Cu-ZSM-5 zeolite highly active in reduction of NO with decane under water vapor presence: Comparison of decane, propane and propene by in situ FTIR

Selective catalytic reduction of NO_x (SCR-NO_x) with decane, and for comparison with propane and propene over Cu-ZSM-5 zeolite (Cu/Al 0.49, Si/Al 13.2) was investigated under presence and absence of water vapor. Decane behaves in SCR-NO_x like propene, i.e. the Cu-zeolite activity increased under increasing concentration of water vapor, as demonstrated by a shift of the NO_x–N₂ conversion to lower temperatures, in contrast to propane, where the NO_x–N₂ conversion is highly suppressed. In situ FTIR spectra of sorbed intermediates revealed similar spectral features for C₁₀H₂₂– and C₃H₆–SCR-NO_x, where –CH_x, R–NO₂, –NO₃⁻, Cu⁺–CO, –CN, –NCO and –NH species were found. On contrary, with propane –CH_x, R–NO₂, NO₃⁻, Cu⁺–CO represented prevailing species. A comparison of the in situ FTIR spectra (T–O–T and intermediate vibrations) recorded at pulses of propene and propane, moreover, under presence and absence of water vapor in the reaction mixture, revealed that the Cu²⁺–Cu⁺ redox cycle operates with the C₃H₆–SCR-NO_x reactions in both presence/absence of water vapor, while with C₃H₈–SCR-NO_x, the redox cycle is suppressed by water vapor. It is concluded that decane cracks to low-chain olefins and paraffins, the former ones, more reactive, preferably take part in SCR-NO_x. It is concluded that formation of olefinic compounds at C₁₀H₂₂–SCR-NO_x is decisive for the high activity in the presence of water vapor, while water molecules block propane activation. The increase in NO_x–N₂ conversion due to water vapor in C₁₀H₂₂–SCR-NO_x should be connected with the increased reactivity of intermediates. These are suggested to pass from R–NO_x → –CN → –NCO → NH₃; the latter reacts with another activated NO_x molecule to molecular nitrogen. The positive effect of water vapor on the NO_x–N₂ conversion is attributed to increased hydrolysis of –NCO intermediates.     

Pyrolysis of oil sand from the Whiterocks deposit in a rotary kiln

A rotary kiln reactor was evaluated for thermal recovery of oil from Utah oil sands. A series of continuous-flow pyrolysis experiments was conducted. Process variables investigated included temperature (748–848 K), solids retention time (10–27 min) and sweep gas flow rate (1.27–2.83 m_s³ h⁻¹). The results indicated that the pyrolysis temperature and the solids retention time were the two most important variables affecting the liquid and gas yields. The liquid yield (C₅⁺]) decreased and the gas yield (C₁–C₄) increased with increasing temperature. The liquid yield increased with decreasing solids retention time, while the gas yield decreased. No significant effect of the sweep gas flow rate on the product distribution and yields was observed. The quality of the bitumen-derived liquids was significantly better than that of the bitumen. A preliminary process kinetics model which conforms to the observed trends was proposed.     

Single-event microkinetics for coke formation during the catalytic cracking of (cyclo)alkane/1-octene mixtures

A single-event microkinetic model (SEMK) is applied to model initial coking rates during the catalytic cracking of (cyclo)alkane/1-octene mixtures at 693–753 K and (cyclo)alkane and 1-octene inlet partial pressures of 26.6 and 4.8 kPa on a REUSY equilibrium catalyst. Three types of irreversible alkylations involving both gas phase and surface coke precursors, viz., alkylation of phenyl substituted carbenium ions with C₃–C₅ alkenes, alkylation of the nucleus of monoaromatics with C₃–C₅ alkylcarbenium ions, and alkylation of C₈–C₁₀ alkylcarbenium ions with C₃–C₅ alkenes, have been considered as rate-determining steps in coke formation. The bulky alkylated species formed out of these alkylations are considered as coke. The activation energies for these alkylations obtained via non-isothermal regression are independent of the feedstock within the parameters confidence limits reflecting the fundamental character of the SEMK. The negative effect of temperature on the experimentally observed coking rates is qualitatively described and is explained in terms of an overcompensation of the increase of the rate coefficient by a lower surface coke precursor concentration.     

