Catalytic production of olefins using natural halloysite nanotubes

The production of C₂-C₄ olefins by deep catalytic cracking and the thermocontact pyrolysis of vacuum gas oil, commercial-grade cottonseed oil, and a vacuum gas oil-cottonseed oil 90: 10 mixture in the temperature range of 600–800°C is studied using natural halloysite extracted from kaolinite fields in the form of aluminosilicate sheets rolled in nanotubes. It is found that in the deep catalytic cracking of vacuum gas oil at 600°C using halloysite as a catalyst, the gain in the yield of ethylene is 6.4–10.1 wt %, compared to yields of this product when using ZSM-5 catalyst. Adding 10% commercial-grade cottonseed oil to the vacuum gas oil further increases the yield of ethylene by 2.2 wt % with a simultaneous 3.3 wt % rise in the yield of propylene. The cracking of pure cottonseed oil under identical conditions yields ethylene and propylene of 16.1 and 9.2 wt %, respectively. The possibility of using halloysite nanotubes as a heating surface for the thermal pyrolysis of the above feedstocks at temperatures of 700–800°C in order to obtain yields of C₂-C₃ olefins exceeding those of identical products in industry, and of reusing halloysites in the thermoconversion of the studied feedstocks via their complete regeneration, is confirmed.     

Upgrading of low rank coal with solvent

In this study, thermal upgrading of low-rank coal with solvent at 380–440 °C under an initial nitrogen pressure of 2 MPa was studied as a possible method for producing clean solid fuel with a high heating value and less spontaneous ignition behavior. Upgrading of Buckskin coal (USA, subbituminous coal) in the presence of t-decalin (non hydrogen-donor solvent) at 440 °C gave 11.4 wt.% of gas, 5.3 wt.% of oil and 74.1 wt.% of upgraded solid product with a small amount of water. The gaseous product consisted mainly of carbon dioxide (67 wt.%), methane, carbon monoxide, hydrogen and a trace of C₂ and C₃ hydrocarbon gases. The oil product from coal contained BTX, phenol, and their alkyl-derivatives. The heating value of the upgraded solid product from the Buckskin coal increased to 31.0 MJ/kg in dry base as compared to the heating value of wet base of the untreated raw coal, which was 19.3 MJ/kg. Spontaneous ignition behavior was greatly reduced by the upgrading. The effect of catalyst and additives on the upgrading was investigated in terms of product distribution and the quality of the solid product. Taiheiyo (Japan, subbituminous) and Yallourn (Australia, brown) coals were also studied.     

Fuels by pyrolysis of waste plastics from agricultural and packaging sectors in a pilot scale reactor

The pyrolysis of waste plastics (so called chemical recycling) is one perspective way of their utilizations, but the end product properties are a key point of the industrial leading of processes. In this paper a pilot scale pyrolysis process has been investigated. Waste plastics were decomposed in a tube reactor at 520 °C, using hourly feed rate of 9.0 kg. Raw materials were selectively collected wastes from agricultural and packaging industry. For supporting the more intensive cracking of CC bonds of main polymer structure a commercial ZSM-5 catalyst was tested in concentration of 5.0%. Products were separated into gases, gasoline, light and heavy oil by distillation. Plastic wastes could be converted into gasoline and light oil with yields of 20–48% and 17–36% depending on the used parameters. The gas and liquid products had significant content of unsaturated hydrocarbons, principally olefins. In the presence of ZSM-5 catalyst the yields of lighter fractions (especially gasoline) could be considerably increased and the average molecular weight of each fraction has decreased. Gasoline had C₅–C₁₅ hydrocarbons, while light oil had C₁₂–C₂₈. The used catalyst has promoted the formation of i-butane in gases and affected the composition of both gasoline and light oil. Properties of products are advantageous for fuel-like applications, and they are able to increase the productivity of refinery. On the other hand the possibility for further utilization of products from pyrolysis basically was affected by the source and the properties of raw materials. Waste polyethylene from agricultural consisted of some elements from fertilizers (N, S, P and Ca), which could not be removed from the surfaces of raw materials by pre-treatment (e.g. washing). In that case significant concentration of N, S, P and Ca can be measured in all products, but the catalyst has decreased the concentration of impurities. Gasoline, light oil and heavy oil were nitrogen free and sulphur content was below 12 mg/kg in hydrocarbons obtained by the pyrolysis of polypropylene waste from packaging.     

