Pd-Supported Catalysts: Evolution of Support Porous Texture along Pd Deposition and Alkali-Metal Doping

Adsorption of N-2 at 77 K and scanning electron microscopy have been used to measure the changes in the support morphology, at nano- and microscale level, along the processes involved in the preparation of a supported Pd catalyst: Pd deposition, doping, and thermal treatments. Among the investigated supports, viz., activated carbons, gamma-Al2O3, SiO2, and SiO2-Al2O3 (SA), the SA one was found particularly sensitive to these processes, as a result of its high plasticity and reactivity. Involved processes can be summarized as follows: (i) During the I'd deposition, the support itself is partially dissolved and removed as a result of both the basicity of the precipitating agent and the final washing. (ii) When the undoped sample is thermally treated up to 823 K, only modest phenomena are observed. (iii) Upon doping with potassium carbonate, the support dissolution continues, and the greater the carbonate concentration, the greater the dissolution extent. In this case the dissolved material is not removed, but reprecipitates (partially outside the pores), during the subsequent drying at 393 K. (iv) When doped samples are thermally treated, the reaction between carbonate and support causes the mobilization of the support itself, with sintering phenomena that can reach the total collapse of the porous structure. The starting temperature of the pore collapse decreases with increasing potassium carbonate concentration. The modification of the support influences, directly or indirectly, the surface properties and the availability of Pd particles that can be doped or even covered by materials from support and made more or less accessible or even inaccessible by pore narrowing, widening, or blocking.

Novel structured adsorber and oxidation catalysts for the removal of VOCs in low concentration

