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Project 1 Abstract: Ethylene Oxychlorination
The current two-step process for the industrial process of vinyl chloride production involves CuCl2 catalyzed ethylene oxychlorination to ethylene dichloride followed by thermal cracking of the latter to vinyl chloride. To date, no industrial application of a one-step process is available. To close this gap, this work evaluates a wide range of self-prepared supported CeO2 and EuOCl catalysts for one-step production of vinyl chloride from ethylene in a fixed-bed reactor at 623 773 K and 1 bar using feed ratios of C2H4:HCl:O2:Ar:He = 3:3 6:1.5 6:3:82 89.5. Among all studied systems, CeO2/ZrO2 and CeO2/Zeolite MS show the highest activity but suffer from severe combustion of ethylene, forming COx, while 20 wt.% EuOCl/γ-Al2O3 leads to the best vinyl chloride selectivity of 87% at 15.6% C2H4 conversion with complete suppression of CO2 formation and only 4% selectivity to CO conversion for over 100 h on stream. Characterization by XRD and EDX mapping reveals that much of the Eu is present in non-active phases such as Al2Eu or EuAl4, indicating that alternative synthesis methods could be employed to better utilize the metal. A linear relationship between conversion and metal loading is found for this catalyst, indicating that always part of the used Eu is available as EuOCl, while the rest forms inactive europium aluminate species. Zeolite-supported EuOCl slightly outperforms EuOCl/γ Al2O3 in terms of total yield, but is prone to significant coking and is unstable. Even though a lot of Eu seems locked in inactive species on EuOCl/γ Al2O3, these results indicate possible savings of nearly 16,000 USD per kg of catalyst compared to a bulk EuOCl catalyst. These very promising findings constitute a crucial step for process intensification of polyvinyl chloride production and exploring the potential of supported EuOCl catalysts in industrially-relevant reactions.
Project 2 Abstract: Alkyne Semihydrogenation
Despite strongly suffering from poor noble metal utilization and a highly toxic selectivity modifier (Pb), the archetypal catalyst applied for the three-phase alkyne semihydrogenation, the Pb-doped Pd/CaCO3 (Lindlar catalyst), is still being utilized at industrial level. Inspired by the very recent strategies involving the modification of Pd with p-block elements (i.e., S), this work extrapolates the concept by preparing crystalline metal phosphides with controlled stoichiometry. To develop an affordable and environmentally-friendly alternative to traditional hydrogenation catalysts, nickel, a metal belonging to the same group as Pd and capable of splitting molecular hydrogen has been selected. Herein, a simple two-step synthesis procedure involving nontoxic precursors was used to synthesize bulk nickel phosphides with different stoichiometries (Ni2P, Ni5P4, and Ni12P5) by controlling the P:Ni ratios. To uncover structural and surface features, this catalyst family is characterized with an array of methods including X-ray diffraction (XRD), 31P magic-angle nuclear magnetic resonance (MAS-NMR) spectroscopy, and X-ray photoelectron spectroscopy (XPS). Bulk-sensitive techniques prove the successful preparation of pure phases while XPS analysis unravels the facile passivation occurring at the NixPy surface that persists even after reductive treatment. To assess the characteristic surface fingerprints of these materials, Ar sputtering was carried out at different penetration depths, reveling the presence of Ni+ and P-species. Continuous-flow three-phase hydrogenations of short-chain acetylenic compounds display that the oxidized layer covering the surface is reduced under reaction conditions, as evidenced by the induction period before reaching the steady state performance. To assess the impact of the phosphidation treatment on catalytic performance, the catalysts were benchmarked against a commercial Ni/SiO2-Al2O3 sample. While Ni/SiO2-Al2O3 presents very low selectivity to the alkene (the selectivity is about 10% at full conversion) attributed to the well-known tendency of naked nickel nanoparticles to form hydrides, the performance of nickel phosphides is highly selective and independent of P:Ni ratio. In line with previous findings on PdxS, kinetic tests indicate the occurrence of a dual-site mechanism where the alkyne and hydrogen do not compete for the same site.
This work is the subject of a publication of which I am a co-author, as cited below.
D. Albani; K. Karajovic; B. Tata; Q. Li; S. Mitchell; N. López; J. Pérez-Ramírez. Ensemble Design in Nickel Phosphide Catalysts for Alkyne Semi-Hydrogenation. ChemCatChem 2019. doi.org/10.1002/cctc.201801430
A perovskite oxide material, La0.1Sr0.9Co0.9Fe0.1O3-δ (LSCF1991), was investigated first for high-temperature air separation. The oxygen sorption/desorption behavior of LSCF1991 was studied by thermogravimetric analysis (TGA) and fixed-bed breakthrough experiments. A parametric study was performed to design and optimize the operating parameters of the high-temperature air separation process by pressure swing adsorption (PSA). The results have shown great potential for applying LSCF1991 to the high-temperature air separation due to its excellent separation performance and low energy requirement.
Research on using nanostructured zeolite NaX (NZ) as adsorbents for CO2 capture was subsequently conducted. The CO2/N2 adsorption characterizations indicated that the NZ samples lead to enhanced adsorption properties compared with the commercial zeolites (MZ). From the two-bed six-step PSA simulation, NZ saved around 30% energy over MZ for CO2 capture and recovery while achieving a higher CO2 purity and productivity.
A unique screening method was developed for efficient evaluation of adsorbents for PSA processes. In the case study, 47 novel adsorbents have been screened for coal bed methane (CBM) recovery. The adsorbents went through scoring-based prescreening, PSA simulation, and optimization. The process performance indicators were correlated with the adsorption selectivity and capacities, which provides new insights for predicting the PSA performance.
