Catalytic liquid- and gas-phase oxidations for the synthesis of intermediates and specialty chemicals: some examples of industrial relevance

Nowadays, it is clear that the target of creating a sustainable future for the next generations requires to re-think the industrial application of chemistry. It is also evident that more sustainable chemical processes may be economically convenient, in comparison with the conventional ones, because fewer by-products means lower costs for raw materials, for separation and for disposal treatments; but also it implies an increase of productivity and, as a consequence, smaller reactors can be used. In addition, an indirect gain could derive from the better public image of the company, marketing sustainable products or processes. In this context, oxidation reactions play a major role, being the tool for the production of huge quantities of chemical intermediates and specialties. Potentially, the impact of these productions on the environment could have been much worse than it is, if a continuous efforts hadn’t been spent to improve the technologies employed. Substantial technological innovations have driven the development of new catalytic systems, the improvement of reactions and process technologies, contributing to move the chemical industry in the direction of a more sustainable and ecological approach. The roadmap for the application of these concepts includes new synthetic strategies, alternative reactants, catalysts heterogenisation and innovative reactor configurations and process design. Actually, in order to implement all these ideas into real projects, the development of more efficient reactions is one primary target. Yield, selectivity and space-time yield are the right metrics for evaluating the reaction efficiency. In the case of catalytic selective oxidation, the control of selectivity has always been the principal issue, because the formation of total oxidation products (carbon oxides) is thermodynamically more favoured than the formation of the desired, partially oxidized compound. As a matter of fact, only in few oxidation reactions a total, or close to total, conversion is achieved, and usually the selectivity is limited by the formation of by-products or co-products, that often implies unfavourable process economics; moreover, sometimes the cost of the oxidant further penalizes the process. During my PhD work, I have investigated four reactions that are emblematic of the new approaches used in the chemical industry. In the Part A of my thesis, a new process aimed at a more sustainable production of menadione (vitamin K3) is described. The “greener” approach includes the use of hydrogen peroxide in place of chromate (from a stoichiometric oxidation to a catalytic oxidation), also avoiding the production of dangerous waste. Moreover, I have studied the possibility of using an heterogeneous catalytic system, able to efficiently activate hydrogen peroxide. Indeed, the overall process would be carried out in two different steps: the first is the methylation of 1-naphthol with methanol to yield 2-methyl-1-naphthol, the second one is the oxidation of the latter compound to menadione. The catalyst for this latter step, the reaction object of my investigation, consists of Nb2O5-SiO2 prepared with the sol-gel technique. The catalytic tests were first carried out under conditions that simulate the in-situ generation of hydrogen peroxide, that means using a low concentration of the oxidant. Then, experiments were carried out using higher hydrogen peroxide concentration. The study of the reaction mechanism was fundamental to get indications about the best operative conditions, and improve the selectivity to menadione. In the Part B, I explored the direct oxidation of benzene to phenol with hydrogen peroxide. The industrial process for phenol is the oxidation of cumene with oxygen, that also co-produces acetone. This can be considered a case of how economics could drive the sustainability issue; in fact, the new process allowing to obtain directly phenol, besides avoiding the co-production of acetone (a burden for phenol, because the market requirements for the two products are quite different), might be economically convenient with respect to the conventional process, if a high selectivity to phenol were obtained. Titanium silicalite-1 (TS-1) is the catalyst chosen for this reaction. Comparing the reactivity results obtained with some TS-1 samples having different chemical-physical properties, and analyzing in detail the effect of the more important reaction parameters, we could formulate some hypothesis concerning the reaction network and mechanism. Part C of my thesis deals with the hydroxylation of phenol to hydroquinone and catechol. This reaction is already industrially applied but, for economical reason, an improvement of the selectivity to the para di-hydroxilated compound and a decrease of the selectivity to the ortho isomer would be desirable. Also in this case, the catalyst used was the TS-1. The aim of my research was to find out a method to control the selectivity ratio between the two isomers, and finally to make the industrial process more flexible, in order to adapt the process performance in function of fluctuations of the market requirements. The reaction was carried out in both a batch stirred reactor and in a re-circulating fixed-bed reactor. In the first system, the effect of various reaction parameters on catalytic behaviour was investigated: type of solvent or co-solvent, and particle size. With the second reactor type, I investigated the possibility to use a continuous system, and the catalyst shaped in extrudates (instead of powder), in order to avoid the catalyst filtration step. Finally, part D deals with the study of a new process for the valorisation of glycerol, by means of transformation into valuable chemicals. This molecule is nowadays produced in big amount, being a co-product in biodiesel synthesis; therefore, it is considered a raw material from renewable resources (a bio-platform molecule). Initially, we tested the oxidation of glycerol in the liquid-phase, with hydrogen peroxide and TS-1. However, results achieved were not satisfactory. Then we investigated the gas-phase transformation of glycerol into acrylic acid, with the intermediate formation of acrolein; the latter can be obtained by dehydration of glycerol, and then can be oxidized into acrylic acid. Actually, the oxidation step from acrolein to acrylic acid is already optimized at an industrial level; therefore, we decided to investigate in depth the first step of the process. I studied the reactivity of heterogeneous acid catalysts based on sulphated zirconia. Tests were carried out both in aerobic and anaerobic conditions, in order to investigate the effect of oxygen on the catalyst deactivation rate (one main problem usually met in glycerol dehydration). Finally, I studied the reactivity of bifunctional systems, made of Keggin-type polyoxometalates, either alone or supported over sulphated zirconia, in this way combining the acid functionality (necessary for the dehydrative step) with the redox one (necessary for the oxidative step). In conclusion, during my PhD work I investigated reactions that apply the “green chemistry” rules and strategies; in particular, I studied new greener approaches for the synthesis of chemicals (Part A and Part B), the optimisation of reaction parameters to make the oxidation process more flexible (Part C), and the use of a bioplatform molecule for the synthesis of a chemical intermediate (Part D).

