Recent advances in bifunctional synthesis gas conversion to chemicals and fuels with a comparison to monofunctional processes

In order to meet the climate goals of the Paris Agreement and limit the potentially catastrophic consequences of climate change, we must move away from the use of fossil feedstocks for the production of chemicals and fuels. The conversion of synthesis gas (a mixture of hydrogen, carbon monoxide and/or carbon dioxide) can contribute to this. Several reactions allow to convert synthesis gas to oxygenates (such as methanol), olefins or waxes. In a consecutive step, these products can be further converted into chemicals, such as dimethyl ether, short olefins, or aromatics. Alternatively, fuels like gasoline, diesel, or kerosene can be produced. These two different steps can be combined using bifunctional catalysis for direct conversion of synthesis gas to chemicals and fuels. The synergistic effects of combining two different catalysts are discussed in terms of activity and selectivity and compared to processes based on consecutive reaction with single conversion steps. We found that bifunctional catalysis can be a strong tool for the highly selective production of dimethyl ether and gasoline with high octane numbers. In terms of selectivity bifunctional catalysis for short olefins or aromatics struggles to compete with processes consisting of single catalytic conversion steps.

Numerical Design of Granular Support for Three-Way Catalyzed Solid- and Porous-Particles Membrane Filters

A granular substrate used as a support for a three-way catalyzed (TWC) solid-particle membrane filter was investigated through numerical simulation. The proposed support could reduce the amount of required catalyst material by 39% and lower the pressure drop by 33%, compared to a conventional filter, while achieving almost 100% soot-filtration. Moreover, TWC porous particles, which are designed to introduce a fluid flow into their interconnected pore network, further decrease the pressure drop. However, a trade-off exists between the amount of the introduced fluid flow and the specific surface area.

Waste-Extracted Zn and Ag Co-Doped Spent Catalyst-Extracted V2O5 for Photocatalytic Degradation of Congo Red Dye: Effect of Metal-Nonmetal Co-Doping

The current study applies the eco-friendly principle of “wastes treat wastes”. By swift methods, a composite photocatalyst was prepared from waste-extracted oxides, namely V2O5, Ag, and ZnO. The metal–lixiviant complexes were used as metal precursors, where the lixiviants act as auto-templates and increase the compatibility between the mixed metallic species, and their controlled thermal removal generates pores. The tri-constitute composite catalyst was doped with nitrogen. The constitution, surface composition, and optical properties of the doped catalysts were investigated by XRD, SEM, TEM, BET surface analysis, XPS, diffuse reflectance, and PL spectra. The as-prepared catalysts were employed in the photodegradation of Congo red dye (CR) under visible irradiation at ambient temperature. The degree of Ag dispersion had a significant effect on the bandgap, as did metal and metal-nonmetal co-doping. The efficiency of dye removal changes dramatically with time up to 120 min, after which it begins to decrease. According to the pH effect, the normal pH of Congo red dye (6.12) is optimal. At a catalyst dose of 1 g L−1 and an irradiation period of 120 min, photodegradation efficiency reached 89.9% and 83.4% over [Ag0.05 ZnO0.05 V2O5(0.90)] and [Ag0.05 ZnO0.05 V2O5(0.90)]N, respectively. The kinetic study depicted the significant role of mass transfer in the reaction rate. The obtained rate constants were 0.995 mole L−1 S−1 and 0.998 mole L−1 S−1 for [Ag0.05 ZnO0.05 V2O5(0.90)] and [Ag0.05 ZnO0.05 V2O5(0.90)]N, respectively.

Photocatalytic Performance of Organically Templated Cr-Doped Co3O4 in Remediation of Industrial Wastewater: Effect of Order–Disorder in the Lattice

In photocatalysis, the optical properties and surface parameters significantly affect the catalytic performance. To engineer the optical properties and textural structure, Cr and p-phenylene diamine (PDA) were utilized as dopant and textural structure regulator, respectively. A series of Cr-doped Co3O4 with dopant percentages of 0, 1, 3, and 5, templated PDA at a fixed ratio of 5%, and another un-templated sample with a dopant ratio of 5% were prepared. The co-precipitation method was applied in swift and innovative procedures, where a calculated amount of NaOH was used as a precipitant. The optical properties, dopant concentration quenching, and surface parameters are strongly affected by the order–disorder in the lattice and dopant concentration. The lattice regularity affects the optical properties and the surface parameters along with the dopant concentration. The photocatalysts were evaluated in the disposal of organic pollutants in a representative sample of wastewater collected from different industrial activities. The function of another function was applied to monitor the pollutants' disposal, taking the total organic carbon (TOC) as a function of the pollutants' concentration and the photometric absorbance as a function of the TOC. The kinetic investigation exhibited the significant role of the pore system on the reaction rate.