Pyrolysis of used sunflower oil in the presence of sodium carbonate by using fractionating pyrolysis reactor

Pyrolysis of used sunflower oil was carried out in a reactor equipped with a fractionating packed column (in three different lengths of 180, 360 and 540 mm) at 400 and 420°C in the presence of sodium carbonate (1, 5, 10 and 20% based on oil weight) as a catalyst. The use of packed column increased the residence times of the primer pyrolysis products in the reactor and packed column by the fractionating of the products which caused the additional catalytic and thermal reactions in the reaction system and increased the content of liquid hydrocarbons in gasoline boiling range. The conversion of oil was high (42–83 wt.%) and the product distribution was depended strongly on the reaction temperature, packed column length and catalyst content. The pyrolysis products consisted of gas and liquid hydrocarbons, carboxylic acids, CO, CO₂, H₂ and water. Increase in the column length increased the amount of gas and coke–residual oil and decreased the amount of liquid hydrocarbon and acid phase. Also, increase of sodium carbonate content and the temperature increased the formation of liquid hydrocarbon and gas products and decreased the formation of aqueous phase, acid phase and coke–residual oil. The major hydrocarbons of the liquid hydrocarbon phase were C₅–C₁₁ hydrocarbons. The highest C₅–C₁₁ yields (36.4%) was obtained by using 10% Na₂CO₃ and a packed column of 180 mm at 420°C. The gas products included mostly C₁–C₃ hydrocarbons.     

Pyrolysis of scrap tyres

Cross-section samples (2–3 cm wide), representative of a whole car tyre, have been pyrolysed under nitrogen in a 3.5 dm³ autoclave at 300°C, 400°C, 500°C, 600°C and 700°C. The whole solid, liquid and gaseous products generated during each pyrolysis were collected and characterised. No significant influence of temperature on the amount and characteristics of pyrolysis products was observed over 500°C. Tyre-pyrolysis liquids are a complex mixture of C₅–C₂₀ organic compounds, with a great proportion of aromatics. They have high gross calorific values, GCV (∼42 MJ kg⁻¹) and N and S contents (0.4% and 1.2%, respectively) within those specified for certain heating fuels. About 30 wt.% of such liquids is an easily distillable fraction with boiling points (70–210°C) in the range of commercial petrol, and about 60 wt.% of them have the boiling point range (150–370°C) typical of diesel oil. Pyrolysis gases are composed of hydrocarbons of which C₁ and C₄ are predominant, together with some CO, CO₂ and SH₂; they have very high gross calorific values (68–84 MJ m⁻³). Tyre-pyrolysis residues have equal dimensions as the original tyre portion and are easily disintegrable into black powder and steel cords. The black powder has surface areas comparable to those of commercial carbon blacks, but it has a great proportion of ash and impurities (∼12 wt.%), which are the inorganic fillers added to tyre rubber; it may have a potential use as semireinforcing or nonreinforcing carbon black.     

Conversion of vegetable oils under conditions of catalytic cracking

The effect of the composition of zeolite containing catalyst, the conditions of conducting the process, and the nature of oils on the distribution of target products during conversion under conditions of catalytic cracking is studied. The study is performed on bizeolite catalysts containing zeolites (ultrastable Y and ZSM-5 at different ratios) and on catalyst LUX containing18 wt % of zeolite Y in the HREY form. It is shown that the presence of zeolite ZSM-5 in the catalyst composition promotes the formation of olefines C₂–C₄. An increase in the severity of cracking process (elevated temperatures and catalyst: raw material ratios) improves the yield of gaseous products and coke with a simultaneous reduction in the yield of the gasoline fraction. The effect the nature of vegetable oils has is studied using the examples of palm, rapeseed, mustard, and sunflower oils. It is demonstrated that for the maximum yield of olefines C₂–C₄ and gasoline, we must use oils with elevated contents of saturated fatty acids. The regularities of the simultaneous cracking of sunflower oil and vacuum gas oil are studied. It is been found that upon simultaneous cracking, the total conversion of the mixed feedstock and yield of gasoline fraction increase; the maximum effect is attained with the addition of 3–10 wt % of vegetable oil.     