Tratamento de esgoto sanitário em reator anaeróbio horizontal de leito fixo (RAHLF): escala piloto

Este trabalho apresenta as avaliações de desempenho, das demandas operacionais e dos fatores intervenientes no aumento da escala da unidade piloto do Reator anaeróbio Horizontal de Leito Fixo (RAHLF) no tratamento de esgoto sanitário após passagem por peneira com malha de 1 mm, durante dois anos de operação. O reator dispunha de volume total de 237,5 1, construídos com tubos comerciais de PVC de 14,5 cm de diâmetro (D), dispostos em cinco módulos horizontais em série de 2,88 m, perfazendo um comprimento total de (L) de 14,4 m e relação de total de L/D de 100. O suporte de imobilização de biomassa, espuma de poliuretano em matrizes cúbicas de 1 cm de aresta, mostrou-se adequado ao desenvolvimento do biofilme. Em partida, sem inoculação prévia, ocorreu a sua consolidação a partir de 70 dias, com predominância de morfologia semelhante a Methanosaeta sp. em relação a da Methanosarcina. Em torno de 90 dias com afluente de 350 mg/l de DQO, observe-se a melhor qualidade do efluente, com valor de 100 mg/l de DQO. Em longa operação ocorreu queda de rendimento e menor reprodutibilidade das previsões do projeto, atribuída aos constantes entupimentos e ineficácia das operações de limpeza, com o comprometimento de volume reacional verificados por estudos de hidrodinâmica. Da investigação das origens dos equipamentos observou-se tratar mais de um efeito local e qualitativamente relacionado à biomassa retida que propriamente quantitativo e extensivo ao longo de todo reator, com produção continuada de polímeros extracelulares, promovendo um efeito sinérgico com os predominantes organismos filamentosos e com os sólidos particulados retidos no leito. Diante das potencialidades desta configuração de reator apontam-se alternativas de mitigação dos entupimentos e o direcionamento dos estudos necessários para novo aumento de escala para o tratamento de esgoto sanitário.