Recent Advances in Photocatalytic Oxidation of Methane to Methanol

Methane is one of the promising alternatives to non-renewable petroleum resources since it can be transformed into added-value hydrocarbon feedstocks through suitable reactions. The conversion of methane to methanol with a higher chemical value has recently attracted much attention. The selective oxidation of methane to methanol is often considered a “holy grail” reaction in catalysis. However, methanol production through the thermal catalytic process is thermodynamically and economically unfavorable due to its high energy consumption, low catalyst stability, and complex reactor maintenance. Photocatalytic technology offers great potential to carry out unfavorable reactions under mild conditions. Many in-depth studies have been carried out on the photocatalytic conversion of methane to methanol. This review will comprehensively provide recent progress in the photocatalytic oxidation of methane to methanol based on materials and engineering perspectives. Several aspects are considered, such as the type of semiconductor-based photocatalyst (tungsten, titania, zinc, etc.), structure modification of photocatalyst (doping, heterojunction, surface modification, crystal facet re-arrangement, and electron scavenger), factors affecting the reaction process (physiochemical characteristic of photocatalyst, operational condition, and reactor configuration), and briefly proposed reaction mechanism. Analysis of existing challenges and recommendations for the future development of photocatalytic technology for methane to methanol conversion is also highlighted.

Highly polymerized linear polyimide /H3PW12O40 photocatalyst with full visible light region absorption

The degree of polymerization in polyimides has significant effects on their photoelectric properties. Increase the degree of polymerization in polyimide can improve its light absorption capability as well as reduce the recombination rate of photogenerated electrons and holes. However, it is difficult to promote the polymerization of polyimides by conventional approaches, such as increasing the polymerization temperature since polyimides are susceptible to high temperature and can be decomposed. In this paper, a suitable proportion of phosphotungstic acid was introduced to increase the degree of polymerization of polyimide at a lower polymerization temperature, so as to improve the light absorption capability of the composite and inhibit the recombination of electron and hole. The p-phenylenediamine based polyimide with the one-dimensional linear polymer chain has excellent charge transfer ability, so the POM-π effect formed with phosphotungstic acid is stronger, correspondingly, the light absorption capacity of the composite photocatalyst formed is stronger than that of the cross-linked polyimide/phosphotungstic acid.

Application of magnetic field to CO hydrogenation using a confined-space catalyst: effect on reactant gas diffusivity and reactivity

An external magnetic field has recently been applied in reaction processes to promote movement and avoid agglomeration of magnetic particles, and also reduce the activation energy through improving the gas-solid contact. In this work, the effect of an external magnetic field on reactant gas diffusivity and reactivity in CO hydrogenation within a confined-space catalyst was investigated for the first time using a conventional reactor packed with a bimetallic 5Fe-5Co/ZSM-5 molecular sieve catalyst. The synergistic effect between magnetic field and limited mass transfer within zeolite cavities improved the mass transfer ability and reaction phenomena of the reactant molecules, leading to enhancement of catalytic activity with tailored reaction pathways. As a result, CO conversion and CH4 selectivity were increased by factors of 1.9 and 1.3 compared to those without a magnetic field. These synergistic interactions are able to provide an innovative challenge for green and sustainable chemical processes and separation processes by means of selective reactant and product mass transfer designed for selective catalytic conversion in the future.

A Review of the Critical Aspects in the Multi-Scale Modelling of Structured Catalytic Reactors

Structured catalytic reactors are enjoying an increasingly important role in the reaction engineering world. At the same time, there are large and growing efforts to use advanced computational models to describe such reactors. The structured reactor represents a multi-scale problem that is typically modelled at the largest scale only, with sub-models being used to improve the model granularity. Rather than a literature review, this paper provides an overview of the key factors that must be considered when choosing these sub-models (or scale bridges). The example structured reactor selected for illustration purposes is the washcoated honeycomb monolith design. The sub-models reviewed include those for pressure drop, inter- and intra-phase mass and heat transfer, and effective thermal conductivity.

