Optimising catalytic properties of supported sulfonic acid catalysts

Siliceous mesoporous molecular sieves (SBA-15) have been functionalised with propylsulfonic acid groups by both co-condensing 3-mercaptopropyltrimethoxysilane with the solid at the synthesis (sol-gel) stage and by grafting the same compound to pre-prepared SBA-15, followed, in both cases, by oxidation to sulfonic acid. The acidic and catalytic properties of the supported sulfonic acids prepared in the two ways have been compared, using ammonia adsorption calorimetry and the benzylation reaction between benzyl alcohol and toluene. Using a combination of X-ray photoelectron spectroscopy and other analytical techniques, the level of functionalisation and the extent of subsequent oxidation of tethered thiol to sulfonic acid, both in the bulk and close to the surface of SBA-15 particles, have been assessed. The research shows that the co-condensing route leads to higher levels of functionalisation than the grafting route. The extent of oxidation of added thiol to acid groups is similar using the two routes, about 70% near the surface and only 50% in the bulk. Comparison is made with polymer supported sulfonic acid catalysts, Amberlysts 15 and 35, and Nafion. Nafion shows the highest acid strength and the highest specific catalytic activity of all materials studied. Amongst the other materials, average acid strengths are broadly similar but there appears to be a relationship between the concentration of acid sites on the catalysts and their specific activity in the benzylation reaction. A model is proposed to explain this, in which clustering of sulfonic acid groups, even to a small extent, leads to disproportionately enhanced catalytic activity. © 2009 Elsevier B.V. All rights reserved.

An energy-efficient route to the rapid synthesis of organically-modified SBA-15 via ultrasonic template removal

A low energy route for the removal of Pluronic P123 surfactant template during the synthesis of SBA-15 mesoporous silicas is explored. The conventional reflux of the hybrid inorganic-organic intermediate formed during co-condensation routes to Pr-SOH-SBA-15 is slow, utilises large solvent volumes, and requires 24 h to remove ∼90% of the organic template. In contrast, room temperature ultrasonication in a small methanol volume achieves the same degree of template extraction in only 5 min, with a 99.9% energy saving and 90% solvent reduction, without compromising the textural, acidic or catalytic properties of the resultant Pr-SOH-SBA-15. © 2014 The Royal Society of Chemistry.

Zr-containing hybrid organic-inorganic mesoporous materials:hydrophobic acid catalysts for biodiesel production

Zirconium-containing periodic mesoporous organosilicas (Zr-PMOs) with varying framework organic content have been synthesized through a direct synthesis method. These materials display the excellent textural properties of the analogous inorganic solid acid Zr-SBA-15 material. However, the substitution of silica by organosilicon species provides a strong hydrophobic character. This substitution leads to meaningful differences in the environment surrounding the zirconium metal sites, leading the modification of the catalytic properties of these materials. Although lower metal incorporation is accomplished in the final materials, leading to a lower population of metal sites, hydrophobisation leads to an impressive beneficial effect on the intrinsic catalytic activity of the zirconium sites in biodiesel production by esterification/transesterification of free fatty acid -containing feedstock. Moreover, the catalytic activity of the highly hybridised materials is hardly affected in presence of large amounts of water, confirming their very good water-tolerance. This makes Zr-PMO materials interesting catalysts for biodiesel production from highly acidic water-containing feedstock. © 2013 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Structure-reactivity correlations in sulphated-zirconia catalysts for the isomerisation of α-pinene

A range of mesoporous sulphated zirconias with tuneable structural and catalytic properties have been prepared by direct impregnation. The surface sulphate coverage can be readily varied, achieving a maximum value of ∼0.2 monolayers. High-temperature calcination induces the crystallisation of tetragonal zirconia while suppressing the monoclinic phase and enhances surface acidity. Superacid sites only appear above a critical threshold SO4 coverage of 0.08 mL (corresponding to 0.44 wt% total S). Sulphated zirconias show good activity towards α-pinene isomerisation of under mild conditions. Conversion correlates with the number Brønsted acid sites, while the selectivity towards mono- versus polycyclic products depends on the corresponding acid site strength; superacidity promotes limonene formation over camphene.