Effect of the preparation technique on the catalytic properties of mesoporous V-HMS for the oxidation of toluene

Various mesoporous catalysts with vanadium loadings between 0.5 and 6 V wt.% and surface areas around 1300 m(2)/g were synthesized using the isomorphous substitution (IS) and molecular designed dispersion (MDD) techniques. Their catalytic properties were tested using toluene as a model VOC in a fixed bed reactor at temperatures between 300 and 550 degrees C. It was found that during the oxidation of toluene, over V-HMS synthesized via IS, conversion of toluene mainly results in carbon oxides, benzene, benzaldehyde and water. Total conversion is greatly improved when the vanadium content is increased from around 1.5 to 3.0 wt.%, but an increase in the textural porosity (V-TEX/V-MESO) from 0.3 to 0.6 had no discernable effect on the conversion. This can be explained by the fact that a V-TEX/V-MESO as low as 0.3 is sufficient to facilitate the access of toluene into the framework confined mesopores without any molecular transport limitations. However, when using V-HMS synthesized by MDD, conversion of toluene is greatly improved when the V-TEX/ V-MESO ratio is increased from 0.1 to 0.6. This is because the diffusion limitations are minimized by this increase. V-HMS synthesized via MDD does not exhibit selectivity to benzaldehyde, favoring total oxidation to CO and CO2. This different oxidation mechanism can be explained in terms of location, accessibility and number of active species on the surface of the HMS support. (c) 2005 Elsevier Inc. All rights reserved.

Comparison of the effect of pre-treatment and catalysts on liquid quality from fast pyrolysis of biomass

The overall objective of this work was to compare the effect of pre-treatment and catalysts on the quality of liquid products from fast pyrolysis of biomass. This study investigated the upgrading of bio-oil in terms of its quality as a bio-fuel and/or source of chemicals. Bio-oil used directly as a biofuel for heat or power needs to be improved particularly in terms of temperature sensitivity, oxygen content, chemical instability, solid content, and heating values. Chemicals produced from bio-oil need to be able to meet product specifications for market acceptability. There were two main objectives in this research. The first was to examine the influence of pre-treatment of biomass on the fast pyrolysis process and liquid quality. The relationship between the method of pre-treatment of biomass feedstock to fast pyrolysis oil quality was studied. The thermal decomposition behaviour of untreated and pretreated feedstocks was studied by using a TGA (thermogravimetric analysis) and a Py-GC/MS (pyroprobe-gas chromatography/mass spectrometry). Laboratory scale reactors (100g/h, 300g/h, 1kg/h) were used to process untreated and pretreated feedstocks by fast pyrolysis. The second objective was to study the influence of numerous catalysts on fast pyrolysis liquids from wheat straw. The first step applied analytical pyrolysis (Py-GC/MS) to determine which catalysts had an effect on fast pyrolysis liquid, in order to select catalysts for further laboratory fast pyrolysis. The effect of activation, temperature, and biomass pre-treatment on catalysts were also investigated. Laboratory experiments were also conducted using the existing 300g/h fluidised bed reactor system with a secondary catalytic fixed bed reactor. The screening of catalysts showed that CoMo was a highly active catalyst, which particularly reduced the higher molecular weight products of fast pyrolysis. From these screening tests, CoMo catalyst was selected for larger scale laboratory experiments. With reference to the effect of pre-treatment work on fast pyrolysis process, a significant effect occurred on the thermal decomposition of biomass, as well as the pyrolysis products composition, and the proportion of key components in bio-oil. Torrefaction proved to have a mild influence on pyrolysis products, when compared to aquathermolysis and steam pre-treatment.