Production of gasoline range hydrocarbons from catalytic reaction of methane in the presence of ethylene over W/HZSM-5

The catalytic conversion of a methane and ethylene mixture to gasoline range hydrocarbons has been studied over W/HZSM-5 catalyst. The effect of process variables, such as temperature, percentage of volume of ethylene in the methane stream and catalyst loading on the distribution of hydrocarbons was studied. The reaction was conducted in a fixed-bed quartz-micro reactor in the temperature range of 300–500 °C using percentage of volume of ethylene in methane stream between 25 and 75% and catalyst loading of 0.2–0.4 g. The catalyst showed good catalytic performance yielding hydrocarbons consisting of gaseous products along with gasoline range liquid products. The mixed feed stream can be converted to higher hydrocarbons containing a high-liquid gasoline product selectivity (>42%). Non-aromatics C₅–C₁₀ hydrocarbons selectivity in the range of 12–53% was observed at the operating conditions studied. Design of experiment was employed to determine the optimum conditions for maximum liquid hydrocarbon products. The distribution of the gasoline range hydrocarbons (C₅–C₁₀ non-aromatics and aromatics hydrocarbons) was also determined for the optimum conditions.     

CO hydrogenation over a rhodium vanadate catalyst: Reduction and regeneration of RhVO4 on SiO2

The hydrogenation of CO over an Rh vanadate (RhVO₄) catalyst supported on SiO₂ (RhVO₄/SiO₂) has been investigated after H₂ reduction at 500°C, and the results are compared with those of vanadia-promoted (V₂O₅–Rh/SiO₂) and unpromoted Rh/SiO₂ catalysts. The mean size of Rh particles, which were dispersed by the decomposition of RhVO₄ after the H₂ reduction, was smaller (41 Å) than those (91–101 Å) of V₂O₅–Rh/SiO₂ and Rh/SiO₂ catalysts. The RhVO₄/SiO₂ catalyst showed higher activity and selectivity to C₂ oxygenates than the unpromoted Rh/SiO₂ catalyst after the H₂ pretreatment. The CO conversion of the RhVO₄/SiO₂ catalyst was much higher than that of V₂O₅–Rh/SiO₂ catalyst, and the yield of C₂ oxygenates increased. We also found that the RhVO₄/SiO₂ catalyst can be regenerated by calcination or O₂ treatment at high temperature after the reaction.     

Mineral matter effects on the rapid pyrolysis and hydropyrolysis of a bituminous coal: 2. Effects of yields of C3-C8 hydrocarbons

Effects of minerals on yields of C₃-C₈ volatiles from rapid pyrolysis of a Pittsburgh Seam bituminous coal were investigated. Whole, demineralized, and mineral-treated samples of pulverized coal were heated in 101 kPa He or 6.99 MPaH₂ at 1000 K s⁻¹ to temperatures of up to 1300 K. Yields of C₃, C₄–C₆, and C₆–C₈ hydrocarbon gases were determined as a function of time-temperature history. Calcium minerals decrease yields of all three fractions in pyrolysis under He atmosphere but have little effect on hydropyrolysis. Kaolinite reduces yields in pyrolysis, but increases them in hydropyrolysis. Other minerals, notably FeSO₄, have varying effects on product yields depending on run conditions.     

Diamond and graphite crystallization from C–O–H fluids under high pressure and high temperature conditions

Crystallization of diamond was studied in the CO₂–C, CO₂–H₂O–C, H₂O–C, and CH₄–H₂–C systems at 5.7 GPa and 1200–1420°C. Thermodynamic calculations show generation of CO₂, CO₂–H₂O, H₂O and CH₄–H₂ fluids in experiments with graphite and silver oxalate (Ag₂C₂O₄), oxalic acid dihydrate (H₂C₂O₄·2H₂O), water (H₂O), and anthracene (C₁₄H₁₀), respectively. Diamond nucleation and growth has been found in the CO₂–C, CO₂–H₂O–C, and H₂O–C systems at 1300–1420°C. At a temperature as low as 1200°C for 136 h there was spontaneous crystallization of diamond in the CO₂–H₂O–C system. For the CH₄–H₂–C system, at 1300–1420°C no diamond synthesis has been established, only insignificant growth on seeds was observed. Diamond octahedra form from the C–O–H fluids at all temperature ranges under investigation. Diamond formation from the fluids at 5.7 GPa and 1200–1420°C was accompanied with the active recrystallization of metastable graphite.     