Evaluation of catalytic pyrolysis of cassava rhizome by principal component analysis

Rhizome of cassava plants (Manihot esculenta Crantz) was catalytically pyrolysed at 500 °C using analytical pyrolysis–gas chromatography/mass spectrometry (Py–GC/MS) method in order to investigate the relative effect of various catalysts on pyrolysis products. Selected catalysts expected to affect bio-oil properties were used in this study. These include zeolites and related materials (ZSM-5, Al-MCM-41 and Al-MSU-F type), metal oxides (zinc oxide, zirconium (IV) oxide, cerium (IV) oxide and copper chromite) catalysts, proprietary commercial catalysts (Criterion-534 and alumina-stabilised ceria-MI-575) and natural catalysts (slate, char and ashes derived from char and biomass). The pyrolysis product distributions were monitored using models in principal components analysis (PCA) technique. The results showed that the zeolites, proprietary commercial catalysts, copper chromite and biomass-derived ash were selective to the reduction of most oxygenated lignin derivatives. The use of ZSM-5, Criterion-534 and Al-MSU-F catalysts enhanced the formation of aromatic hydrocarbons and phenols. No single catalyst was found to selectively reduce all carbonyl products. Instead, most of the carbonyl compounds containing hydroxyl group were reduced by zeolite and related materials, proprietary catalysts and copper chromite. The PCA model for carboxylic acids showed that zeolite ZSM-5 and Al-MSU-F tend to produce significant amounts of acetic and formic acids.

Catalytic pyrolysis of agricultural residues for bio-oil production

Agricultural residues from Thailand, namely stalk and rhizome of cassava plants, were employed as raw materials for bio-oil production via fast pyrolysis technology. There were two main objectives of this project. The first one was to determine the optimum pyrolysis temperature for maximising the organics yield and to investigate the properties of the bio-oils produced. To achieve this objective, pyrolysis experiments were conducted using a bench-scale (150 g/h) reactor system, followed by bio-oil analysis. It was found that the reactor bed temperature that could give the highest organics yield for both materials was 490±15ºC. At all temperatures studied, the rhizome gave about 2-4% higher organics yields than the stalk. The bio-oil derived from the rhizome had lower oxygen content, higher calorific value and better stability, thus indicating better quality than that produced from the stalk. The second objective was to improve the bio-oil properties in terms of heating value, viscosity and storage stability by the incorporation of catalyst into the pyrolysis process. Catalytic pyrolysis was initially performed in a micro-scale reactor to screen a large number of catalysts. Subsequently, seven catalysts were selected for experiments with larger-scale (150 g/h) pyrolysis unit. The catalysts were zeolite and related materials (ZSM-5, Al-MCM-41 and Al-MSU-F), commercial catalysts (Criterion-534 and MI-575), copper chromite and ash. Additionally, the combination of two catalysts in series was investigated. These were Criterion-534/ZSM-5 and Al-MSU-F/ZSM-5. The results showed that all catalysts could improve the bio-oils properties as they enhanced cracking and deoxygenation reactions and in some cases such as ZSM-5, Criterion-534 and Criterion-534/ZSM-5, valuable chemicals like hydrocarbons and light phenols were produced. The highest concentration of these compounds was obtained with Criterion-534/ZSM-5.

Catalytic pyrolysis of rice husk for bio-oil production

Catalytic pyrolysis experiments have been carried out on Brunei rice husk (BRH) to obtain bio-oil using a fixed-bed pyrolysis rig. ZSM-5, Al-MCM-41, Al-MSU-F and Brunei rice husk ash (BRHA) were used as the catalysts for the catalytic pyrolysis experiments and comparison was done to analyse the changes in the bio-oil properties and yield. Properties of the liquid catalytic and non-catalytic bio-oil were analysed in terms of water content, pH, acid number, viscosity, density and calorific value. The bio-oil chemical composition shows that ZSM-5 increases the production of aromatic hydrocarbons and light phenols, whilst Al-MCM-41 reduces the acetic acid production. The catalytic runs increased the calorific value and water content in the bio-oil, whilst viscosity, density and acid number is decreased. © 2012 Elsevier B.V. All rights reserved.