Optimum operating conditions for a two-stage gasification process fueled by polypropylene by means of continuous reactor over ruthenium catalyst

We studied fuel gas production by means of pyrolysis and steam reforming of waste plastics for applications in solid oxide fuel cells. More specifically, we evaluated the effects of pyrolytic gasification temperature, catalyst content, steam reforming temperature, and weight hourly space velocity for a Ru catalyst used in a 60 g h^− 1-scale continuous experimental apparatus, which consisted of a tank reactor for pyrolysis and a packed-bed catalytic reactor for steam reforming. Polypropylene (PP) pellets were used as a model waste plastic. Ru/γ-Al₂O₃ catalysts with two different Ru contents were investigated. To suppress residue formation, the optimum operating temperature of the pyrolyzer was 673 K. To ensure suppressed coke formation, sufficient carbon conversion to gaseous products, and minimized heat loss from the reactor, the optimum operating conditions for the reformer were determined to be 903 K and 0.11 g-sample g-catalyst^− 1 h^− 1 with a 5 wt.% Ru/γ-Al₂O₃ catalyst. The composition of the gas produced with the 5 wt.% catalyst was almost the same as that predicted by chemical equilibrium laws, and it was applicable for a direct hydrocarbon fuel cell.     

Pyrolysis products of uncoated printing and writing paper of MSW

Uncoated printing and writing paper, one of the principal waste papers in Taiwan, was pyrolyzed with a thermogravimetric analysis (TGA) reaction system. The pyrolysis experiments were carried out in nitrogen environment at a constant heating rate of 5 K min⁻¹. The gaseous products and the residues were collected at room temperature (300 K) and analyzed by gas chromatography (GC) and elemental analyzer, respectively. The major gaseous products investigated included non-hydrocarbons (H₂, CO, CO₂, and H₂O) and hydrocarbons (C_1-3, C₄, C₅, C₆, 1-ring, C_10-12, levoglucosan, C_13-15, and C_16-18). The cumulated masses and the instantaneous concentrations of gaseous products were obtained under the experimental conditions. The yields of non-hydrocarbon gases and of hydrocarbon gases were about 10.46 and 0.49% at 623 K, 33.68 and 0.89% at 700 K, 64.52 and 1.05% at 788 K, and 79.10 and 1.63% at 938 K, respectively. The estimation of the mass of tar, yielded at various pyrolysis temperatures was also made. The results of this study might be useful for the design of pyrolysis process as well as for determining the pyrolysis mechanisms of the uncoated printing and writing paper.     

Production of C4 hydrocarbons from Fischer–Tropsch synthesis in a follow bed reactor consisting of Co–Ni–ZrO2 and sulfated-ZrO2 catalyst beds

Fischer–Tropsch synthesis was performed in a fixed-bed microreactor over a single bed consisting of Co–Ni–ZrO₂ catalyst as well as over a follow bed configuration consisting of Co–Ni–ZrO₂ and sulfated-ZrO₂ catalyst beds for the selective production of C₄ hydrocarbons. A maximum C₄ hydrocarbon selectivity of 14.6 wt.% was obtained using the single bed approach at 250°C and weight hourly space velocities (WHSV) of 15 h⁻¹. When a follow bed approach was used, there was an impressive increase in the selectivity for C₄ hydrocarbons to a maximum of 24 wt.% and that for iso-C₄ hydrocarbons to a maximum of 13.8 wt.% from 14.6 and 5.5 wt.%, respectively. However, there was a rapid deactivation of the sulfated-ZrO₂ catalyst due to coking and sulfate reduction.     