Adsorption properties of a Pd/γ-Al2O3 catalyst using inverse gas chromatography

The adsorption properties of a commercial Pd/Al₂O₃ catalyst were studied and compared with those of the Al₂O₃ support of the same specific surface area. Inverse gas chromatography (IGC) was used to determine the adsorption isotherms of five n-alkanes (C₈–C₁₂) in the 200–230 °C temperature range. Moreover, heats of adsorption, solubility coefficients and free energy of adsorption, are also reported. Interaction parameters of polar molecules with the stationary phase have also been determined and compared with those for the n-alkanes. Experiments with both the reduced and oxidized catalyst have been carried out by IGC and the results compared with those obtained by temperature programmed reduction (TPR) experiments.     

Methanol formation from methane partial oxidation in CH4–O2–NO gaseous phase at atmospheric pressure

The reaction condition for high yield of methanol in a gaseous reaction between methane and oxygen in the presence of NO at atmospheric pressure was explored. Methane partial oxidation without NO (CH₄–O₂) gave only 1% conversion of methane at 966 K. The addition of NO led to a remarkable increase in methane conversion and to high selectivity to C₁-oxygenates. The conversion of methane attained 10% at 808 K in the presence of NO (0.5%) where the selectivities to methanol and formaldehyde were 22.1 and 24.1%, respectively. Nitromethane and carbon oxides were also observed in the product gas. The amount of nitromethane was almost equal and/or near to that of initial NO. The carbon monoxide produced was several times higher than carbon dioxide. Influences of NO concentration, ratio of methane to oxygen, water vapor, and dilution with helium gas on product distribution were measured. Low concentration of NO (0.35–0.55%) was favorable for methanol formation. High selectivity to methanol was obtained at low value of the ratio of methane to oxygen (2.0–3.0) or low concentration of dilution gas (<16%). The NO₂ added promoted methane partial oxidation and selectivity to methanol. Therefore, it was assured that NO_x promoted the formation of CH₃√ and CH₃O√ in the gas phase reaction for CH₄–O₂–NO.     

Conversion of naphthenes to a high value steamcracker feedstock using H-ZSM-5 based catalysts in the second step of the ARINO-process

Future regulations for the limitation of sulfur and aromatics in fuels driven by the European Auto Oil Program (AOP II) stimulate the need for an alternative utilization of the resulting surplus of pyrolysis gasoline (pygas). The conversion of heavy pyrolysis gasoline into valuable steam cracker feedstock with a maximum yield of C₂–C₄ n-alkanes is achieved via the ARINO^® two-step process, jointly developed by Linde, VEBA Oil and Süd-Chemie. The first step involves a hydrogenation of aromatics to naphthenes followed by the subsequent ring opening and cracking in the second step.

Süd-Chemie developed a new commercial cracking catalyst for the second step of the ARINO^® process with the aim to maximize the yield of C₂–C₄ n-alkanes at low formation of methane and aromatics. The ring opening and cracking reaction of naphthenes was studied in a bench scale tubular reactor over extruded H-ZSM-5 based zeolite catalysts.

In a series of screening tests using a commercial, hydrogenated and desulphurized heavy pyrolysis gasoline, the influence of the preparation parameters such as zeolite acidity, palladium content as well as the type of binder were investigated. Furthermore, the influence of the process conditions space velocity and temperature was studied.

High yields of C₂–C₄ n-alkanes at low formation of undesired methane and aromatics were achieved over an alumina bound zeolite with medium Brønsted acidity loaded with palladium.

The reduction of the space velocity resulted in an increase in the C₂–C₄ n-alkane yield and lower formation of aromatics, but a simultaneous increase in the methane make. Raising the temperature from 280 to 370 °C significantly increased the catalyst activity.     

