Kinetics of the water–gas shift reaction over nanostructured copper–ceria catalysts

Water–gas shift reaction was studied over two nanostructured Cu_xCe_1−xO_2−y catalysts: a Cu_0.1Ce_0.9O_2−y catalyst prepared by a sol–gel method and a Cu_0.2Ce_0.8O_2−y catalyst prepared by co-precipitation method. A commercial low temperature water–gas shift CuO–ZnO–Al₂O₃ catalyst was used as reference. The kinetics was studied in a plug flow micro reactor at an atmospheric pressure in the temperature interval between 298 and 673 K at two different space velocities: 5.000 and 30.000 h⁻¹, respectively. Experimentally estimated activation energy, E_af, of the forward water–gas shift reaction at CO/H₂O = 1/3 was 51 kJ/mol over the Cu_0.1Ce_0.9O_2−y, 34 kJ/mol over the Cu_0.2Ce_0.8O_2−y and 47 kJ/mol over the CuO–ZnO–Al₂O₃ catalyst. A simple rate expression approximating the water–gas shift process as a single reversible surface reaction was used to fit the experimental data in order to evaluate the rate constants of the forward and backward reactions and of the activation energy for the backward reaction.     

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.     

Fuel cell grade hydrogen from methanol on a commercial Cu/ZnO/Al2O3 catalyst

This paper presents the results of experiments of the methanol decomposition reaction catalyzed by a commercial Cu/ZnO/Al₂O₃ in the absence and presence of water. Methanol decomposition of 100% in the absence of water was obtained at 290 °C and a space velocity of 2 cm³/h g cat. At these conditions, the hydrogen yield was 1.9–2.0. Water addition to the feed increased the yield of hydrogen and reduced the formation of: dimethyl ether; methyl formate and methane. The variation of the catalyst’s activity and selectivity with time, temperature and feed composition was consistent with previous studies of methanol–steam reforming and water–gas shift reaction, however, this appears to be the first study over the same catalyst of methanol decomposition and methanol–steam reforming. XPS analysis of used catalyst samples and time on-stream data showed that the Cu²⁺ oxidation state of copper favors methanol decomposition, and we propose that the deactivation of the catalyst is mainly caused by the change in the oxidation state of copper.     

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.     

Au–TiO2 catalysts stabilised by carbon nanofibres

The catalytic activity and stability in the water–gas shift reaction have been tested for Au-based catalysts prepared by deposition of Au from colloid solutions. The supports that have been used are TiO₂, TiO₂ supported on carbon nanofibres (CNF) and CNF. Thermal treatments of the samples show that the Au particle size depends on the support material and hence the interaction between the Au particles and the support. In situ X-ray absorption spectroscopic (XAS) measurements during the water–gas shift reaction show no changes in the first Au–Au coordination number for the catalysts containing CNF. Furthermore, improved short-time stability is obtained compared to the AuTiO₂ catalysts. The improved stability is achieved by the CNF stabilising small TiO₂ particles and hence prevent subsequent sintering of the Au particles.     

Methanol reforming for fuel-cell applications: development of zirconia-containing Cu–Zn–Al catalysts

The steam reforming of methanol to form mixtures of carbon dioxide and hydrogen, together with traces of carbon monoxide, is considered to be a potential source of hydrogen as the fuel for a fuel-cell to be used in mobile power sources. After outlining some of the constraints inherent in the use of the reaction and the types of catalysts which have been used by other investigators, this paper presents results on the preparation and testing of a series of copper-containing catalysts for this reaction. It is shown that the reaction sequence probably involves the formation of methyl formate which then decomposes to give CO₂ as the primary product; CO is formed by the reverse water–gas shift reaction and this only occurs to an appreciable extent when the methanol is almost completely converted. A number of different copper-containing catalysts are then described and it is shown that of these sequentially precipitated Cu/ZnO/ZrO₂/Al₂O₃ materials have the highest activities and stabilities for the steam reforming reaction.     

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.     