A new medium-temperature oxygen sorbent, YBaCo4O7+δ (YBC114), was investigated as an oxygen pumping material to facilitate solar thermochemical fuel production. The oxygen uptake and release attributes of YBC114 were studied by both TGA and a small-scale evacuation test. The study proved that the particle size has a significant effect on the oxygen pumping behavior of YBC114, especially for the uptake kinetics.
The first part of this thesis focuses on the synthesis of ZnO nanowires. Uniform ZnO nanowires with ~30 nm in width are produced at 1100℃ in a tube furnace with flowing gases (N2: 500 sccm; O2: 15 sccm). The temperature control is one of the most important parameters for making thin and ultra-long ZnO nanowires.
The second part of the thesis is about the synthesis of nanocarbons. Ultrapure ethanol is used as the carbon source to make carbonaceous deposition on ZnO nanowires. The thickness of the nanocarbons can be controlled by reaction temperature and reaction time. When the reaction time was controlled around 1h, the carbonaceous materials coating the ZnO nanowires become very thin. Then by flowing (1000 sccm) hydrogen at 750℃ through the reaction tube the ZnO nanowires are removed due to reduction and evaporation. Electrochemical evaluation of the produced nanocarbons shows that the nanocarbons possess very high specific surface area (>1400 m2/g) and a capacitance as high as 180 F/g at 10A/g in 6M KOH).
The third part of the thesis is the treatment of the as-synthesized nanocarbons to further increase capacitance. NH3 was used as the nitrogen source to react with nanocarbons at 700℃ to incorporate nitrogen group. Nitric acid (HNO3) is used as the oxidant to introduce oxygen groups. After proper nitrogen doping, the nitrogen doped nanocarbons can show high specific capacitance of 260 F/g at 1A/g in 6M KOH. After further oxidation treatment, the capacitance of the oxidized N-doped nanocarbons increased to 320 F/g at 1A/g in 6M KOH.
Bio-modification of asphalt binder brings significant benefits in terms of increasing sustainable and environmental practices, stabilizing prices, and decreasing costs. However, bio-modified asphalt binders have shown varying performance regarding susceptibility to moisture damage; some bio-oil modifiers significantly increase asphalt binder's susceptibility to moisture damage. This variability in performance is largely due to the large number of bio-masses available for use as sources of bio-oil, as well as the type of processing procedure followed in converting the bio-mass into a bio-oil for modifying asphalt binder. Therefore, there is a need for a method of properly evaluating the potential impact of a bio-oil modifier for asphalt binder on the overall performance of asphalt pavement, in order to properly distinguish whether a particular bio-oil modifier increases or decreases the moisture susceptibility of asphalt binder. Therefore, the goal of this study is a multi-scale investigation of bio-oils with known chemical compositions to determine if there is a correlation between a fundamental property of a bio-oil and the resulting increase or decrease in moisture susceptibility of a binder when it is modified with the bio-oil. For instance, it was found that polarizability of asphalt constituents can be a promising indicator of moisture susceptibility of bitumen. This study will also evaluate the linkage of the fundamental property to newly developed binder-level test methods. It was found that moisture-induced shear thinning of bitumen containing glass beads can differentiate moisture susceptible bitumen samples. Based on the knowledge determined, alternative methods of reducing the moisture susceptibility of asphalt pavement will also be evaluated. It was shown that accumulation of acidic compounds at the interface of bitumen and aggregate could promote moisture damage. It was further found that detracting acidic compounds from the interface could be done by either of neutralizing active site of stone aggregate to reduce affinity for acids or by arresting acidic compounds using active mineral filler. The study results showed there is a strong relation between composition of bitumen and its susceptibility to moisture. This in turn emphasize the importance of integrating knowledge of surface chemistry and bitumen composition into the pavement design and evaluation.
Oxygen sorption/desorption properties of perovskite oxides with and without oxygen vacancy were investigated first by thermogravimetric analysis (TGA) and fixed-bed experiments. The oxide with unique disorder-order phase transition during desorption exhibited an enhanced oxygen desorption rate during the TGA measurement but not in fixed-bed demonstrations. The difference in oxygen desorption rate is due to much higher oxygen partial pressure surrounding the sorbent during the fixed-bed oxygen desorption process, as revealed by X-ray diffraction (XRD) patterns of rapidly quenched samples.
Research on using perovskite oxides as CO2-permeable dual-phase membranes was subsequently conducted. Two CO2-resistant MIEC perovskite ceramics, Pr0.6Sr0.4Co0.2Fe0.8 O3-δ (PSCF) and SrFe0.9Ta0.1O3-δ (SFT) were chosen as support materials for membrane synthesis. PSCF-molten carbonate (MC) and SFT-MC membranes were prepared for CO2-O2 counter-permeation. The geometric factors for the carbonate phase and ceramic phase were used to calculate the effective carbonate and oxygen ionic conductivity in the carbonate and ceramic phase. When tested in CO2-O2 counter-permeation set-up, CO2 flux showed negligible change, but O2 flux decreased by 10-32% compared with single-component permeation. With CO2 counter-permeation, the total oxygen permeation flux is higher than that without counter-permeation.
A new concept of CO2-permselective membrane reactor for hydrogen production via steam reforming of methane (SRM) was demonstrated. The results of SRM in the membrane reactor confirm that in-situ CO2 removal effectively promotes water-gas shift conversion and thus enhances hydrogen yield. A modeling study was also conducted to assess the performance of the membrane reactor in high-pressure feed/vacuum sweep conditions, which were not carried out due to limitations in current membrane testing set-up. When 5 atm feed pressure and 10-3 atm sweep pressure were applied, the membrane reactor can produce over 99% hydrogen stream in simulation.