Assessing the performance of an industrial SBCR for Fischer–Tropsch synthesis: Experimental and modeling

The main objective of this study is to predict the performance of an industrial‐scale (ID = 5.8 m) slurry bubble column reactor (SBCR) operating with iron‐based catalyst for Fischer–Tropsch (FT) synthesis, with emphasis on catalyst deactivation. To achieve this objective, a comprehensive reactor model, incorporating the hydrodynamic and mass‐transfer parameters (gas holdup, ε_G, Sauter‐mean diameter of gas bubbles, d₃₂, and volumetric liquid‐side mass‐transfer coefficients, k_La), and FT as well as water gas shift reaction kinetics, was developed. The hydrodynamic and mass‐transfer parameters for He/N₂ gaseous mixtures, as surrogates for H₂/CO, were obtained in an actual molten FT reactor wax produced from the same reactor. The data were measured in a pilot‐scale (0.29 m) SBCR under different pressures (4–31 bar), temperatures (380–500 K), superficial gas velocities (0.1–0.3 m/s), and iron‐based catalyst concentrations (0–45 wt %). The data were modeled and predictive correlations were incorporated into the reactor model. The reactor model was then used to study the effects of catalyst concentration and reactor length‐to‐diameter ratio (L/D) on the water partial pressure, which is mainly responsible for iron catalyst deactivation, the H₂ and CO conversions and the C₅₊ product yields. The modeling results of the industrial SBCR investigated in this study showed that (1) the water partial pressure should be maintained under 3 bars to minimize deactivation of the iron‐based catalyst used; (2) the catalyst concentration has much more impact on the gas holdup and reactor performance than the reactor height; and (3) the reactor should be operated in the kinetically controlled regime with an L/D of 4.48 and a catalyst concentration of 22 wt % to maximize C₅₊ products yield, while minimizing the iron catalyst deactivation. Under such conditions, the H₂ and CO conversions were 49.4% and 69.3%, respectively, and the C₅₊ products yield was 435.6 ton/day. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3838–3857, 2015     

Hydrolysis of poly(ethylene terephthalate) waste bottles in the presence of dual functional phase transfer catalysts

The hydrolysis of poly(ethylene terephthalate) (PET) obtained from waste bottles was studied. The dual functional phase transfer catalyst [(CH₃)₃N(C₁₆H₃₃)]₃[PW₁₂O₄₀] exhibited outstanding catalytic activity to the hydrolysis of PET. Fourier transform infrared spectroscopy and proton nuclear magnetic resonance spectroscopy were used to confirm the main product terephthalic acid (TPA) of hydrolysis. The effects of temperature, time, particle size of PET and dosage of catalyst on hydrolysis reaction were examined. Under the optimum conditions of reaction temperature 145°C, time 2 h, particle size of PET at 0.5–1 mm and dosage of catalyst at 7 wt %, the conversion of PET and the yield of TPA were almost 100% and 93%, respectively. After easily separated from the product, the catalyst could be reused more than three times without obvious decrease in the conversion of PET and yield of TPA. An economical and convenient process was developed for hydrolysis of PET. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 130: 2790–2795, 2013     

Study on characterization of pyrolysis and hydrolysis products of poly(vinyl chloride) waste

Poly(vinyl chloride) PVC pyrolysis and hydrolysis are conducted in a fixed bed reactor and in an autoclave, respectively, under different operating conditions such as the temperature and time. The product distribution is studied. For the PVC pyrolysis process, the main gas product is HCl (55% at 340°C), there is 9% hydrocarbon gas (C₁–C₅), the liquid product fraction is about 5% (at 340°C), and the solid residue fraction is about 31% (at 340°C). For the hydrolysis process, the main gas product is HCl (55.8% at 240°C) and the solid residue is about 49.6% (at 240°C). The pyrolysis liquid product is analyzed by using gas chromatography with magic‐angle spinning. Aromatic hydrocarbons are the main class (90%), of which the major part is benzene (33%). The residue produced through pyrolysis and hydrolysis is investigated by high‐resolution solid‐state ¹³C‐NMR. These details revealed by the high‐field NMR spectra provide importmant information about the chemical changes in the PVC pyrolysis and hydrolysis process. The mechanism of PVC hydrolysis dechlorination is also discussed. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 3252–3259, 2003     

