Catalytic wet peroxide oxidation over mixed (Al–Fe) pillared clays

Mixed (Al–Fe) pillared clays are very efficient solid catalysts for oxidation of organic compounds in water by hydrogen peroxide. We have shown that in rather mild experimental conditions (atmospheric pressure, T≤70°C) and with a low excess (20%) of hydrogen peroxide, phenol was rapidly converted, mainly to CO₂, without significant catalyst leaching. The (Al–Fe) pillared clay catalyst (called FAZA) can be used several times without any change of its catalytic properties. According to the low leaching observed and a previous Mössbauer spectroscopy study, the iron species appear to be strongly bonded to the aluminium pillars.     

Intermetallic powders of Ni–Al, Cu–Al and Cr–Al systems obtained by the self-disintegration method

The intermetallic compounds of the Ni–Al, Cu–Al and Cr–Al systems are characterised by the profitable set of mechanical and physical properties, such as good abrasion resistance, high temperature oxidation and sulfur corrosion resistance.

Alloy powders, among them intermetallic powders, are widely used and methods of their production are under development. The technology described here takes advantage of a natural phenomenon, i.e. self-disintegration which takes place in alloys containing Al₄C₃ carbide, e.g. in high aluminium cast iron. The result of chemical reaction between this carbide and moisture are products of bigger volume. It causes cracking of the matrix, i.e. self-disintegration into a powder. The physical–chemical principles of the powder production using self-disintegration are presented in this article.

In Ni–Al–C, Cu–Al–C and Cr–Al–C alloys, Al₄C₃ phase is not present in the liquid melt. Therefore, the presence of a catalysing component, increasing the chemical activity of carbon, is required. Iron can be one of such additions. The mechanism of the influence of the iron on the Al₄C₃ carbide crystallisation and the physical–chemical properties of the powders obtained by the self-disintegration process is presented in this work. Applications (plasma spraying, powder metallurgy) of the intermetallic powders obtained in this way are mentioned.     

High-throughput synthesis and screening of V–Al–Nb and Cr–Al–Nb oxide libraries for ethane oxidative dehydrogenation to ethylene

High-throughput synthesis and screening of mixed metal oxide libraries for ethane oxidative dehydrogenation to ethylene have been developed. A 144-member catalyst library was prepared on a 3 in. quartz wafer. An apparatus for screening catalytic activity and selectivity of a 144-member catalyst library consists of a reaction chamber, where each member can be heated individually by a CO₂ laser and reactant gases can be delivered locally to each member. The reaction products, ethylene and CO₂, are detected by photothermal deflection spectroscopy and by mass spectrometry. A 144-member catalyst library can be screened in slightly more than 2 h. V–Al–Nb oxide and Cr–Al–Nb oxide libraries are illustrated as examples. V–Al–Nb oxide catalysts are high temperature catalysts and Nb did not affect the catalytic activity of the V–Al oxides in contrast to the effect of Nb found in Mo–V–Nb oxides. However, for the Cr–Al–Nb oxide library, the most active catalyst contains about 4% Nb. These results suggest that a fine composition mapping is necessary for discovery of new heterogeneous catalysts in those ternary systems.     

Ion-exchanged pillared clays for selective catalytic reduction of NO by ethylene in the presence of oxygen

Ion-exchanged pillared clays (PILCs) were studied as catalysts for selective catalytic reduction (SCR) of NO by ethylene. Three most important pillared clays, Al₂O₃-PILC (or Al-PILC), ZrO₂-PILC (or Zr-PILC) and TiO₂-PILC (or Ti-PILC), were synthesized. Cation exchanges were performed to prepare the following catalysts: Cu–Ti-PILC, Cu–Al-PILC, Cu–Zr-PILC, Cu–Al–Laponite, Fe–Ti-PILC, Ce–Ti-PILC, Ce–Ti-PILC, Co–Ti-PILC, Ag–Ti-PILC and Ga–Ti-PILC. Cu–Ti-PILC showed the highest activities at temperatures below 370°C, while Cu–Al-PILC was most active at above 370°C, and both catalysts were substantially more active than Cu-ZSM-5. No detectable N₂O was formed by all of these catalysts. H₂O and SO₂ only slightly deactivated the SCR activity of Cu–Ti-PILC, whereas severe deactivation was observed for Cu-ZSM-5. The catalytic activity of Cu–Ti-PILC was found to depend on the method and amount of copper loading. The catalytic activity increased with copper content until it reached 245% ion-exchange. The doping of 0.5 wt% Ce₂O₃ on Cu–Ti-PILC increased the activities from 10% to 30% while 1.0 wt% of Ce₂O₃ decreased the activity of Cu–Ti-PILC due to pore plugging. Cu–Ti-PILC was found to be an excellent catalyst for NO SCR by NH₃, but inactive when CH₄ was used as the reducing agent. Subjecting the Cu–Ti-PILC catalyst to 5% H₂0 and 50 ppm SO₂ at 700°C for 2 h only slightly decreased its activity. TPR results showed that the overexchanged (245%) PILC sample contained Cu²⁺, Cu⁺ and CuO. The TPR temperatures for the Cu–Ti-PILC were substantially lower than that for Cu-ZSM-5, indicating easier redox on the PILC catalyst and hence higher SCR activity.     

