Structure Sensitivity of Alkynol Hydrogenation on Shape- and Size-Controlled Palladium Nanocrystals: Which Sites Are Most Active and Selective?

The activity and selectivity of structure-sensitive reactions are strongly correlated with the shape and size of the nanocrystals present in a catalyst. This correlation can be exploited for rational catalyst design, especially if each type of surface atom displays a different behavior, to attain the highest activity and selectivity. In this work, uniform Pd nanocrystals with cubic (in two different sizes), octahedral, and cuboctahedral shapes were synthesized through a solution-phase method with poly(vinyl pyrrolidone) (PVP) serving as a stabilizer and then tested in the hydrogenation of 2-methyl-3-butyn-2-ol (MBY). The observed activity and selectivity suggested that two types of active sites were involved in the catalysis those on the planes and at edges which differ in their coordination numbers. Specifically, semihydrogenation of MBY to 2-methyl-3-buten-2-ol (MBE) occurred preferentially at the plane sites regardless of their crystallographic orientation, Pd-(111) and/or Pd-(100), whereas overhydrogenation occurred mainly at the edge sites. The experimental data can be fit with a kinetic modeling based on a two-site Langmuir Hinshelwood mechanism. By considering surface statistics for nanocrystals with different shapes and sizes, the optimal catalyst in terms of productivity of the target product MBE was predicted to be cubes of roughly 3-5 nm in edge length. This study is an attempt to close the material and pressure gaps between model single-crystal surfaces tested under ultra-high-vacuum conditions and real catalytic systems, providing a powerful tool for rational catalyst design.

Novel catalytic applications of carbon nanofibers on sintered metal fibers filters as structured supports

Marina Ruta

Supported metal catalysts are important from both an industrial and a scientific point of view. They are used, amongst others, in large-scale processes such as catalytic reforming, hydrotreating, polymerization reactions and hydrogenations. Often, these catalysts consist of nanosized metal particles deposited on a suitable support, which acts as an anchor for the active phase and, in several cases, contributes to improve the overall catalyst performances. The growth of carbon nanofibers on sintered metal fibers filters (CNF/SMF) by hydrocarbons catalytic decomposition results in a structured composite material presenting all the suitable characteristics for its application as catalyst support. The main objective of this thesis was to develop novel catalytic systems based on CNF/SMF as catalytic support for continuous gas-phase hydrogenations. At first, the synthesis of CNF/SMF was optimized to tailor the properties of the material for further applications as catalytic support. The use of ethylene as carbon precursor and high synthesis temperature (973K) provided high yields of well-ordered CNF with increased specific surface area (SSA), up to 516 m2/g. On the other hand, the synthesis of CNF by ethane decomposition, which is less reactive than ethylene, resulted in a support with higher permeability, minimizing the pressure drop and being more suitable in a continuous-flow reactor. After the synthesis, the CNF surface was activated by treatment with O3 or H2O2. A novel technique, which consist of XPS analysis after step-wise TPD in UHV conditions, was developed and applied for the surface characterization. It allowed to assess the nature of the functional groups created on the CNF surface. The O3-activation was found the most effective for increasing the acidity of the CNF/SMF surface, yielding a relatively high amount of carboxylic functional groups. These groups are important because involved in the chemical anchoring and stabilization of the active metal deposited on the support. Industrially, many hydrogenations are performed over supported metal catalyst. The majority of these reactions are known to be structure sensitive reactions, so the control of the metal particle size is crucial in order to study the catalyst activity and selectivity. We prepared monodisperse-sized Pd nanoparticles (8, 11 and 13 nm) via the reverse microemulsion method and deposited on CNF/SMF and activated-CNF/SMF for a two-fold study: the effect of the nanoparticles size and the effect of the support nature on the selective hydrogenation of acetylene. The antipathetic size dependence of the TOF disappeared at particle size bigger than 11 nm. The initial selectivity to ethylene (∼60%) was found size-independent. The structure-sensitivity relations have been discussed in terms of "geometric" and "electronic" nature of the size-effect and rationalized assuming a Pd-Cx phase formation which is known to be size-dependent. CNF/SMF supports with increased acidity diminished the formation of coke and changed the by-products distribution, diminishing the catalyst deactivation. Subsequently, CNF/SMF was applied to develop a new catalytic system: the Structured Supported Ionic Liquid Phase (SSILP) catalyst, embedding an active Rh complex. The selective gas-phase hydrogenation of 1,3-cyclohexadiene to cyclohexene was used as model reaction. The SSILP based on CNF/SMF supports showed a high turnover frequency, up to 250 h-1 and selectivity > 96%. Multiple advantages of supporting a homogeneous active phase, dissolved in IL, on CNF/SMF have been demonstrated: the thin layer of IL was homogeneously distributed over the mesoporous support, so mass transfer limitations could be avoided, furthermore the chemical inertness of the CNF prevented any interaction between the active phase dissolved in IL ensuring an efficient use of the Rh complex. The SSILP concept can be applied not only for the "heterogenization" of a transition metal catalyst, but also to obtain metal nanoparticles with monodispersed size via the reduction of a metal precursor dissolved in IL. In this case, IL provides a suitable environment for the nucleation and growth of the nanoparticles. By applying the SSILP concept to the selective hydrogenation of acetylene, the influence of IL on the stability of the nanoparticles was investigated. Moreover, the different solubilities of reactants and products in the IL phase allowed to improve the selectivity toward ethylene. Monodispersed Pd nanoparticles of 5 and 10 nm in SILP on CNF/SMF showed excellent long-term stability. The lower solubility of ethylene than acetylene in the IL had the beneficial effect of allowing high selectivity to ethylene up to 85%, due to the inhibition of its consecutive hydrogenation to ethane. In conclusion, a novel catalytic system for continuous-flow, gas-phase hydrogenations was conceived, taking advantage of the suitable characteristics of CNF/SMF supports. The SSILP concept, involving both homogeneous and heterogeneous active phases has been demonstrated, indicating a great potential and flexibility for continuous-flow industrial applications.