Pyrolysis of tetra pack in municipal solid waste

The pyrolysis of tetra pack in nitrogen was investigated with a thermogravimetric analysis (TGA) reaction system. The pyrolysis kinetics experiments for the tetra pack and its main components (kraft paper and low‐density poly(ethene) (LDPE)) were carried out at heating rates (β) of 5.2, 12.8, 21.8 K min^?1. The results indicated that the one‐reaction model and two‐reaction model could be used to describe the pyrolysis of LDPE and kraft paper respectively. The total reaction rate of tetra pack can be expressed by the summation of the individual class of LDPE and kraft paper by multiplying the weighting factors. The pyrolysis products experiments were carried out at a constant heating rate of 5.2 K min^?1. The gaseous products were collected at room temperature (298 K) and analyzed by gas chromatography (GC). The residues were collected at some significant pyrolysis reaction temperatures and analyzed by an elemental analyzer (EA) and X‐ray powdered diffraction (XRPD). The accumulated masses and the instantaneous concentrations of gaseous products were obtained under the experimental conditions. The major gaseous products included non‐hydrocarbons (CO₂, CO, and H₂O) and hydrocarbons (C_1–5). In the XRPD analysis, the results indicated that pure aluminum foil could be obtained from the final residues. The proposed model may be supported by the pyrolysis mechanisms with product distribution. © 2001 Society of Chemical Industry     

Catalytic conversion of postconsumer PE/PP waste into hydrocarbons using the FCC process with an equilibrium FCC commercial catalyst

A mixture of postconsumer polyolefin waste (PE/PP) was pyrolyzed over cracking catalysts using a fluidizing reaction system similar to the fluid catalytic cracking (FCC) process operating isothermally at ambient pressure. Experiments carried out with various catalysts gave good yields of valuable hydrocarbons with differing selectivity in the final products dependent on reaction conditions. Greater product selectivity was observed with a commercial FCC equilibrium catalyst (Ecat‐F1) with more than 50 wt % olefins products in the C₃‐C₆ range. A kinetic model based on a lumping reaction scheme for the observed products and catalyst coking deactivations has been investigated. The model gave a good representation of experiment results. Moreover, this model provides the benefits of lumping product selectivity, in each reaction step, in relation to the performance of the FCC equilibrium catalyst used, the effect of reaction temperature, and the particle size selected. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

A molecular level model for the nucleation of a single-wall carbon nanotube cap over a transition metal catalytic particle

Recent in-situ video rate TEM studies have revealed that the base growth of single-wall carbon nanotubes (SWCNT) in thermal chemical vapour deposition (CVD) is accompanied by a considerable deformation of the Ni catalyst nanoparticle and the creation of a subsurface carbon layer. In this paper we argue that these effects may be produced by the adsorption – on the catalyst nanoparticle – of cyclopentadienyl ions formed in gas phase during C₂H₂ pyrolysis. These ions can, at the same time, facilitate the nucleation of a SWCNT cap by the provision of “ready made” pentagons. To this end we have performed semi-empirical quantum mechanical calculations with the ZINDO method. The results support the above proposed mechanism. We also suggest that this mechanism could also explain the increased rate of SWCNT production in plasma enhanced CVD, where these ions are expected to be present in higher concentrations during C₂H₂ pyrolysis.     

Ruthenium promoted cobalt–alumina catalysts for the synthesis of high-molecular-weight solid hydrocarbons from CO and hydrogen

The effect of the ruthenium promotion of Fischer–Tropsch (FT) cobalt–alumina catalysts on the temperature of catalyst activation reduction and catalytic properties in the FT process is studied. The addition of 0.2–1 wt % of ruthenium reduces the temperature of reduction activation from 500 to 330–350°C while preserving the catalytic activity and selectivity toward C₅₊ products in FT synthesis. FT ruthenium-promoted Co–Al catalysts are more selective toward higher hydrocarbons; the experimental value of parameter α_ASF of the distribution of paraffinic products for ruthenium-promoted catalysts is 0.93–0.94, allowing us to estimate the selectivity toward C₂₀₊ synthetic waxes to be 48 wt %, and the selectivity toward C₃₅₊ waxes to be 23 wt %. Ruthenium-promoted catalysts also exhibit high selectivity toward olefins.     