Copper-impregnated Al–Ce-pillared clay for selective catalytic reduction of NO by C3H6

The selective catalytic reduction (SCR) of NO by hydrocarbon is an efficient way to remove NO emission from lean-burn gasoline and diesel exhaust. In this paper, a thermally and hydrothermally stable Al–Ce-pillared clay (Al–Ce-PILC) was synthesized and then modified by SO₄²⁻, whose surface area and average pore diameter calcined at 773 K were 161 m²/g and 12.15 nm, respectively. Copper-impregnated Al–Ce-pillared clay catalyst (Cu/SO₄²⁻/Al–Ce-PILC) was applied for the SCR of NO by C₃H₆ in the presence of oxygen. The catalyst 2 wt% Cu/SO₄²⁻/Al–Ce-PILC showed good performance over a broad range of temperature, its maximum conversion of NO was 56% at 623 K and remained as high as 22% at 973 K. Furthermore, the presence of 10% water slightly decreased its activity, and this effect was reversible following the removal of water from the feed. Py-IR results showed SO₄²⁻ modification greatly enhanced the number and strength of Brönsted acidity on the surface of Cu/SO₄²⁻/Al–Ce-PILC, which played a vital role in the improvement of NO conversion. TPR and XPS results indicated that both Cu⁺ and isolated Cu²⁺ species existed on the optimal catalyst, mainly Cu⁺, as Cu content increased to 5 wt%, another species CuO aggregates which facilitated the combustion of C₃H₆ were formed.     

Effect of pH in a sol–gel synthesis on the physicochemical properties of Pd–alumina three-way catalyst

The effect of pH during sol–gel synthesis on the structural and physicochemical properties of a Pd–Al₂O₃ three-way catalyst (TWC) prepared by the sol–gel method was investigated by using BET, X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM) and solid state ²⁷Al MAS NMR. The Pd–Al₂O₃ catalyst prepared at pH=10 (Pd–Al₂O₃–B) showed a high activity in three-way catalytic reaction, a high dispersion of Pd, and large surface area and pore volume. A basic condition (pH=10) in the sol–gel process was essential for the preparation of highly dispersed palladium clusters on alumina gel. The formation of highly stable palladium oxide species in Pd–Al₂O₃–B that were not completely reduced at 423 K was ascribed to the strong interaction between Pd and oxygen in alumina texture, resulting in the formation of –Al–O–Pd bond.     

Cu–Mn mixed oxides for low temperature NO reduction with NH3

Cu–Mn mixed oxides were prepared by a co-precipitation method and applied for low temperature NO reduction with NH₃ in the presence of excess oxygen. Effects of [Cu]/[Mn] ratio and calcination temperatures on NOx conversions were investigated. Cu–Mn oxide catalysts containing small amounts of copper showed the complete NOx conversion in a wide range of reaction temperature from 323 to 473 K. This catalyst showed a reversible deactivation due to the presence of water vapor and SO₂. Different catalytic activities of Cu–Mn mixed oxides could be attributed mainly to surface areas and the crystalline nature.     