Effect of pretreatment on the activity of Ni catalyst for CO removal reaction by water–gas shift and methanation

An Ni metal catalyst manufactured by the tapecasting method for use as a structural catalyst did not exhibit catalytic activity for the carbon monoxide (CO) removal reaction. However, the catalyst pretreated by an oxidation and reduction process showed superior activity for CO removal via water–gas shift and methanation, resulting in a decrease of the CO concentration to below 1% in reformate gas. The catalytic activity was generated by the reorganization of the surface structure of Ni metal, and enhanced by surface oxygen intermediates such as Ni(OH)₂ and NiOOH promoted by NiO oxidized incompletely after the pretreatment. After the reorganization process induced by the pretreatment, the Ni metal on the surface was converted to active Ni and NiO which played the role of a promoter.     

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.     

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.     

Optimization of Cu oxide catalysts for methanol synthesis by combinatorial tools using 96 well microplates, artificial neural network and genetic algorithm

Compact and economic processes for methanol synthesis from syngas demand a new catalyst that is active under low-pressure and low temperature. Combinatorial approach comprising a high-pressure high-throughput screening (HTS) reactor system, an artificial neural network (NN), and a genetic algorithm (GA) was applied for the catalyst development. A variety of 96 microplates were used in the HTS reactor system for both preparation and activity testing to handle 96 catalyst samples simultaneously. Activity test results were used as training data for NN. After training, the NN can map catalyst activity as a function of catalyst composition and parameters for catalyst preparation. GA was used as an optimization tool to find maximum catalyst activity in the trained artificial neural network. Composition of methanol synthesis catalyst (Cu–Zn–Al–Sc–B–Zr), calcination temperature and the amount of precipitant were optimized simultaneously under pressure (1 MPa) because optimum catalyst composition is usually affected by both preparation and reaction conditions. The composition of the optimum catalyst was Cu/Zn/Al/Sc/B/Zr=43/17/23/11/0/6 prepared using 2.2 times the equivalent of oxalic acid and calcined at 605 K. The activity (427 g-MeOH/kg-cat./h) was much higher than that of industrial catalyst (250 g-MeOH/kg-cat./h) at 1 MPa, 498 K.     

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.     

A novel catalyst fabricated from Al–Cu–Fe quasicrystal for steam reforming of methanol

The optimum preparation condition of Al–Cu–Fe quasicrystalline (QC) catalyst with excellent catalytic performance for steam reforming of methanol (SRM) has been investigated. The QC alloy is superior to the other crystalline Al–Cu–(Fe) alloys (i.e., beta and theta phase) as a catalyst material because of the brittle nature of QC. The wet milling process (in ethanol) for the QC powders is much better than the dry milling process to obtain fine particles with high surface area. The QC powder prepared by the wet process followed by leaching in Na₂CO₃ aq. at 323 K exhibited the highest catalytic performance (activity and stability) in the present study. From these findings, it is clear that the QC catalyst with the excellent catalytic performance could be obtained by controlling the initial grain size of the QC powder and the leaching temperature.     

V–Mg–O catalysts for oxidative dehydrogenation of alkylpyridines and alkylthiophenes

Vanadium appears to be the element that is most frequent (along with molybdenum) used in the catalyst formulations for oxidative dehydrogenation (ODH) of hydrocarbons and alcohols. In the present work the employment of ODH reaction in the presence of air has been extended for the preparation of vinyl substituted pyridines and thiophenes using vanadium (and for comparison molybdenum) oxide catalysts.The efficiency of vanadium–magnesium oxide catalysts in the production of vinylpyridines and vinylthiophenes has been evaluated. A strong dependence of the yield and selectivity of the latter upon the vanadium (molybdenum) oxide loading and the conditions of heat treatment were observed. In optimized reaction conditions V–Mg–O catalysts at the temperature approximate 450 °C ensured the formation of vinylpyridines and vinylthiophenes with the yield of 40–60% at the selectivity of 90%. In prolonged runs no visible changes in the performance of the catalyst were observed. DTA–DTG, XRD, IR ESR, NMR methods have been used detecting the formation of species of V–Mg–O catalysts that appear to be responsible for the catalyst efficiency in the reactions under consideration.     