Recent developments in catalyst pretreatment technologies for cobalt based Fisher–Tropsch synthesis

Stringent environmental regulations and energy insecurity necessitate the development of an integrated process to produce high-quality fuels from renewable resources and to reduce dependency on fossil fuels, in this case Fischer–Tropsch synthesis (FTS). The FT activity and selectivity are significantly influenced by the pretreatment of the catalyst. This article reviews traditional and developing processes for pretreatment of cobalt catalysts with reference to their application in FTS. The activation atmosphere, drying, calcination, reduction conditions and type of support are critical factors that govern the reducibility, dispersion and crystallite size of the active phase. Compared to traditional high temperature H2 activation, both hydrogenation–carbidisation–hydrogenation and reduction–oxidation–reduction pretreatment cycles result in improved metal dispersion and exhibit much higher FTS activity. Cobalt carbide (Co2C) formed by CO treatment has the potential to provide a simpler and more effective way of producing lower olefins, and higher alcohols directly from syngas. Syngas activation or direct synthesis of the metallic cobalt catalyst has the potential to remove the expensive H2 pretreatment procedure, and consequently simplify the pretreatment process, which would make it more economical and thus more attractive to industry.

Is the Fischer-Tropsch Conversion of Biogas-Derived Syngas to Liquid Fuels Feasible at Atmospheric Pressure?

Biogas resulting from anaerobic digestion can be utilized for the production of liquid fuels via reforming to syngas followed by the Fischer-Tropsch reaction. Renewable liquid fuels are highly desirable due to their potential for use in existing infrastructure, but current Fischer-Tropsch processes, which require operating pressures of 2–4 MPa (20–40 bar), are unsuitable for the relatively small scale of typical biogas production facilities in the EU, which are agriculture-based. This paper investigates the feasibility of producing liquid fuels from biogas-derived syngas at atmospheric pressure, with a focus on the system’s response to various interruption factors, such as total loss of feed gas, variations to feed ratio, and technical problems in the furnace. Results of laboratory testing showed that the liquid fuel selectivity could reach 60% under the studied conditions of 488 K (215 °C), H2/CO = 2 and 0.1 MPa (1 bar) over a commercial Fischer–Tropsch catalyst. Analysis indicated that the catalyst had two active sites for propagation, one site for the generation of methane and another for the production of liquid fuels and wax products. However, although the production of liquid fuels was verified at atmospheric pressure with high liquid fuel selectivity, the control of such a system to maintain activity is crucial. From an economic perspective, the system would require subsidies to achieve financial viability.

The Fischer–Tropsch synthesis performance over cobalt supported on silicon-based materials: the effect of thermal conductivity of the support

The effect of thermal conductivity of support on the catalytic performance of supported Co-based Fischer–Tropsch catalysts is investigated.

Immobilization of ultrafine Ag nanoparticles on well-designed hierarchically porous silica for high-performance catalysis

Catalyst immobilization is of much significance not only for maintaining the high activity of the ultrafine catalyst, but also for the separation of catalyst during the practical application. Herein, a novel support material, three-dimensional hierarchically porous silica (HPS) with interconnected micro-meso-macro pores and high specific surface area was successfully fabricated though a freeze-drying technique in the presence of poly(vinyl alcohol) (PVA) and subsequent calcination process. A series of characterizations revealed that the specific surface area of HPS can be well adjusted by changing the addition of PVA. The specific surface area of HPS was as high as 360 m² g^-1, which was 211-fold higher than HPS-0 (silica prepared without using PVA). To demonstrate the potential application of such novel support material, highly dispersed silver nanoparticles (AgNPs) were immobilized on the surfaces of HPS and HPS-0 through in-situ reduction. By contrast, the catalytic activity of AgNPs anchored on HPS (531 s^-1 g^-1) was about 42-fold higher than that of AgNPs anchored on HPS-0 (12.67 s^-1 g^-1). The significantly enhanced catalytic activity of AgNPs/HPS was believed to be related to their high specific surface area and interconnected macroporous scaffolds, which could provide numerous reactive sites and mass transfer routes for the reactants.

Role of mesopores in Co/ZSM-5 for the direct synthesis of liquid fuel by Fischer–Tropsch synthesis

In a complex reaction system, in which gas, liquid, and solid catalysts work together, understanding the impact of mass transfer that varies with the catalyst pore structure is very challenging but also essential to designing selective catalysts.

Effect of hierarchical meso–macroporous structures on the catalytic performance of silica supported cobalt catalysts for Fischer–Tropsch synthesis

A series of meso–macroporous silica supports with the same macroporous diameter but different mesoporous diameters were prepared by introducing phase separation into a sol–gel process and used to prepare cobalt catalysts for Fischer–Tropsch synthesis.

In situ investigation on Co-phase evolution and its performance for Fischer–Tropsch synthesis over Nb-promoted cobalt catalysts

The influences of Nb on the Co-phase evolution, reducibility, chemisorption, and Fischer–Tropsch synthesis performance of catalysts were in situ researched.