Nano-structured CeO2 supported Cu-Pd bimetallic catalysts for the oxygen-assisted water–gas-shift reaction

The present work focuses on the development of novel Cu-Pd bimetallic catalysts supported on nano-sized high-surface-area CeO₂ for the oxygen-assisted water–gas-shift (OWGS) reaction. High-surface-area CeO₂ was synthesized by urea gelation (UG) and template-assisted (TA) methods. The UG method offered CeO₂ with a BET surface area of about 215 m²/g, significantly higher than that of commercially available CeO₂. Cu and Pd were supported on CeO₂ synthesized by the UG and TA methods and their catalytic performance in the OWGS reaction was investigated systematically. Catalysts with about 30 wt% Cu and 1 wt% Pd were found to exhibit a maximum CO conversion close to 100%. The effect of metal loading method and the influence of CeO₂ support on the catalytic performance were also investigated. The results indicated that Cu and Pd loaded by incipient wetness impregnation (IWI) exhibited better performance than that prepared by deposition–precipitation (DP) method. The difference in the catalytic activity was related to the lower Cu surface concentration, better Cu–Ce and Pd–Ce interactions and improved reducibility of Cu and Pd in the IWI catalyst as determined by the X-ray photoelectron spectroscopy (XPS) and temperature-programmed reduction (TPR) studies. A direct relation between BET surface area of the CeO₂ support and CO conversion was also observed. The Cu-Pd bimetallic catalysts supported on high-surface-area CeO₂ synthesized by UG method exhibited at least two-fold higher CO conversion than the commercial CeO₂ or that obtained by TA method. The catalyst retains about 100% CO conversion even under extremely high H₂ concentration.     

Selective catalytic reduction of nitrogen oxides from exhaust of lean burn engine over in situ synthesized monolithic Cu–TS-1/cordierite

Titanium silicalite (TS-1) zeolite was in situ synthesized successfully on the surface of honeycomb cordierite substrate, which was certified by XRD and SEM techniques. The in situ synthesized monolithic TS-1/cordierite showed superior thermal and hydrothermal stabilities. Cu–TS-1/cordierite prepared with ion-exchange and impregnation methods were studied as catalysts for selective catalytic reduction (SCR) of nitrogen oxides (NO_x). For practicality, the evaluation experiments were carried out in exhaust of a real lean burn engine without any other additive. Cu–TS-1/cordierite prepared with two methods both exhibited similar high activities, and at about 715 K, the max NO_x conversion could reach 58% in the space velocity (SV) of 12000 h⁻¹. Ion-exchanged Cu–TS-1/cordierite had superior duration and anti-poison properties while impregnated Cu–TS-1/cordierite not. Cooper is the main active component in the catalyst and Cu(I), which was found in the catalyst during the proceeding of reaction by XPS, is thought to be essential.     

Catalytic properties of novel La–Sr–Cu–O–S perovskites for automotive C3H6/CO oxidation in the presence of SOx

A La–Sr–Cu–O–S system with K₂NiF₄ perovskite-type structure has been studied as a novel SO_x-resistant combustion catalyst. The XRD result implied that sulfur is incorporated into the structure as non-sulfate-type cations. An introduction of sulfur with highly positive valence (S⁶⁺ or S⁴⁺) into the lattice requires the charge compensation by decreasing the oxidation number of Cu. This is accompanied by the creation of more reducible Cu species, which would achieve the light-off of catalytic C₃H₆ oxidation at lower temperatures. More important feature of sulfur-containing compounds is that the catalytic C₃H₆ oxidation was significantly accelerated by addition of SO₂ to the gas feed. The catalytic performance for the oxidation of C₃H₆ and CO and the reduction of NO was finally evaluated in a simulated automotive exhaust in the presence of SO₂.     

Development of Fe2O3-CeO2-TiO2/γ-Al2O3 as catalyst for catalytic wet air oxidation of methyl orange azo dye under room condition

In order to develop a catalyst with high activity and stability for catalytic wet air oxidation (CWAO) process at room temperature and atmospheric pressure, we prepared Fe₂O₃-CeO₂-TiO₂/γ-Al₂O₃ by consecutive impregnation, and determined its properties using BET, SEM, XRF, XPS and chemical analysis techniques. The degradation of an azo dye, methyl orange, in CWAO process with Fe₂O₃-CeO₂-TiO₂/γ-Al₂O₃ used as catalyst at room temperature and atmospheric pressure was also investigated, and the results show that the catalyst has an excellent catalytic activity in treating synthetic wastewater containing 500 mg/L methyl orange, and 98.09% of color and 96.08% of total organic carbon (TOC) can be removed in 2.5 h. The degradation pathway of methyl orange was analyzed by UV–vis and FT-IR spectra. The result of leaching tests shows the catalyst has an excellent stability with negligible leaching ions, and the leaching of Ce is effectively controlled by adding Ti, because Ce and Ti in the catalyst take the form of compound oxides, and the deactivation of the catalyst in successive runs is caused by the adsorption of intermediates on the surface and coverage of the active sites. The catalytic activity of the deactivated catalyst can be generally restored by rinsing it in hydrochloric acid followed by calcination.     