Novel utilization of mesoporous molecular sieves as supports of cobalt catalysts in Fischer–Tropsch synthesis

Mesoporous molecular sieves (MCM-41 and SBA-15) with different pore diameters have been studied as supports of high loading of Co catalysts, and the performances in FT synthesis have been examined with a fixed bed stainless steel reactor at 2.0 MPa for the purpose of efficient production of C₁₀–C₂₀ fraction as the main component of diesel fuel. The method of exchanging template ions in uncalcined MCM-41 with Co²⁺ ions is effective for holding 10–20% Co within the mesopores while keeping the structure regularity of MCM-41 to some extent, compared with the conventional impregnation method using calcined MCM-41. At 523 K, CO conversion and selectivity to C₁₀–C₂₀ hydrocarbons are both higher at larger loading of 20% Co for the exchanged catalysts with pore diameters of 2.7–2.9 nm. When four kinds of 20% Co/SBA-15 with the diameters of 3.5–13 nm, prepared by the impregnation method using an ethanol solution of Co acetate, are used in FT synthesis at 523 K, the catalyst with the diameter of 8.3 nm shows the largest CO conversion, which is higher than those over MCM-41 supported Co catalysts. At a lower temperature of 503 K, however, the acetate-derived Co is almost inactive. In contrast, the use of Co nitrate alone or an equimolar mixture of the acetate and nitrate as Co precursor drastically enhances the reaction rate and consequently provides high space–time yield (260–270 g C/kg_cat h) of C₁₀–C₂₀ hydrocarbons. The X-ray diffraction and temperature-programmed reduction measurements show that the dependency of the catalytic performance of 20% Co/SBA-15 on its precursor originates probably from the differences in not only the reducibility of the calcined catalyst but also the dispersion of metallic Co. Catalyst characterization after FT synthesis strongly suggests the high stability of the most effective Co/SBA-15 in the dispersion and reducibility of the oxide species and in the mesoporous structure.     

Hydroisomerisation of n-alkanes over partially reduced MoO3: Promotion by CoAlPO-11 and relations to reaction mechanism and rate-determining step

The reaction mechanism and the rate-determining step (RDS) of the isomerisation of n-alkanes (C₄–C₆) over partially reduced MoO₃ catalysts were studied through the effects of the addition of an alkene isomerisation catalyst (i.e. CoAlPO-11). When an acidic CoAlPO-11 sample was mechanically mixed with the MoO₃, a decrease of the induction period and an increase of the steady-state conversion of n-butane to isobutane were observed. These data support previous assumptions that a bifunctional mechanism occurred over the partially reduced MoO₃ (a complex nanoscale mixture of oxide-based phases) during n-butane isomerisation and that the RDS was the skeletal isomerisation of the linear butene intermediates. The only promotional effect of CoAlPO-11 on the activity of partially reduced MoO₃ for C₅–C₆ alkane hydroisomerisation was a reduction of the induction period, as the RDS at steady-state conditions appeared to be dehydrogenation of the alkane in this case. However, lower yields of branched isomers were observed in this case, the reason of which is yet unclear.     

Enhanced activity of metal oxide-doped Ga2O3–Al2O3 for NO reduction by propene

Effect of additives, In₂O₃, SnO₂, CoO, CuO and Ag, on the catalytic performance of Ga₂O₃–Al₂O₃ prepared by sol–gel method for the selective reduction of NO with propene in the presence of oxygen was studied. As for the reaction in the absence of H₂O, CoO, CuO and Ag showed good additive effect. When H₂O was added to the reaction gas, the activity of CoO-, CuO- and Ag-doped Ga₂O₃–Al₂O₃ was depressed considerably, while an intensifying effect of H₂O was observed for In₂O₃- and SnO₂-doped Ga₂O₃–Al₂O₃. Of several metal oxide additives, In₂O₃-doped Ga₂O₃–Al₂O₃ showed the highest activity for NO reduction by propene in the presence of H₂O. Kinetic studies on NO reduction over In₂O₃–Ga₂O₃–Al₂O₃ revealed that the rate-determining step in the absence of H₂O is the reaction of NO₂ formed on Ga₂O₃–Al₂O₃ with C₃H₆-derived species, whereas that in the presence of H₂O is the formation of C₃H₆-derived species. We presumed the reason for the promotional effect of H₂O as follows: the rate for the formation of C₃H₆-derived species in the presence of H₂O is sufficiently fast compared with that for the reaction of NO₂ with C₃H₆-derived species in the absence of H₂O. Although the retarding effect of SO₂ on the activity was observed for all of the catalysts, SnO₂–Ga₂O₃–Al₂O₃ showed still relatively high activity in the lower temperature region.     

