precisely tailored by varying the steric hindrance imposed by bound ligands. An interesting relationship is deduced that correlates the steric hindrance around the metal to the final size of the nanoparticles. The synthesised AuNPs are immobilised onto TS-1 zeolite (Au/TS-1) with minimal change in the final size of the AuNPs. The catalytic performance of Au/TS-1 catalyst is evaluated for the direct gas phase epoxidation of propylene with hydrogen and oxygen, an environmentally friendly route to produce propylene oxide. The results indicate that smaller AuNPs exhibit enhanced catalytic activity and selectivity. Furthermore, this synthetic approach is beneficial when tailored synthesis of gold nanoparticles of specific sizes is required.

Precisely Engineered Supported Gold Clusters as a Stable Catalyst for Propylene Epoxidation

Designing a stable and selective catalyst with high H₂ utilisation is of pivotal importance for the direct gas-phase epoxidation of propylene. This work describes a facile one-pot methodology to synthesise ligand-stabilised sub-nanometre gold clusters immobilised onto a zeolitic support (TS-1) to engineer a stable Au/TS-1 catalyst. A non-thermal O₂ plasma technique is used for the quick removal of ligands with limited increase in particle size. Compared to untreated Au/TS-1 catalysts prepared using the deposition precipitation method, the synthesised catalyst exhibits improved catalytic performance, including 10 times longer lifetime (>20 days), increased PO selectivity and hydrogen efficiency in direct gas phase epoxidation. The structure-stability relationship of the catalyst is illustrated using multiple characterisation techniques, such as XPS, ³¹ P MAS NMR, DR-UV/VIS, HRTEM and TGA. It is hypothesised that the ligands play a guardian role in stabilising the Au particle size, which is vital in this reaction. This strategy is a promising approach towards designing a more stable heterogeneous catalyst.

Nature-Inspired Chemical Engineering for Process Intensification

A nature-inspired solution (NIS) methodology is proposed as a systematic platform for innovation and to inform transformative technology required to address Grand Challenges, including sustainable development. Scalability, efficiency, and resilience are essential to nature, as they are to engineering processes. They are achieved through underpinning fundamental mechanisms, which are grouped as recurring themes in the NIS approach: hierarchical transport networks, force balancing, dynamic self-organization, and ecosystem properties. To leverage these universal mechanisms, and incorporate them effectively into engineering design, adaptations may be needed to accommodate the different contexts of nature and engineering applications. Nature-inspired chemical engineering takes advantage of the NIS methodology for process intensification, as demonstrated here in fluidization, catalysis, fuel cell engineering, and membrane separations, where much higher performance is achieved by rigorously employing concepts optimized in nature. The same approach lends itself to other applications, from biomedical engineering to information technology and architecture.

Diffusion in nanopores: inspecting the grounds

This paper provides a general overview of the phenomenon of guest diffusion in nanoporous materials. It introduces the different types of diffusion measurement that can be performed under both equilibrium and non-equilibrium conditions in either single- or multicomponent systems. In the technological application of nanoporous materials for mass separation and catalytic conversion diffusion often has a significant impact on the overall rate of the process and is quite commonly rate controlling. Diffusion enhancement is therefore often a major goal in the manufacture of catalysts and adsorbents.

Nature-inspired electrocatalysts and devices for energy conversion

A NICE approach for the design of nature-inspired electrocatalysts and electrochemical devices for energy conversion.

Re-designing materials for biomedical applications: from biomimicry to nature-inspired chemical engineering

Gathering inspiration from nature for the design of new materials, products and processes is a topic gaining rapid interest among scientists and engineers. In this review, we introduce the concept of nature-inspired chemical engineering (NICE). We critically examine how this approach offers advantages over straightforward biomimicry and distinguishes itself from bio-integrated design, as a systematic methodology to present innovative solutions to challenging problems. The scope of application of the nature-inspired approach is demonstrated via examples from the field of biomedicine, where much of the inspiration is still more narrowly focused on imitation or bio-integration. We conclude with an outlook on prospective future applications, offered by the more systematic and mechanistically based NICE approach, complemented by rapid progress in manufacturing, computation and robotics. This article is part of the theme issue 'Bioinspired materials and surfaces for green science and technology'.

3D printing of sacrificial templates into hierarchical porous materials

Hierarchical porous materials are widespread in nature and find an increasing number of applications as catalytic supports, biological scaffolds and lightweight structures. Recent advances in additive manufacturing and 3D printing technologies have enabled the digital fabrication of porous materials in the form of lattices, cellular structures and foams across multiple length scales. However, current approaches do not allow for the fast manufacturing of bulk porous materials featuring pore sizes that span broadly from macroscopic dimensions down to the nanoscale. Here, ink formulations are designed and investigated to enable 3D printing of hierarchical materials displaying porosity at the nano-, micro- and macroscales. Pores are generated upon removal of nanodroplets and microscale templates present in the initial ink. Using particles to stabilize the droplet templates is key to obtain Pickering nanoemulsions that can be 3D printed through direct ink writing. The combination of such self-assembled templates with the spatial control offered by the printing process allows for the digital manufacturing of hierarchical materials exhibiting thus far inaccessible multiscale porosity and complex geometries.