Optimization of process parameters and catalyst compositions in carbon dioxide oxidative coupling of methane over CaO–MnO/CeO2 catalyst using response surface methodology

The optimization of process parameters and catalyst compositions for the CO₂ oxidative coupling of methane (CO₂-OCM) reaction over CaO–MnO/CeO₂ catalyst was developed using Response Surface Methodology (RSM). The relationship between the responses, i.e. CH₄ conversion, C₂ hydrocarbons selectivity or yield, with four independent variables, i.e. CO₂/CH₄ ratio, reactor temperature, wt.% CaO and wt.% MnO in the catalyst, were presented as empirical mathematical models. The maximum C₂ hydrocarbons selectivity and yields of 82.62% and 3.93%, respectively, were achieved by the individual-response optimization at the corresponding optimal process parameters and catalyst compositions. However, the CH₄ conversion was a saddle function and did not show a unique optimum as revealed by the canonical analysis. Moreover pertaining to simultaneous multi-responses optimization, the maximum C₂ selectivity and yield of 76.56% and 3.74%, respectively, were obtained at a unique optimal process parameters and catalyst compositions. It may be deduced that both individual- and multi-responses optimizations are useful for the recommendation of optimal process parameters and catalyst compositions for the CO₂-OCM process.     

Supercritical water gasification of aqueous fraction of pyrolysis oil in the presence of a Ni‐Ru catalyst

This study demonstrated that aqueous fraction of pyrolysis oil can be efficiently gasified into fuel gases methane and hydrogen via supercritical water gasification (SCWG) at moderate temperatures (500–700°C) over Ni_20%Ru_2%/γ‐Al₂O₃ catalyst. All experiments were performed in a bench‐scale continuous down‐flow tubular reactor packed with the catalyst. Carbon gasification efficiency of 0.91 mol/mol‐C (converted into CH₄ and CO₂) was achieved in SCWG of the aqueous fraction of pyrolysis oil (containing 2.98 wt % C) at 700°C in the presence of the catalyst. A similar carbon gasification efficiency (approx. 0.89 mol/mol‐C) was obtained at a lower temperature (600°C) with a diluted feedstock (0.7 wt %C). Scanning Electron Microscopy coupled with Energy Dispersive x‐ray and inductively coupled plasma analysis results confirmed that this catalyst was stable during SCWG of aqueous fraction of pyrolysis oil after 6 h on‐stream. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2786–2793, 2016     

Flash pyrolysis of coals: behaviour of three coals in a 20 kg h−1 fluidized-bed pyrolyser

Flash pyrolysis of Loy Yang brown coal, and Liddell and Millmerran bituminous coals has been studied using a fluidized-bed reactor with a nominal throughput of 20 kg h^?1. The apparatus and its performance are described. The yields of tar and hydrocarbon gases are reported for each coal in relation to pyrolysis temperature, as also are analytical data on the pyrolysis products. The peak tar yields for the dry, ash-free Loy Yang and Millmerran coals were respectively 23% wt/wt (at ≈ 580 °C) and 35% wt/wt (at $\text{\$}\text{?}$600 °C). The tar yield from Liddell coal was 31% wt/wt at ≈ 580 °C. Hydro-carbon gases were produced in notable quantities during flash pyrolysis; e.g. Millmerran coal at 810 °C gave 6% wt/wt (daf) methane, 0.9% wt/wt ethane, 6% wt/wt ethylene, and 2.5% wt/wt propylene. The atomic $\text{H}\text{C}$ ratios and the absolute levels of hydrogen in product tars and chars decreased steadily with increasing pyrolysis temperature.     

Gas evolution kinetics of two coal samples during rapid pyrolysis

Quantitative gas evolution kinetics of coal primary pyrolysis at high heating rates is critical for developing predictive coal pyrolysis models. This study aims to investigate the gaseous species evolution kinetics of a low rank coal and a subbituminous coal during pyrolysis at a heating rate of 1000 °C s^− 1 and pressures up to 50 bar using a wire mesh reactor. The main gaseous species, including H₂, CO, CO₂, and light hydrocarbons CH₄, C₂H₂, C₂H₄, C₂H₆, C₃H₆, C₃H₈, were quantified using high sensitivity gas chromatography. It was found that the yields of gaseous species increased with increasing pyrolysis temperature up to 1100 °C. The low rank coal generated more CO and CO₂ than the subbituminous coal under similar pyrolysis conditions. Pyrolysis of the low rank coal at 50 bar produced more gas than at atmospheric pressure, especially CO₂, indicating that the tar precursor had undergone thermal cracking during pyrolysis at the elevated pressure.