Reversible sorption–desorption of NOx by mixed oxides under various atmospheres

Characteristics of MnO_y–ZrO₂ and Pt–ZrO₂–Al₂O₃ as reversible sorbents of NO_x were investigated under dynamic changes in atmosphere. These sorbents can be used reversibly with a change of C₃H₈ concentration in the reaction gases. Catalytic reduction of NO occurred in the presence of propane, which was more pronounced on Pt–ZrO₂–Al₂O₃ than on MnO_y-ZrO₂ due to high activity of Pt surface for this reaction on MnO_y in MnO_y–ZrO₂. The sorption was observed as soon as the atmosphere changed from a reducing to an oxidizing one. This implies that a high equilibrium partial pressure of O₂ is necessary for NO uptake since the sorbed NO⁻₃ species becomes stable. The beginning of NO_x desorption atmospheres was somewhat dependent on the amount of stored NO_x. The presence of propane in the gas phase strongly affected the characteristic sorption and desorption properties of MnO_y–ZrO₂ and Pt–ZrO₂–Al₂O₃. The sorption and desorption properties are different for MnO_y–ZrO₂ and Pt–ZrO₂–Al₂O₃, since the noble metal or metal oxide possesses unique activity for the NO reaction with C₃H₈ and the amount of oxygen available for oxidative sorption of NO.     

Deactivated iron catalyst in the fischer-tropsch synthesis

The selectivity for higher hydrocarbons (C₁₁–C₁₇) has been studied in the Fischer-Tropsch synthesis using fresh and used fused iron catalysts under different reaction conditions. On increasing the temperature higher hydrocarbon products were formed in the C₁₁–C₁₇ range. The deactivated fused iron catalyst is less active but selective to heavier hydrocarbon chain molecules. The product distribution is shifted towards heavier hydrocarbons due to the effects of the pore volume, presence of potassium and site densities at the surface.     

Relative rates of various steps of NO–CH4–O2 reaction catalyzed by Pd/H-ZSM-5

Reaction mechanism of the reduction of nitrogen monoxide by methane in an oxygen excess atmosphere (NO–CH₄–O₂ reaction) catalyzed by Pd/H-ZSM-5 has been studied at 623–703 K in the absence of water vapor, in comparison with the mechanism for Co-ZSM-5. Kinetic isotope effect for the N₂ formation in NO–CH₄–O₂ vs. NO–CD₄–O₂ reactions was 1.65 at 673 K and decreased with a decrease in the reaction temperature. In addition, H–D isotopic exchange took place significantly in NO–(CH₄+CD₄)–O₂ reaction. These results are in marked contrast with the case of Co-ZSM-5, for which the C–H dissociation of methane is the only rate-determining step, and show that the C–H dissociation is slow but not the only rate-determining step in the case of Pd/H-ZSM-5.

A reaction scheme was proposed, in which the relative rates of the three steps ((i)–(iii) below) vary depending on the reaction conditions.

Further, in contrast to Co-ZSM-5, NO_x–CH₄–O₂ reaction was much slower than CH₄–O₂ reaction for Pd/H-ZSM-5; the presence of NO_x retards the reaction of CH₄ over the latter catalyst, while it accelerates the reaction over the former. It is suggested that CH₄ is activated directly by the Pd atoms in the case of Pd/H-ZSM-5, but by NO₂ strongly adsorbed on Co ion for Co-ZSM-5. The reaction order of the NO–CH₄–O₂ reaction with respect to NO pressure was consistent with this mechanism; 1.05 for Pd/H-ZSM-5 and 0.11 for Co-ZSM-5.     