Architectural Designs and Synthetic Strategies of Advanced Nanocatalysts

Advanced nanocatalysts with high compositional and structural tailorability have emerged as a new class of heterogeneous catalysts exhibiting many new technical merits over their conventional counterparts. Generally, preparation of such catalysts involves the integration of catalyst components with compositional, size, and shape controls into a larger material system in order to bring along collective and synergetic effects of individual components. Herein, a brief review of architectural designs and synthetic strategies for making these nanocatalysts is presented. Due to length constraints, only four major types of them are highlighted together with some general rules of design and synthesis. Finally, a critical outline of future perspective in this field is proposed.

Diffusion in Nanoporous Materials: Novel Insights by Combining MAS and PFG NMR

Pulsed field gradient (PFG) nuclear magnetic resonance (NMR) allows recording of molecular diffusion paths (notably, the probability distribution of molecular displacements over typically micrometers, covered during an observation time of typically milliseconds) and has thus proven to serve as a most versatile means for the in-depth study of mass transfer in complex materials. This is particularly true with nanoporous host materials, where PFG NMR enabled the first direct measurement of intracrystalline diffusivities of guest molecules. Spatial resolution, i.e., the minimum diffusion path length experimentally observable, is limited by the time interval over which the pulsed field gradients may be applied. In “conventional” PFG NMR measurements, this time interval is determined by a characteristic quantity of the host-guest system under study, the so-called transverse nuclear magnetic relaxation time. This leads, notably when considering systems with low molecular mobilities, to severe restrictions in the applicability of PFG NMR. These restrictions may partially be released by performing PFG NMR measurements in combination with “magic-angle spinning” (MAS) of the NMR sample tube. The present review introduces the fundamentals of this technique and illustrates, via a number of recent cases, the gain in information thus attainable. Examples include diffusion measurements with nanoporous host-guest systems of low intrinsic mobility and selective diffusion measurement in multicomponent systems.

Molecular Modelling for Reactor Design

Chemical reactor modelling based on insights and data on a molecular level has become reality over the last few years. Multiscale models describing elementary reaction steps and full microkinetic schemes, pore structures, multicomponent adsorption and diffusion inside pores, and entire reactors have been presented. Quantum mechanical (QM) approaches, molecular simulations (Monte Carlo and molecular dynamics), and continuum equations have been employed for this purpose. Some recent developments in these approaches are presented, in particular time-dependent QM methods, calculation of van der Waals forces, new approaches for force field generation, automatic setup of reaction schemes, and pore modelling. Multiscale simulations are discussed. Applications of these approaches to heterogeneous catalysis are demonstrated for examples that have found growing interest over the last few years, such as metal-support interactions, influence of pore geometry on reactions, noncovalent bonding, reaction dynamics, dynamic changes in catalyst nanoparticle structure, electrocatalysis, solvent effects in catalysis, and multiscale modelling.

3D printing in chemical engineering and catalytic technology: structured catalysts, mixers and reactors

Computer-aided fabrication technologies combined with simulation and data processing approaches are changing our way of manufacturing and designing functional objects. Also in the field of catalytic technology and chemical engineering the impact of additive manufacturing, also referred to as 3D printing, is steadily increasing thanks to a rapidly decreasing equipment threshold. Although still in an early stage, the rapid and seamless transition between digital data and physical objects enabled by these fabrication tools will benefit both research and manufacture of reactors and structured catalysts. Additive manufacturing closes the gap between theory and experiment, by enabling accurate fabrication of geometries optimized through computational fluid dynamics and the experimental evaluation of their properties. This review highlights the research using 3D printing and computational modeling as digital tools for the design and fabrication of reactors and structured catalysts. The goal of this contribution is to stimulate interactions at the crossroads of chemistry and materials science on the one hand and digital fabrication and computational modeling on the other.

Biocarbon-templated synthesis of porous Ni–Co-O nanocomposites for room-temperature NH3 sensors

Mesoporous nickel–cobalt oxide (Ni–Co-O) nanocomposites were fabricated using a mesoporous biocarbon material (BCM), resulting from hemp stem, as a template.

Process intensification

Process intensification (PI) is a rapidly growing field of research and industrial development that has already created many innovations in chemical process industry. PI is directed toward substantially smaller, cleaner, more energy-efficient technology. Furthermore, PI aims at safer and sustainable technological developments. Its tools are reduction of the number of devices (integration of several functionalities in one apparatus), improving heat and mass transfer by advanced mixing technologies and shorter diffusion pathways, miniaturization, novel energy techniques, new separation approaches, integrated optimization and control strategies. This review discusses many of the recent developments in PI. Starting from fundamental definitions, microfluidic technology, mixing, modern distillation techniques, membrane separation, continuous chromatography, and application of gravitational, electric, and magnetic fields will be described.

Additive Manufacturing: Unlocking the Evolution of Energy Materials

The global energy infrastructure is undergoing a drastic transformation towards renewable energy, posing huge challenges on the energy materials research, development and manufacturing. Additive manufacturing has shown its promise to change the way how future energy system can be designed and delivered. It offers capability in manufacturing complex 3D structures, with near-complete design freedom and high sustainability due to minimal use of materials and toxic chemicals. Recent literatures have reported that additive manufacturing could unlock the evolution of energy materials and chemistries with unprecedented performance in the way that could never be achieved by conventional manufacturing techniques. This comprehensive review will fill the gap in communicating on recent breakthroughs in additive manufacturing for energy material and device applications. It will underpin the discoveries on what 3D functional energy structures can be created without design constraints, which bespoke energy materials could be additively manufactured with customised solutions, and how the additively manufactured devices could be integrated into energy systems. This review will also highlight emerging and important applications in energy additive manufacturing, including fuel cells, batteries, hydrogen, solar cell as well as carbon capture and storage.