Advanced Nanopowder Synthesis

Frank Pilger
EPFL, 2017
Thèse EPFL

Résumé

CeO2-based nanomaterials and their rich redox chemistry provide a possible route to pollutant abatement in various heterogeneous processes, and are in particular used as sorbents for flue gases and as oxygen promoters in three-way catalytic converters. The use of CeO2-based materials as an active compound participating in catalytic processes is associated to its function as an oxygen buffer, a key property of many materials central to a variety of economically and environmentally important technologies, such as automotive pollution control. In fact, due to the rapid interconversion between the Ce3+ and Ce4+ states, oxygen vacancies and highly mobile O2â ions, CeO2 shows a superior oxygen storage capacity - a property which can be further tuned and optimized by synthesis methods and the addition of further compounds. Noble metal catalysts supported on CeO2-based materials are key components for these applications and makes the search for a material with an optimal oxygen storage capacity an important task. This thesis deals with the synthesis and characterization of CeO2-based materials, and the investigation of structure-performance relationships for catalytic applications. The one-pot polyol synthesis is introduced for the preparation of nanosized M/CeO2 (M = Pt or Au) CO oxidation catalysts, for which the parameters for single-batch syntheses were defined. A further investigation of the reaction products led to the remarkable formulation of the incorporation-segregation mechanism: Pt is at first ionically dispersed in the support lattice (incorporation, Pt:CeO2) and then exsolutes in strongly anchored subnanometric entities (segregation, Pt/CeO2), whose size can be controlled by this approach depending on the thermal treatment and atmosphere. Secondly, an in-depth investigation of this segregation process and its kinetics with ex- and in-situ/operando characterization techniques employing synchrotron-based diffraction and X-ray absorption spectroscopy were carried out by observing the growth of the Pt entities, the change of oxidation states and the interaction with a provided gas composition. In addition, the synthesis methodology was extended to other material systems, which led to ionically dispersed Pt on ceria-zirconia (M:CeO2-ZrO2) in a broad compositional range and an investigation of the thermal behaviour and interplay between Pt and the CeO2-ZrO2 support composition was carried out. Growth inhibition of the support crystallites was observed upon Pt-doping, because of a pinning effect of Pt2+/4+ ions. A compromise between Zr (thermal stability) content and Pt load (active sites) needs to be found and correlated with the final catalytic performance, since the incorporation of Zr and Pt-doping have an effect on the stability range of the cubic CeO2-ZrO2 phases and on the solubility limit of ionic Pt. To conclude the studies on polyol syntheses of CeO2-based materials, the amount of the products was successfully increased by carrying out the process in a continuous manner ("outscaling") with the Segmented Flow Tubular Reactor. Finally, CeO2-based materials were prepared via hydrothermal synthesis in an increased volume in autoclave reactors ("upscaling") to obtain preferably rod-like particles for sorption applications. Overall, this thesis presents a number of novel findings, such as new synthesis approaches allowing for materials engineering, characterization methods and properties of CeO2-based materials themselves.

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https://infoscience.epfl.ch/record/230443?ln=fr

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Frank Pilger
EPFL, 2017
Thèse EPFL

Résumé

Official source

https://infoscience.epfl.ch/record/230443?ln=fr

À propos de ce résultat

Concepts associés (17)

Concepts associés

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Publications associées (80)

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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