EPFL2008

Highly selective immobilized bimetallic Ni-Au nanoparticle catalyst for the partial hydrogenation of m-dinitrobenzene

Oliver Anthony Beswick, Fernando Cardenas Lizana, Paul Joseph Dyson, Lioubov Kiwi, Daniel André Samuel Lamey

Transition metal nanoparticles (NPs) are extensively used as catalysts for a wide and diverse range of organic transformations when immobilized on appropriate solid supports. We describe the development of a highly active and highly selective heterogeneous catalyst based on Ni-Au NPs supported on activated carbon fibers (ACFs) for the partial reduction of m-dinitrobenzene (m-DNB) to m-nitroaniline (m-NAN), an important platform chemical used in the synthesis of dyes and polymers. Initially, Ni NPs with narrow size distribution and ranging from 2 to 14 nm were prepared with poly-N-vinyl-2-pyrrolidone (PVP) as a stabilizer. Evaluation of the NPs as catalysts in the liquid-phase hydrogenation of m-dinitrobenzene led to the establishment of an antipathetic structure sensitivity, i.e. the larger NPs displayed a 6-fold higher turnover frequency than the smaller NPs. The selectivity to the target m-NAN product is independent of the size of the Ni NPs, possibly due to preferential PVP absorption of the NP edges and vertices. Consequently, Ni NPs of 2 nm were supported on ACFs and residual PVP was removed by a ultra-violet ozone (UVO) treatment, rendering a highly selective structured catalyst that affords m-NAN in almost 96% yield. A two-site (plane vs. edge Ni-atoms) Langmuir-Hinshelwood kinetic model is consistent with the experimental kinetic data confirming that low-coordination atoms (edges and vertices) are responsible for selective reaction. Consequently, we prepared bimetallic Ni-Au NPs (Ni:Au = 1:1) aiming to generate Ni surface sites mimicking the properties of edge and vertex atoms. The resulting UVO-treated Ni-Au NPs of 3 nm immobilized on ACFs afford m-NAN with a yield exceeding 98%. Such a high yield appears to be unprecedented and shows how careful nanocatalyst design, guided by detailed structural characterization and mechanistic studied, can lead to highly selective catalysts of industrial relevance.