Kim Martin Nikolajsen

One possibility for the removal of volatile organic compounds (VOCs) is catalytic oxidation. For the removal of VOCs in low concentration (≲ 3000 ppmv for propane) it is not possible to sustain the required oxidation temperature over the catalyst without external heating. An approach to overcome this problem is to concentrate the VOC by adsorption, in a "two-step adsorption-incineration" process. This is an unsteady state process in which the VOC laden effluent gas is cleaned by passing it through an adsorber. Once the adsorber is saturated the VOC is desorbed by heating and purging. The concentrated VOC from the desorber can then be oxidized over the catalyst, producing enough heat to sustain the oxidation temperature. Conventional adsorbents have some drawbacks such as tailing during desorption due to the large particle size, high pressure drop and hot-spot formation. The objective of this work was to develop, characterize and test the adsorbent and catalyst, with low resistance to mass transfer resulting from thin films of active material, for the two-step adsorption-incineration process. Both the adsorbent and the oxidation catalysts were supported on sintered metal fibers (SMF). This is a novel, structured support offering several advantages over conventional randomly packed beds: Low pressure drop, due to the high porosity of the SMF, which is important where large flow rates and/or high quantities of gas must be treated. High thermal conductivity, due to the metallic nature, leading to smaller temperature gradients in the fixed-bed. A very high geometric surface area, due to the small fiber size. On the order of 200,000 m2/m3 with a fiber diameter of 20 µm. Furthermore, a mathematical model was developed to show the feasibility of the coupling of the two steps in the process. The adsorber was made from a thin, homogeneous film of MFI-type zeolite covering the fibers of the SMF. The film was grown by the seed-film method by hydrothermal treatment. A 3 µm film was obtained with 10 wt.% zeolite on the fiber after 24 h synthesis at 125 °C. This material had a specific surface area of 30 m2/g. The adsorption equilibrium of propane was described well by the Langmuir isotherm and the heat of adsorption was found to be ΔH0ads = - 43.1 kJ/mol. Isothermal breakthrough curves were measured as a function of temperature and film thickness. A mathematical model, comprised of a tanks-in-series model with a linear driving force (LDF) mass transfer description, successfully described the breakthrough behavior. The overall mass transfer was found to be solely due to diffusion in the zeolite film. However, the thin films show very low resistance to mass transfer leading to low internal concentration gradients and efficient utilization of the adsorbent. The pressure drop was measured and compared to that of a randomly packed fixed-bed of spheres. The equivalent diameter for a constant volumetric flow rate and superficial cross sectional area was dp = 180 µm, for a fiber diameter of df = 26 µm at 10 wt.% zeolite loading. The oxidation catalysts were all supported on SMF and cobalt oxide was used as the active phase. Three different groups of catalysts were developed. The support was modified by coating the fibers either with a thin film of fine powder (alumina or catalyst powder) or with a MFI-type zeolite film identical to the adsorbent. The third group was made from cobalt oxide impregnated directly on the oxidized fibers. The latter type of catalyst was found to be the most active during the screening experiments. The base support composition was varied (stainless steel (SS), FeCrAlloy and inconel) to investigate the support effect on the kinetics. The stainless steel and FeCrAlloy supports had similar activities, surpassing that of the inconel supported catalyst, which might be attributed to a Co3O4 surface enriched with iron from the support. Between the 1.1 wt.%Co3O4/SMFSS and 1.5 wt.%Co3O4/SMFFeCrAlloy catalyst the FeCrAlloy based had the highest normalized activity at low temperature (< 310 °C), low propane mole fraction (0.13 %) and high oxygen mole fraction (16.7 %). The chemical kinetics were determined from a novel and efficient experimental design. The apparent activation energy for this catalyst was found to be 87.5 ± 2.6 kJ/mol, with reaction orders in propane of 0.38 ± 0.04 and in oxygen of 0.30 ± 0.08. The catalysts were tested up to 350 °C. Mass transfer limitations were absent and the kinetics was described well with the power rate law as compared to the Mars-van Krevelen model. Catalysts based on Co3O4, supported directly on oxidized SMF, are very active catalysts, simple to prepare, withstand deactivation due to hot-spot formation and show great potential in comparison to the industrial reference catalyst (copper and manganese oxide supported on alumina). The adiabatic desorption process was investigated by mathematical modeling. Simply purging the adsorption bed with the hot exhaust gas from the reactor cannot result in the concentration of the VOC due to the high heat capacity of the fixed-bed. Hence, it will be necessary to use either a high heat carrier like steam, with the adverse effects of drying and separation of water and VOC, or an approach in which the desorber is heated prior to purging the bed, changing the adsorption equilibrium in favor of high gas concentrations. For the latter method, the minimum theoretical propane mole fraction for an autothermal process was found to be 350 ppmv to sustain a catalytic incinerator at 250 °C. Finally, it can be concluded that for the first time zeolite films on SMF were used as structured adsorbents, leading to very low internal mass transfer and increased process efficiency. Furthermore, the advantages of the SMF can be exploited in a catalytic oxidizer, which can be combined with the adsorber to annihilate VOCs in low concentrations. A novel method for the deposition of fine powder catalyst on SMF was also developed for the first time.

EPFL2007

Influence of the substrate geometrical parameters on microcrystalline silicon growth for thin-film solar cells

Christophe Ballif, Omid Madani Ghahfarokhi, Martin Python

The effect of substrate morphology on the growth and electrical properties of single-junction microcrystalline silicon cells is investigated. A large variety of V-shaped and U-shaped substrates are characterized by scanning electron microscopy (SEM) and the growth of thin-film microcrystalline silicon (mc-Si:H) devices is observed by cross-sectional transmission electron microscopy (TEM). It is shown that enhanced electrical properties of solar cells are obtained when U-shaped substrates are used and the effect is universal, i.e. independent of the substrate or feature size. U-shaped substrates prevent the formation of two dimensional ‘‘cracks’’, which are identified as zones of porous material, from propagating throughout the active part of the solar cell. A numerical growth simulation program reproduces satisfactorily these experimental observations. According to these simulations, shadowing effect due to surface morphology and low adatom surface diffusion length are responsible for the formation of cracks in mc-Si:H material.