Hydrogenation of 3,4-epoxy-1-butene over Cu–Pd/SiO2 catalysts prepared by electroless deposition

Electroless deposition has been used to prepare Cu–Pd/SiO₂ bimetallic catalysts wherein initial Cu coverages are limited only to the pre-existing Pd surface. Cu loading on the Pd surface can be systematically varied by modification of deposition kinetic parameters. In this case deposition time was used as the kinetic variable for the preparation of a series of Cu–Pd catalysts. These materials have been characterized using atomic absorption, CO chemisorption, and FT-IR (adsorption of CO), and then evaluated for the hydrogenation of 3,4-epoxy-1-butene, a functionalized olefin having many potential reaction pathways. Catalyst performance and characterization results suggest that Cu is not distributed in a monodisperse manner on the Pd surface, indicating the existence of autocatalytic deposition of Cu on Cu sites. The FT-IR results suggest that although CO adsorption on all sites is suppressed by Cu addition, initial Cu deposition occurs more readily on certain sites. The bimetallic Cu–Pd sites that are formed exhibit unusually high activity for EpB conversion and formation of unsaturated alcohols and aldehydes. This bimetallic effect on catalyst activity and selectivity is best explained, not by the existence of either ligand or ensemble effects, but rather by the bifunctional nature of the Cu–Pd sites present on the surface of these catalysts.     

Study on the supported Cu-based catalysts for the low-temperature water–gas shift reaction

This paper presents a study on the influence of support (Al₂O₃, MgO, SiO₂-Al₂O₃, SiO₂-MgO, β-zeolite, and CeO₂) of Cu-ZnO catalysts for the low-temperature water–gas shift reaction. Supported Cu-ZnO catalysts were prepared by the conventional impregnation method, followed by the H₂ reduction. The activity of Cu-ZnO catalysts for the water–gas shift (WGS) reaction was largely influenced by the kind of support; Cu-ZnO catalysts supported on Al₂O₃, MgO, and CeO₂ showed high activity, while those on SiO₂-Al₂O₃, SiO₂-MgO and β-zeolite showed less activity in the temperature range 423–523 K. XRD analysis demonstrated that the copper species were highly dispersed on the supports used in the present study, except for a MgO support. TPR results of a series of supported CuO-ZnO catalysts suggest that the reducibility of CuO is one of the important factors controlling the activity of the WGS reaction over the supported catalysts.     

Selective oxidation of methanol to formaldehyde over V–Mg–O catalysts

The results of a complex investigation of V–Mg–O catalysts for oxidative dehydrogenation (ODH) of methanol are presented. The efficiency of vanadium–magnesium oxide catalysts in production of formaldehyde has been evaluated. Strong dependence of the formaldehyde yield and selectivity upon vanadium oxide loading and the conditions of heat treatment of the catalyst were observed. The parameters of the preparation mode for the efficient catalyst were identified. In optimised reaction conditions the V–Mg–O catalysts at the temperature approximate 450 °C ensured the formation of formaldehyde with the yield of 94% at the selectivity of 97%.

No visible changes in the performance of the catalyst (methanol conversion, formaldehyde yield and selectivity) were detected during the 60 h of operation in prolonged runs. Characterization of the catalyst by XRD, IR, and UV methods suggests the formation of species of the pyrovanadate type (Mg₂V₂O₇) with irregular structure on the surface of a V–Mg–O catalyst. These species make the catalyst efficient for methanol ODH.     

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.     

Effect of preparation and reaction condition on the catalytic performance of Mo–V–Te–Nb catalysts for selective oxidation of propane to acrylic acid by high-throughput methodology

Combinatorial screening technique has been applied to investigate the catalytic activity and selectivity of quaternary Mo–V–Te–Nb mixed oxide catalysts treated with various chemicals during preparation for selective oxidation of propane to acrylic acid. The catalyst libraries were prepared by the slurry method and catalytic activities were examined in 32-channel high-throughput screening reactor system coupled with a mass spectrometer and/or gas chromatograph.The obtained results provided substantial evidence that the sample preparation condition would have strong effect on the catalytic performance for propane selective oxidation. Among screened samples, Mo–V–Te–Nb treated with HIO₃ solution presented a better performance. The reaction results of promising catalysts selected from the libraries were applied to further scale-up of the system and confirmed catalytic performance. Quantification of the result of Mo–V–Te–Nb treated with HIO₃ solution was realized by combination of GC and MS and relationship between the MS data and the GC results can be established.