Elsevier Science Bv2017

Développement de réacteurs microstructurés pour la conversion du propane en produits valorisés

Olivier Wolfrath

Industry requires continuously new chemical processes to convert raw materials to valuable products limiting the formation of by-products. Since a few years, an increasing interest has been given to the intensification of chemical processes. This represents a new approach in chemical reaction engineering and calls for a new type of chemical reactors: the microstructured reactors. They are characterized by miniature structures whose components have a sub-millimeter size. The flow channels, for example, have a diameter from ten to several hundred microns. The distinctive feature of these structures is a very large surface/volume ratio, namely between 10'000 and 50'000 m2/m3. In these conditions, heat transfer coefficient is very high, up to 25 kW · m-2 · K-1. It is accepted that the residence time distribution in a reactor strongly influences the product selectivity and yield. In these thin channels, the RTD is particularly narrow due to a short radial diffusion time (ms), allowing a precise control of the residence time. Another advantage of these microstructures is an increase of the inherent safety due to a small amount of the compounds used. However, fabrication of microreactors, especially the introduction of active catalyst in microchannels remains a difficult operation. And integration of microsystems in conventional chemical processes is still a challenge. The aim of this work is first to develop a novel membrane reactor based on a new microstructured catalytic packing in the filamentous form and to apply it to the nonoxydative dehydrogenation of propane. A second objective is to develop a reactor with micro heat exchangers allowing an optimized control of homogeneous reactions. This reactor was tested with the partial oxidation of propene to propylene oxide. The microstructured catalyst above is made of thin and long catalytic filaments placed in parallel with a tubular reactor. This new kind of catalyst is based on silica fibres covered by a γ-alumina layer. The position in parallel of these filaments of 7 μm diameter forces the gases to flow in the fibres direction between the filaments. The hydraulic diameter is about 70 μm. Due to this laminar and regular flow, the pressure drop in the bed was divided by 5 compared to a conventional bed (100-160 μm spheres) and the residence time distribution was particularly narrower. Such novel packing brings new opportunities to the heterogeneous catalysis domain because it can be used for many other reactions improving highly the hydrodynamics and keeping an excellent contact with the reactants. The microstructured catalyst was installed in two concentric zones of a tubular reactor separated by a palladium-silver membrane permeable to hydrogen. This product was removed from the gas phase to shift the thermodynamic equilibrium, enhancing the propane conversion from 22% up to 30%. Another significant advantage in this reactor is the increase of propene selectivity up to 97% in comparison to conventional industrial processes reaching 80-90%. This difference is due to the diminution of hydrogenolysis and hydroisomerization reactions. The dehydrogenation is known to be endothermic. Oxidation of the hydrogen passing through the membrane produced heat for this reaction along the catalytic zone. Moreover, a periodic regeneration by air allowed recovering the activity of the catalyst deactivated by coke formed during dehydrogenation. Periodic reaction operations allowed producing continuously propene with a high selectivity, and regenerating simultaneously the catalyst. The second microstructured reactor was developed integrating two micro heat exchangers at the inlet and outlet of a macroscopic tube. The aim is to heat up very fast the gas and to cool it down as well. Without these exchangers, heating and cooling duration corresponded each to about 20% of the total residence time. The use of the microstructures allowed diminishing significantly these durations (4-5% each). Applied to partial oxidation of propene, this reactor reached a more precise control of reaction temperature and duration. The propylene oxide (PO) selectivity was not increased with this system but, due to the microstructures, it was possible to work at higher temperatures where the reaction becomes very fast, without reaching an oxygen conversion of 100%. Indeed, it is essential to avoid this situation where oligomers and coke form dividing by 2 the PO selectivity. So another new kind of reactor was developed suitable for any fast exothermic reaction whose progression has to be limited because of potential consecutive reactions reducing, for example, the selectivity of an intermediate desired compound.

EPFL2001