The intermediate pyrolysis and catalytic steam reforming of brewers spent grain

Brewers spent grain (BSG) is a widely available feedstock representing approximately 85% of the total by-products generated in the brewing industry. This is currently either disposed of to landfill or used as cattle feed due to its high protein content. BSG has received little or no attention as a potential energy resource, but increasing disposal costs and environmental constraints are now prompting the consideration of this. One possibility for the utilisation of BSG for energy is via intermediate pyrolysis to produce gases, vapours and chars. Intermediate pyrolysis is characterised by indirect heating in the absence of oxygen for short solids residence times of a few minutes, at temperatures of 350-450 °C. In the present work BSG has been characterised by chemical, proximate, ultimate and thermo-gravimetric analysis. Intermediate pyrolysis of BSG at 450 °C was carried out using a twin coaxial screw reactor known as Pyroformer to give yields of char 29%, 51% of bio-oil and 19% of permanent gases. The bio-oil liquid was found to separate in to an aqueous phase and organic phase. The organic phase contained viscous compounds that could age over time leading to solid tars that can present problems in CHP application. The quality of the pyrolysis vapour products before quenching can be upgraded to achieve much improved suitability as a fuel by downstream catalytic reforming. A Bench Scale batch pyrolysis reactor has then been used to pyrolyse small samples of BSG under a range of conditions of heating rate and temperature simulating the Pyroformer. A small catalytic reformer has been added downstream of the reactor in which the pyrolysis vapours can be further cracked and reformed. A commercial reforming nickel catalyst was used at 500, 750 and 850 °C at a space velocity about 10,000 L/h with and without the addition of steam. Results are presented for the properties of BSG, and the products of the pyrolysis process both with and without catalytic post-processing. Results indicate that catalytic reforming produced a significant increase in permanent gases mainly (H2 and CO) with H2 content exceeding 50 vol% at higher reforming temperatures. Bio-oil yield decreased significantly as reforming temperature increased with char remaining the same as pyrolysis condition remained unchanged. The process shows an increase in heating value for the product gas ranging between 10.8-25.2 MJ/m as reforming temperature increased. © 2012 Elsevier B.V. All rights reserved.

In situ catalytic upgrading of bio-oil using supported molybdenum carbide

The aim of this work is to improve some of the less desirable properties of bio-oil via the catalytic fast pyrolysis of sugarcane bagasse using a novel supported molybdenum carbide (20 wt.% MoC/AlO ) catalyst. Proximate and elemental analysis of the bagasse were carried out to determine the moisture, ash, carbon, hydrogen, nitrogen and oxygen content. The ground pellets were classified in sieves to a size range of 0.25-1 mm and were pyrolysed in a 300 g h fluidised bed reactor at 500 C. MoC/AlO replaced the sand in the fluidised bed reactor in different proportions (0 wt.%, 12 wt.%, 25 wt.% and 50 wt.%) to investigate the effect of this catalyst on the pyrolysis products. Bio-oil yield results showed that ground sugarcane bagasse pellets gave high organic yields in the bio-oil of 60.5 wt.% on dry feed with a total liquid yield of 73.1 wt.% on dry feed without catalyst. Increasing the catalyst proportions in the fluidised bed reduced bio-oil yields, significantly reduced sugars (as a-levoglucosan) concentration and increased furanics and phenolics concentration in the bio-oil. It was observed that the higher the concentration of the 20 wt.% MoC/AlO catalyst in the fluidised bed the lower the viscosity of the bio-oil. © 2013 Elsevier B.V. All rights reserved.

Control of spatiotemporal chaos in catalytic CO oxidation by laser-induced pacemakers

Control of spatiotemporal chaos is achieved in the catalytic oxidation of CO on Pt(110) by localized modification of the kinetic properties of the surface chemical reaction. In the experiment, a small temperature heterogeneity is created on the surface by a focused laser beam. This heterogeneity constitutes a pacemaker and starts to emit target waves. These waves slowly entrain the medium and suppress the spatiotemporal chaos that is present in the absence of control. We compare this experimental result with a numerical study of the Krischer-Eiswirth-Ertl model for CO oxidation on Pt(110). We confirm the experimental findings and identify regimes where complete and partial controls are possible.