2009

Interactive Surfaces Based on Polymer Brushes

Dusko Paripovic

While the bulk structure of a material determines its mechanical properties, its surface plays a key role when interactions with the environment are important. Nowadays materials in bio- and nanotechnology are required to possess very complex functionalities and to interact specifically to the stimuli they receive from their surroundings. Thus, their surface modifications are becoming very demanding. In recent years surface initiated controlled radical polymerization techniques have emerged as very versatile strategies that provide a powerful toolbox to tackle the challenges that are set to material scientists. The attractiveness of these methods lies in the possibility to create well defined surface arrangements of polymer chains, which we refer to as polymer brushes, with precise control over thickness, composition and architecture. In addition, these techniques can be applied to very challenging substrates with respect to the chemical composition and geometry, which also includes porous materials. This Thesis, therefore, exploits the possibilities that surface-initiated controlled radical polymerization techniques offer to finely tune interfacial properties of materials and render them capable to interact with chemical and biological species in a desired way. Its paramount aim is to demonstrate how the functionalities and geometry of a polymer brush matrix can be employed to influence inorganic film deposition using synthetic, biomimetic and purely biological mechanism or enhance polymer brushed stability in aqueous media. This Thesis is divided into five distinct chapters, which will be briefly summarized in following paragraphs. Chapter 1 describes the preparation of polymer brushes and strategies that are used to control their chemical composition and architecture. Additionally, it will give an overview on the use of brushes as cell adhesive surfaces as well as templates for the production of nanoparticles and thin inorganic films. Chapter 2 explores a new strategy to guide the chemical solution deposition of thin, microstructured metal films. The proposed strategy is based on the use of poly(2-(methacryloyloxy)ethyl ammonium chloride) (PMETAC) brushes grown via surface-initiated atom transfer radical polymerization as a template. Thin films are prepared by first loading the PMETAC brushes with an appropriate precursor, followed by its reduction by NaBH4 and finally an oxygen plasma treatment to remove the stabilizing polymer brush matrix and generate the desired thin metallic film. Of particular interest is the question whether the thickness and lateral dimensions of the deposited metallic films can be controlled by micropatterning the polymer brush template and varying the brush thickness. In addition, this concept will be extended to the preparation of bimetallic (gold/palladium) films using a single polymer brush matrix. A similar strategy is explored in Chapter 3 to control the deposition of thin calcium carbonate films using a biomimetic process. The process is characterized by the stabilization of amorphous calcium carbonate, the geometry and localication of which can be controlled by the poly(methacrylic acid) brush template. A special focus of this Chapter is to examine the influence of the polymer brush thickness on the mineral deposition and to determine to which extent is the mineral phase is integrated into the polymer brush film. The aim of Chapter 4 is to develop a general approach for the modification of implantable materials with a polymer brush based coating that promotes bone formation. The proposed coatings are prepared via surface-initiated copolymerization of 2-hydoxyethyl methacrylate and 2-(methacryloyl)ethyl phosphate, which results in a thin hydrogel layer that mimics the negatively charged matrix macromolecules involved in natural bone formation. To further emulate the properties of the natural bone extracellular matrix, the coatings will be functionalized with the cell adhesive GGGRGDS peptide. The ability of the proposed coatings to induce bone formation is investigated in in vitro experiments on MC3T3-E1 pre-osteoblasts and evaluated using an ALP and alizarin red assays. Finally, Chapter 5 focuses on studying the parameters that could prevent the hydrolytic cleavage of Si-O bond, which tethers the polymer brushes grafted from SiOx in aqueous media. In the first part of the study, the length of the organosilane initiator's alkyl spacer will be varied, in order to evaluate to which extent it can insulate the site that anchors the hydrophilic polymer brush to the substrate. In the second part, a short, hydrophobic block will be introduced between the silicon oxide substrate and the hydrophilic polymer in order to more efficiently protect the underlying Si-O bond from the surrounding aqueous media and prevent the chain detachment.