Conversion of waste plastics into fuels: Recycling polyethylene in FCC

Low density polyethylene was dissolved into toluene and converted at 500 °C over three different commercial FCC catalysts in a laboratory Riser Simulator reactor. Short reaction-times up to 12 s were used. All the catalysts had qualitatively similar behaviors. The specific contribution of the polymer to the product slate of FCC was centered in hydrocarbons in the range of gasoline, with high aromatic content and highly olefinic C₃–C₄ gases. Saturated C₄–C₅ products were mainly isoparaffins. The additional coke formed by the polymer would make coke yields to increase moderately in relation to the standard operation. These facts confirmed that this recycling option, which is based on a proven technology, represents an interesting alternative to solve a major environmental problem.     

Oxidation state of palladium as a factor controlling catalytic activity of Pd/SiO2–Al2O3 in propane combustion

The oxidation state of palladium on SiO₂–Al₂O₃ used for propane combustion was examined by XPS and XRD, and the correlation of the catalytic activity with the oxidation state of palladium was systematically studied. The propane conversion over 5 wt% Pd/SiO₂–Al₂O₃ was measured in the range 1.0≤S≤7.2 (S is defined as [O₂]/5[C₃H₈] based on stoichiometric ratio). The propane conversion strongly depended on the S value and reached the maximum at S=5.5. The oxidation state of palladium also changed with the S value; palladium particles were more oxidized under the reaction mixture of higher S value. On the sample used for the reaction at S=5.5, both of metallic palladium and palladium oxide were found. It is concluded that partially oxidized palladium which has optimum ratio of metallic palladium to palladium oxide shows the highest catalytic activity in propane combustion.     

Effect of ammonium polyacrylate on rheology of anatase TiO2 nanoparticles dispersed in silicon alkoxide sols

Ammonium polyacrylate (NH₄PA) was introduced into powdered mixtures consisting of anatase-structured TiO₂ nanoparticles and silicon alkoxide precursors at the sol level, and the rheological behavior of the mixtures was examined under various solid loadings (φ=0.05–0.13 in volumetric ratios), shear rates (  s⁻¹) and NH₄PA concentrations. The alkoxide precursors were mixtures of tetraethyl orthosilicate (TEOS, Si(OC₂H₅)₄), ethyl alcohol (C₂H₅OH), H₂O and HCl in a constant [H₂O]/[TEOS] ratio of 11. The nanoparticle–sol mixtures generally exhibited a pseudoplastic flow behavior over the shear-rate regime examined. The NH₄PA appeared to serve as an effective surfactant which facilitates the suspension flow by reducing the flow resistance at low NH₄PA concentrations. At φ=0.10, a viscosity reduction ca. 85% was found at  s⁻¹ when the NH₄PA concentration was held at 2.5 wt.% of the solids. As the NH₄PA exceeded a critical level, e.g., [NH₄PA]≥3.0 wt.%, the NH₄PA acted as a catalyst which quickly turned the TiO₂–silica sol mixtures (φ=0.10) into a gelled structure, resulted in a pronounced increase of mixture viscosity. The maximum solids concentration (φ_m) of the mixtures was experimentally determined from a derivative of relative viscosity, i.e., (1−η_r^−1/2)–φ dependence. The estimated φ_m increased from 0.127 to 0.165 when NH₄PA of 0.5 wt.% was introduced into the TiO₂–silica sol mixtures.     

Fischer–Tropsch synthesis on monolithic catalysts of different materials

Monolithic structures made of cordierite, γ-Al₂O₃ and steel have been prepared as catalysts and tested for Fischer–Tropsch activity. The monoliths made of cordierite and steel were washcoated with a 20 wt.% Co–1 wt.% Re/γ-Al₂O₃ Fischer–Tropsch catalyst whereas the γ-Al₂O₃ monoliths were made by direct impregnation with an aqueous solution of the Co and Re salts resulting in a loading of 12 wt.% Co and 0.5 wt.% Re. The activity and selectivity of the different monoliths were compared with the corresponding powder catalysts.

Higher washcoat loadings resulted in decreased C₅₊ selectivity and olefin/paraffin ratios due to increased transport limitations. The impregnated γ-Al₂O₃ monoliths also showed similar C₅₊ selectivities as powder catalysts of small particle size (38–53 μm). Lower activities were observed with the steel monoliths probably due to experimental problems.