Gold catalysts supported on mesoporous zirconia for low-temperature water–gas shift reaction

Mesoporous ZrO₂ with high surface area and uniform pore size distribution, synthesized by surfactant templating through a neutral [C₁₃(EO)₆–Zr(OC₃H₇)₄] assembly pathway, was used as a support of gold catalysts prepared by deposition–precipitation method. The supports and the catalysts were characterized by powder X-ray diffraction, scanning and transmission electron microscopy, N₂ adsorption analysis, temperature programmed reduction and desorption. The catalytic activity of gold supported on mesoporous zirconia was evaluated in water–gas shift (WGS) reaction at wide temperature range (140–300 °C) and at different space velocities and H₂O/CO ratios. The catalytic behaviour and the reasons for а reversible deactivation of Au/mesoporous zirconia catalysts were studied. The influence of gold content and particle size on the catalytic performance was investigated. The WGS activity of the new Au/mesoporous zirconia catalyst was compared to the reference Au/TiO₂ type A (World Gold Council), revealing significantly higher catalytic activity of Au/mesoporous zirconia catalyst. It is found that the mesoporous zirconia is a very efficient support of gold-based catalyst for the WGS reaction.     

CO2 hydrogenation over Pd-modified methanol synthesis catalysts

The effect of palladium incorporation on the performance of Cu–ZnO(Al₂O₃) during the hydrogenation of carbon dioxide has been assessed. Temperature-programmed reduction profiles and X-ray photoelectron spectra of copper revealed that Pd enhances copper oxide reduction. Carbon dioxide conversion and methanol yield were found to increase on Pd-loaded catalysts. The importance of the palladium incorporated to the base Cu–ZnO(Al₂O₃) catalyst in determining the catalytic activity is discussed in terms of the relative ease with which hydrogen is dissociated on the Pd particles and then spilt over the Cu–ZnO phase of the base catalyst.     

The role of molybdenum in Mo-doped V–Mg–O catalysts during the oxidative dehydrogenation of n-butane

A detailed study on the influence of the addition of molybdenum ions on the catalytic behaviour of a selective vanadium–magnesium mixed oxide catalyst in the oxidation of n-butane has been performed. The catalysts have been prepared by impregnation of a calcined V–Mg–O mixed oxides (23.8 wt% of V₂O₅) with an aqueous solution of ammonium heptamolybdate, and then calcined, and further characterised by several physico-chemical techniques, i.e. S_BET, XRD, FTIR, FT-Raman, XPS, H₂-TPR. MgMoO₄, in addition to Mg₃V₂O₈ and MgO, have been detected in all the Mo-doped samples. The incorporation of molybdenum modifies not only the number of V⁵⁺-species on the catalyst surface and the reducibility of selective sites but also the catalytic performance of V–Mg–O catalysts. The incorporation of MoO₃ favours a selectivity and a yield to oxydehydrogenation products (especially butadiene) higher than undoped sample. In this way, the best catalyst was obtained with a Mo-loading of 17.3 wt% of MoO₃ and a bulk Mo/V atomic ratio of 0.6. From the comparison between the catalytic properties and the catalyst characterisation of undoped and Mo-doped V–Mg–O catalysts, the nature of selective sites in the oxidative dehydrogenation of n-butane is also discussed.     

Synthesis of higher alcohols with cobalt and copper based model catalysts: effect of the alkaline metals

The synthesis of higher alcohols, obtained from CO hydrogenation over transition metals, is an alternative for the production of chemical commodities and less pollutant renewable fuels nowadays. In this work, the influence of different alkali metals (Li, Na, K, Cs) over the formation of active phases of supported catalysts, based on cobalt and copper, as well as the performance of these solids in the reaction of CO hydrogenation under a 50 bar pressure were studied. The solids were prepared by continuous coprecipitation of sodium carbonate with metal nitrate solutions (Al–Co, Al–Cu or Al–Co–Cu) promoted with the alkali metals with dry impregnation. Characterization studies by atomic absorption spectrophotometry, BET, XPS and also the results of catalytic tests show that physico-chemical properties of the obtained catalyst are similar to those of the industrial catalyst used as reference (I).     