Catalytic intermediate pyrolysis of Brunei rice husk for bio-oil production

Rice husks from Brunei were subjected via intermediate pyrolysis for bio-oil production. Two main objectives were set out for this study. The application of intermediate pyrolysis on Brunei rice husk for the production of bio-oil is the main objective of this experiment. Characterisation of the rice husks was inclusive as a pre-requisite step to assess the suitability as feedstock for production of liquid fuels. Following on from the characterisation results, a temperature of 450°C was established as the optimum temperature for the production of bio-oil. A homogenous bio-oil was obtained from the pyrolysis of dry rice husk, and the physicochemical properties and chemical compositions were analysed. The second objective is the introduction of catalysts into the pyrolysis process which aims to improve the bio-oil quality, and maximise the desired liquid bio-oil properties. The incorporation of the catalysts was done via a fixed tube reactor into the pyrolysis system. Ceramic monoliths were used as the catalyst support, with montmorillonite clay as a binder to attach the catalysts onto the catalyst support. ZSM-5, Al-MCM-41, Al-MSU-F and Brunei rice husk ash (BRHA) together with its combination were adopted as catalysts. Proposed criterions dictated the selection of the best catalysts, subsequently leading to the optimisation process for bio-oil production. ZSM-5/Al-MCM-41 proved the most desirable catalyst, which increases the production of aromatics and phenols, decreased the organic acids and improved the physicochemical properties such as the pH, viscosity, density and H:C molar ratios. Variation in the ratio and positioning of both catalysts were the significant key factor for the catalyst optimisation study.

Physicochemical properties of WOx/ZrO2 catalysts for palmitic acid esterification

A series of WOx/ZrO2 with various tungsten loadings was prepared via incipient-wetness impregnation of zirconium hydroxide. The resulting thermally processed materials were characterised by XRD, XPS, porosimetry, NH3-TPD and pyridine FTIR spectroscopy to elucidate their composition, morphology and acidity, and subsequently tested in the esterification of palmitic acid with methanol. Catalytic performance was strongly dependent upon calcination temperature and W surface density. Esterification activity increased with increasing surface W density, reaching a maximum at 8.9Wnm-2 corresponding to near monolayer coverage. Subsequent growth of crystalline WO3 lowered activity, consistent with a decrease in the density of active surface sites. Calcination temperatures as high as 800°C increased surface acidity and hence catalytic activity. The formation of polymeric tungstate species on zirconia is necessary to generate the Brönsted acid sites responsible for palmitic acid esterification under mild conditions. © 2014 Elsevier B.V.

Catalytic systems based on carbon fiber materials for the low-temperature oxidation of carbon monoxide

New heterogenized catalytic systems for the low-temperature oxidation of CO were synthesized by supporting solutions of Pd, Cu, and Fe salts on carbon fibrous materials (carbopon and busofit). The carbon supports were studied by elemental analysis, SEM, TGA, and TPD. The effects of the nature of the support, the concentration and composition of the active component, and the conditions of preparation on the efficiency of the catalytic system were studied. It was ascertained that attenuation of hydrophilic properties of the support led to the decrease in system activity. The investigation of the catalysts by XPS showed that sample treatment in the reaction medium results in redistribution of the components of the active phase in the near-surface layer of the catalyst. The catalytic system based on carbon fibrous material carbopon prepared by supporting active components (Pd, Cu, and Fe salts) in three stages with intermediate activation in the reaction medium ensures 95% conversion of CO under respiratory conditions, and is promising for the design of the main element of breathing masks on its basis.

Thermochemical conversion of Brewers Spent Grain combined with catalytic reforming of pyrolysis vapours

The brewing process is an energy intensive process that uses large quantities of heat and electricity. To produce this energy requires a high, mainly fossil fuel consumption and the cost of this is increasing each year due to rising fuel costs. One of the main by-products from the brewing process is Brewers Spent Grain (BSG), an organic residue with very high moisture content. It is widely available each year and is often given away as cattle feed or disposed of to landfill as waste. Currently these methods of disposal are also costly to the brewing process. The focus of this work was to investigate the energy potential of BSG via pyrolysis, gasification and catalytic steam reforming, in order to produce a tar-free useable fuel gas that can be combusted in a CHP plant to develop heat and electricity. The heat and electricity can either be used on site or exported. The first stage of this work was the drying and pre-treatment of BSG followed by characterisation to determine its basic composition and structure so it can be evaluated for its usefulness as a fuel. A thorough analysis of the characterisation results helps to better understand the thermal behaviour of BSG feedstock so it can be evaluated as a fuel when subjected to thermal conversion processes either by pyrolysis or gasification. The second stage was thermochemical conversion of the feedstock. Gasification of BSG was explored in a fixed bed downdraft gasifier unit. The study investigated whether BSG can be successfully converted by fixed bed downdraft gasification operation and whether it can produce a product gas that can potentially run an engine for heat and power. In addition the pyrolysis of BSG was explored using a novel “Pyroformer” intermediate pyrolysis reactor to investigate the behaviour of BSG under these processing conditions. The physicochemical properties and compositions of the pyrolysis fractions obtained (bio-oil, char and permanent gases) were investigated for their applicability in a combined heat power (CHP) application.