Improving Heterogeneous Catalyst Stability for Liquid-phase Biomass Conversion and Reforming

Biomass is a possible renewable alternative to fossil carbon sources. Today, many bio-resources can be converted to direct substitutes or suitable alternatives to fossil-based fuels and chemicals. However, catalyst deactivation under the harsh, often liquid-phase reaction conditions required for biomass treatment is a major obstacle to developing processes that can compete with the petrochemical industry. This review presents recently developed strategies to limit reversible and irreversible catalyst deactivation such as metal sintering and leaching, metal poisoning and support collapse. Methods aiming to increase catalyst lifetime include passivation of low-stability atoms by overcoating, creation of microenvironments hostile to poisons, improvement of metal stability, or reduction of deactivation by process engineering.

CO Methanation for Synthetic Natural Gas Production

Tilman J. Schildhauer

Energy from woody biomass could supplement renewable energy production towards the replacement of fossil fuels. A multi-stage process involving gasification of wood and then catalytic transformation of the producer gas to synthetic natural gas (SNG) represents progress in this direction. SNG can be transported and distributed through the existing pipeline grid, which is advantageous from an economical point of view. Therefore, CO methanation is attracting a great deal of attention and much research effort is focusing on the understanding of the process steps and its further development. This short review summarizes recent efforts at Paul Scherrer Institute on the understanding of the reaction mechanism, the catalyst deactivation, and the development of catalytic materials with benign properties for CO nnethanation.

Swiss Chemical Soc2015

Engineering the ZrO2–Pd Interface for Selective CO2 Hydrogenation by Overcoating an Atomically Dispersed Pd Precatalyst

Alimohammad Bahmanpour, Yuan-Peng Du, Florent Emmanuel Héroguel, Oliver Kröcher, Jeremy Luterbacher, Mounir Driss Mensi, Luka Milosevic

Tailoring the interfacial sites between metals and metal oxides can be an essential tool in designing heterogeneous catalysts. These interfacial sites play a vital role in many renewable applications, for instance, catalytic CO2 reduction. Postsynthesis deposition of metal oxide on supported metal catalysts can not only create such interfacial sites but also prevent particle sintering at high temperature. Here, we report a sol–gel-based strategy to synthesize an atomically dispersed “precatalyst”. In contrast to the deposition on catalysts containing preformed nanoparticles, overcoating this material before reductive treatment can inhibit particle growth during thermal activation steps, yielding highly accessible, sintering-resistant Pd clusters that are less than 2 nm in diameter. This synthetic approach allows us to engineer interfacial sites while maintaining high metal accessibility, which was difficult to achieve in previous overcoated materials. Notably, engineering the Pd–ZrO2 interface into an inverted interface with an amorphous ZrO2 overcoat might facilitate a C–O cleavage route instead of a mechanism containing a bicarbonate intermediate during CO2 hydrogenation. We also observed that carbon deposition occurring on methanation sites could be a key factor for improving CO selectivity. Alteration of the reaction pathway, along with the deactivation of certain sites, led to 100% CO selectivity on the ZrO2@Pd/ZrO2 catalyst. This work demonstrated that overcoated materials could represent a promising class of heterogeneous catalysts for selective CO2 conversion over noble metals, which have higher rates and thermal stability compared to state-of-the-art Cu-based catalysts.

2020

Techno-economic analysis and life cycle assessment of a biorefinery utilizing reductive catalytic fractionation

Jeremy Luterbacher

Reductive catalytic fractionation (RCF) is a promising approach to fractionate lignocellulose and convert lignin to a narrow product slate. To guide research towards commercialization, cost and sustainability must be considered. Here we report a techno-economic analysis (TEA), life cycle assessment (LCA), and air emission analysis of the RCF process, wherein biomass carbohydrates are converted to ethanol and the RCF oil is the lignin-derived product. The base-case process, using a feedstock supply of 2000 dry metric tons per day, methanol as a solvent, and H-2 gas as a hydrogen source, predicts a minimum selling price (MSP) of crude RCF oil of

1.13 per kg when ethanol is sold at

2.50 per gallon of gasoline-equivalent (

0.66 per liter of gasoline-equivalent). We estimate that the RCF process accounts for 57% of biorefinery installed capital costs, 77% of positive life cycle global warming potential (GWP) (excluding carbon uptake), and 43% of positive cumulative energy demand (CED). Of

563.7 MM total installed capital costs, the RCF area accounts for $323.5 MM, driven by high-pressure reactors. Solvent recycle and water removal via distillation incur a process heat demand equivalent to 73% of the biomass energy content, and accounts for 35% of total operating costs. In contrast, H-2 cost and catalyst recycle are relatively minor contributors to operating costs and environmental impacts. In the carbohydrate-rich pulps, polysaccharide retention is predicted not to substantially affect the RCF oil MSP. Analysis of cases using different solvents and hemicellulose as an in situ hydrogen donor reveals that reducing reactor pressure and the use of low vapor pressure solvents could reduce both capital costs and environmental impacts. Processes that reduce the energy demand for solvent separation also improve GWP, CED, and air emissions. Additionally, despite requiring natural gas imports, converting lignin as a biorefinery co-product could significantly reduce non-greenhouse gas air emissions compared to burning lignin. Overall, this study suggests that research should prioritize ways to lower RCF operating pressure to reduce capital expenses associated with high-pressure reactors, minimize solvent loading to reduce reactor size and energy required for solvent recovery, implement condensed-phase separations for solvent recovery, and utilize the entirety of RCF oil to maximize value-added product revenues.

ROYAL SOC CHEMISTRY2021

Techno-economic analysis and life cycle assessment of a biorefinery utilizing reductive catalytic fractionation

Jeremy Luterbacher

1.13 per kg when ethanol is sold at

2.50 per gallon of gasoline-equivalent (

0.66 per liter of gasoline-equivalent). We estimate that the RCF process accounts for 57% of biorefinery installed capital costs, 77% of positive life cycle global warming potential (GWP) (excluding carbon uptake), and 43% of positive cumulative energy demand (CED). Of

ROYAL SOC CHEMISTRY2021