Characteristics of the Pd-only three-way catalysts prepared by sol–gel method

Pd-only three-way catalysts prepared by the sol–gel method were investigated by the three-way catalytic performance test with a simulated exhaust gas in a continuous U-tube quartz reactor at a gas hourly space velocity of 72 000 h⁻¹. The catalysts were characterized with XRD, XPS, BET surface area and pore volume. The activity and thermal stability of the Pd–Al₂O₃ catalyst prepared at pH 10 were superior to those at pH 4 during hydrolysis and condensation, which could be explained by the anchoring effect. Zr and V were found to be good promoters for the enhancement of the thermal stability and SO₂ resistance, respectively. Optimally formulated catalyst, Pd(1)–V(2)–Zr(10)–Al₂O₃, was thermally stable up to 900^oC and showed a much more improved low-temperature activity and excellent SO₂ resistance.     

Recent advance in catalysis for solving energy and environmental problems

Recent advances in catalysis for solving the energy and environmental problems are summarized. For these purposes, rapid conversion and selective reaction even under conditions deviating extremely from reaction stoichiometry must be indispensable requisites. In order to realize these requisites, changes in the state of catalyst surface during the reaction were studied, and the catalyst structures on which the optimum reaction performance occurs were determined. An ultra-rapid reforming of methane to syngas with a space–time yield (STY) of 25 000 mol/l h was achieved by using a Rh-modified Ni–Ce₂O₃–Pt catalyst in which the Rh played the role of portholes for hydrogen spillover and prevents coke deposition on the catalyst surface. As a result, a stable state of the catalyst and the high reaction rate were exhibited. A new catalyst composed of Cu–Zn–Cr–Al–Ga oxides modified with supported Pd exerted a high activity with a high STY of methanol, 6700 g/l h. The catalyst components, Pd and Ga, controlled the reduction state of the catalyst surface by their role on normal and inverse spillover of hydrogen, respectively. The methanol thus produced was then totally converted selectively on a metallosilicate catalyst containing Ga or Fe into an aromatics-lean gasoline using an STY of 1860 g/l h. Finally, non-linear reaction mechanism is used to explain the elimination of NO on metallosilicate catalysts under O₂-excess conditions.     

High temperature water–gas shift reaction over hollow Ni–Fe–Al oxide nano-composite catalysts prepared by the solution-spray plasma technique

The effect of Fe content in Ni–Fe–Al oxide nano-composites prepared by the solution-spray plasma technique on their catalytic activity for the high temperature water–gas shift reaction was investigated. The composites showed a hollow sphere structure, with highly dispersed Fe–Ni particles supported on the outer surface of the spheres. When the water–gas shift reaction was performed over an Ni–Al oxide composite catalyst without Fe, undesired CO methanation took place predominantly compared to the water–gas shift reaction, and significant amounts of hydrogen were consumed. When appropriate amounts of Fe were added to the Ni–Al oxide composite catalyst during the plasma process, methanation was suppressed remarkably, without serious loss of activity for the water–gas shift reaction. The catalyst was characterized by STEM, XRD and H₂ chemisorption measurements.     

A new alumina-supported, not pyrophoric Raney-type Ni-catalyst

Starting with a 50–50 wt.% Al–Ni alloy powder a new process was developed by which an active alumina supported, not pyrophoric Raney-type Ni catalyst is produced. It consists of very finely dispersed nickel of 25–30 wt.% (specific weight of about 1.2). The Ni is not ferromagnetic. The catalyst is applied in all liquid phase hydrogenations where standard Raney-Ni is used, with the same or higher specific activity.

The structure of the catalyst is described using XRD, SAXS, TEM SEM/EDX, and N₂-sorption. The catalytic activity measurements were performed in liquid phase hydrogenations at room temperature and atmospheric pressure.     

Gold catalysts supported on mesoporous titania for low-temperature water–gas shift reaction

Mesoporous titania with high surface area and uniform pore size distribution was synthesized using surfactant templating method through a neutral [C₁₃(EO)₆–Ti(OC₃H₇)₄] assembly pathway. The different gold content (1–5 wt.%) was supported on the mesoporous titania by deposition–precipitation (DP) method. The catalysts were characterized by X-ray diffraction, TEM, SEM, N₂ adsorption analysis and TPR. The catalytic activity of gold supported mesoporous titania was evaluated for the first time in water–gas shift reaction (WGSR). The influence of gold content and particle size on the catalytic performance was investigated. The catalytic activity was tested at a wide temperature range (140–300 °C) and at different space velocities and H₂O/CO ratios. It is clearly revealed that the mesoporous titania is of much interest as potential support for gold-based catalyst. The gold/mesoporous titania catalytic system is found to be effective catalyst for WGSR.