Chargement

Fuel Cells are electrochemical devices that are able to directly convert chemical energy to electrical energy, without any Carnot limitation. Hence, their energy efficiencies are relatively high. Among the various types of fuel cells, solid oxide fuel cells (SOFC) are operated at high temperatures and in principle can run on various fuels such as natural gas and hydrogen. As natural gas is sought to become one of the main fuels of the next decades, its direct feed to a SOFC is desirable as the reaction free energy is high CH4 + 2O2 = CO2 + 2H2O, ΔrG°800°C = -800.8kJ/mol At present, conventional SOFC are operated with pure hydrogen or partially to fully reformed natural gas implying an efficiency penalty. SOFC anodes are generally made of electrocatalytically active Ni-YSZ cermet. Pure CH4 is not fed directly to the anode, because of problems associated with the anode deactivation and coking as CH4 leads to the detachment of Ni particles from the YSZ support and their encapsulation by carbon. To overcome this problem, partially oxidized or reformed CH4 is used. For SOFCs running on direct CH4 feed, alternative anode materials to Ni-YSZ, or new anode formulations are necessary. However, in this case, several parameters influence the anode performance and stability. The anodes should withstand reduction at a low PO2 of around 10-24 atm, be compatible with the SOFC electrolyte, possess an acceptable conductivity and thermal expansion coefficient, and appropriate catalytic and electrocatalytic properties along with low coking activity. LaCrO3 and CeO2-based materials as well as some metal catalysts were studied here for their potential application as anodes in direct oxidation of CH4. This choice of materials was made as lanthanum chromite and ceria-based materials are mixed conductors known to resist quite well to the very reducing conditions in SOFC as they are commonly used for interconnect and electrolyte materials respectively. Moreover, these compounds possess some catalytic activity for CH4 activation and combustion. LaCrO3 and CeO2-based materials show rather low electrical conductivity (on the order of 1 S/cm in reducing conditions), necessitating the application of an extra material for proper current collection. Nevertheless, these oxides possess many of the stringent characteristics cited above. For SOFC anode purposes, LaCrO3-based compounds, substituted with Ca, Sr, Mg, Mn, Fe, Co and Ni, were synthesized by a modified citrate route from nitrate precursors. An optimal calcination temperature of 1100°C was found to be necessary to obtain XRD-pure yet sinteractive compounds. Conductivity measurements in air and in reducing atmospheres of 10-21 atm showed that the La A-site substituents (Ca and Sr) influenced the conductivity more than the Cr B-site substituents (Mg, Mn, Fe, Co and Ni). In humidifed H2, the total conductivity was maximally of 6.5 S/cm. Surface reaction with YSZ electrolyte was evidenced by SEM, XPS and SIMS, in reducing conditions, especially under current load, when these powders were applied as anodes. A current induced demixing effect was noted for heavily substituted LaCrO3. Ceria-based compounds, doped with Y, Nb, Pr and Gd, were synthesized through 3 different techniques: the solid-state method, coprecipitation and the NbCl5 route. The coprecipitation route was found to be most appropriate for Y, Pr and Gd, whereas for Nb a modified precipitation and the NbCl5 technique were the most efficient. Co-doping of Nb and Gd or Pr was studied in order to increase the electronic as well as the ionic conductivity in CeO2. Among all dopants, Nb was found to promote most the adhesion to YSZ electrolyte sheets. Adding Nb to Gd-doped ceria improved the electrode adhesion on YSZ sheets, but deteriorated its conductivity in oxidizing conditions. No interfacial reaction with YSZ was observed by HRTEM when Nb-doped ceria anodes were sintered on YSZ at 1200°C/4h. Catalytic measurements were undertaken with these materials in CH4 rich atmospheres. Different reaction mixtures were chosen to simulate the various SOFC operating conditions: partial oxidation, CO2 reforming by recycling and H2O reforming. Among the different elements, Sr and Ni were found to be the most active substituents for LaCrO3, as they promote all three types of reactions. The combination of both elements is favorable not only for catalytic use, but also for electrode application as they tend to increase the electronic conductivity of the material. Temperature programmed oxidation (TPO) and TEM made on the catalysts after runs in CH4, showed a very low carbon coverage over these oxides, except in the case of Fe substitution, over which carbon deposition was promoted. XPS analysis showed also that all B-site substituted compounds did not segregate after the catalytic runs whereas Ca and Sr (A-site substituents) tended to segregate in H2 and H2O rich atmospheres. Thermodynamic calculations, made using correlations developed in literature, show that Ca and Sr are expected to segregate in H2 and H2O rich atmospheres as they tend to form volatile hydroxyl species. Also, the thermodynamic stability of the LaCrO3 was observed to depend much on the substitution. For CeO2-based oxides, the activity for steam reforming increased from Nb

EPFL2002

Chargement

Nanofibres de carbone sur filtre métallique comme support catalytique structuré

Pascal Tribolet

The main objectives of this work are 2-fold : The development of a novel type of composite material based on carbon nanofibers supported on sintered metal fibers filters (CNF/SMF) and to explore the use of this material as a catalytic support for a model reaction: selective hydrogenation of acetylene. The advantages of this novel support are: Due to carbon nanofibers, it combines a graphitic structure with a high specific surface area without microporosity. Supported carbon nanofibers can be used in a fixed bed reactor without very high pressure drop. Combination of two materials with high thermal conductivity gives a composite which keeps this property. It is suitable for highly exo/endothermic reactions, diminishing temperature gradients in the catalytic bed. The synthesis of carbon nanofibers on SMF filters was carried out by ethane catalytic decomposition at 655°C directly on metallic filters. An oxidation of SMF followed by a reduction in H2 create surface roughness, leading to a larger area for CNF nucleation. The CNF formation mechanism includes several steps: it starts with carbon deposition on metallic surface followed by its diffusion into the metal leading to carbides formation. When the limit of carbon solubility is attained, a layer of carbon is formed on the surface of metallic fibers. High tension within the bulk metal leads to carbide dissociation and by phase separation to graphite formation, which pushes the metallic particles through the carbon layer. Nickel, stainless steel an Inconel (an alloy of mainly nickel, iron and chromium) filters were used. The latter gave the highest uniformity of the carbon nanofibers layer showing an excellent mechanical stability. In order to control carbon deposition on the filters, a formal kinetic analysis of the decomposition reaction was undertaken. Partial orders of 1 for ethane, -2 for hydrogen and an apparent activation energy of 235 kJ/mol were obtained. The observed kinetics suggests strongly that the C – C bond scission is the rate determining step and not carbon diffusion into the metal which is often reported in the literature. The synthesis procedures like time on stream and reaction temperature were optimized: 1 hour of a mixture C2H6:H2:Ar (3:17:80) decomposition over SMFInconel at 655°C lead to ∼6% of carbon, leading to a CNF layer of 1 µm thickness covering the metallic fibers entirely. This material presents a high specific surface area (22.2 m2/g) and a low pressure drop for the gas flowing through. The carbon nanofibers have a diameter between 20 and 50 nm and a crystalline structure with platelets morphology where the graphene layers are stacked one above the other. Their surface is composed almost exclusively of carbon and hydrogen. Amongst the multiple possible applications of this novel composite material, its use as a catalyst support was assessed. Selective hydrogenation of acetylene was carried out over palladium supported on CNF/SMF and compared with commercial supports (ACF, EGF and AGF). The activated carbon fibers cloth (ACF) led to a Pd activity at least twice as E-type glass fibers tissue (EGF) or EGF covered by an alumina layer (AGF). Reaction kinetics was studied for Pd/ACF, leading to acetylene and hydrogen partial orders of -0.5 and 2.4, respectively and apparent activation energy of 50 kJ/mol. The negative partial order for C2H2 suggests high adsorption strength of this compound compared to other reagents on palladium. This particularity allows Pd to be selective. Hydrogenations are known to be structure sensitive. Therefore the catalyst activity for the model reaction depends on Pd particle size. It increases for large particle sizes. The control of this parameter was a priority. Variations of the palladium precursor, of the support and catalyst treatment were carried out. Micro-wave plasma was used since it is fast and has low energy consumption allowing chemically modifying the carbon support surface and activating catalyst after impregnation. This controls not only palladium sintering, but also decomposes tetraaminopalladate more efficiently, resulting in a catalyst activity of one order of magnitude higher. In order to control the palladium deposition on CNF/SMFInconel composite, it is important to have surface functional groups. The activation of carbon nanofibers was carried out with a 4 hours treatment in a boiling aqueous solution of hydrogen peroxide. This led to an amount on surface oxygen containing groups, per mass of carbon, higher than in ACF. Palladium particle size on the composite was controlled by support activation, the use of several metal precursors or different loadings or by a thermal treatment in argon at 500°C. Optimisation of the procedure allowed to obtain in a controlled way an average palladium particle sizes between 3.6 and 25 nm. The activity and selectivity towards ethylene of Pd/CNF/SMFInconel were observed to be higher compared to palladium supported on activated carbon, alumina or barite. Graphitic nature of carbon nanofibers, leading to strong metal-support interaction, was accounted as responsible for these improvements. The high thermal conductivity of the composite CNF/SMF ensured good heat transfer released due to the exothermicity of the reaction and allowed to work close to isothermal conditions in the catalytic bed. Finally it can be concluded, that for the first time carbon nanofibers synthesis was carried out in one step on sintered metal fibers filters, resulting in a novel structured composite material combining different specific properties and having promising potential applications.

EPFL2006

Chargement

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

Marina Ruta

EPFL2008

Nanofibres de carbone sur filtre métallique comme support catalytique structuré

Pascal Tribolet

EPFL2006

EPFL2002