Zirconia and alumina based catalysts for steam reforming of naphthalene

The present paper deals with experimentation of ZrO2 and Al2O3-supported catalysts for conversion of naphthalene, chosen as tar model compound of pyrolysis or gasification syngas. In particular, the reforming capacity of active metals and promoters such as Co, Ni, Fe, Cr, Ce and Pt was tested in a fixed bed reactor at temperature from 400 to 900 °C. As regards ZrO2-supported catalysts, the best results were achieved by the Ni/Fe/Pt catalyst with 96% naphthalene conversion, 78% and 280% as CO and H2 production yield at 800 °C. Regarding Al2O3-supported catalysts, they were more active on average than the zirconia ones, achieving a very good performance even at 500 °C (90–100% naphthalene conversion, 30–40% CO yield and 300–350% H2 yield at 550 °C). Influence of different amounts of alumina, montmorillonite and carbon on carrier composition as well as pellets’ size were also studied. Both zirconia and alumina catalysts showed deactivation at higher temperatures due to coke deposition, resulting in a strong H2 production drop. Regeneration of catalysts by O2 and steam as well as activation by H2 were also studied. The activated catalyst was able to convert more than 99% naphthalene at 450 °C with a CO and H2 production yield of 26% and 420%, respectively.

Effect of Cu and Sn promotion on the catalytic deoxygenation of model and algal lipids to fuel-like hydrocarbons over supported Ni catalysts

The ability of Cu and Sn to promote the performance of a 20% Ni/Al2O3 catalyst in the deoxygenation of lipids to fuel-like hydrocarbons was investigated using model triglyceride and fatty acid feeds, as well as algal lipids. In the semi-batch deoxygenation of tristearin at 260 °C a pronounced promotional effect was observed, a 20% Ni-5% Cu/Al2O3 catalyst affording both higher conversion (97%) and selectivity to C10-C17 alkanes (99%) in comparison with unpromoted 20% Ni/Al2O3 (27% conversion and 87% selectivity to C10-C17). In the same reaction at 350 °C, a 20% Ni-1% Sn/Al2O3 catalyst afforded the best results, giving yields of C10-C17 and C17 of 97% and 55%, respectively, which contrasts with the corresponding values of 87 and 21% obtained over 20% Ni/Al2O3. Equally encouraging results were obtained in the semi-batch deoxygenation of stearic acid at 300 °C, in which the 20% Ni-5% Cu/Al2O3 catalyst afforded the highest yields of C10-C17 and C17. Experiments were also conducted at 260 °C in a fixed bed reactor using triolein − a model unsaturated triglyceride − as the feed. While both 20% Ni/Al2O3 and 20% Ni-5% Cu/Al2O3 achieved quantitative yields of diesel-like hydrocarbons at all reaction times sampled, the Cu-promoted catalyst exhibited higher selectivity to longer chain hydrocarbons, a phenomenon which was also observed in experiments involving algal lipids as the feed. Characterization of fresh and spent catalysts indicates that Cu enhances the reducibility of Ni and suppresses both cracking reactions and coke-induced deactivation.

Novel input-output prediction approach for biomass pyrolysis

Biomass pyrolysis to bio-oil is one of the promising sustainable fuels. In this work, relation between biomass feedstock element characteristic and pyrolysis process outputs was explored. The element characteristics considered in this study include moisture, ash, fix carbon, volatile matter, carbon, hydrogen, nitrogen, oxygen, and sulphur. A semi-batch fixed bed reactor was used for biomass pyrolysis with heating rate of 30 °C/min from room temperature to 600 °C and the reactor was held at 600 °C for 1 h before cooling down. Constant nitrogen flow rate of 5 L/min was provided for anaerobic condition. Rice husk, Sago biomass and Napier grass were used in the study to form different element characteristic of feedstock by altering mixing ratio. Comparison between each element characteristic to total produced bio-oil yield, aqueous phase bio-oil yield, organic phase bio-oil yield, higher heating value of organic phase bio-oil, and organic bio-oil compounds was conducted. The results demonstrate that process performance is associated with feedstock properties, which can be used as a platform to access the process feedstock element acceptance range to estimate the process outputs. Ultimately, this work evaluated the element acceptance range for proposed biomass pyrolysis technology to integrate alternative biomass species feedstock based on element characteristic to enhance the flexibility of feedstock selection.

Obtenção de Mo2C com adição de Co por reação gás-sólido em reator de leito fixo

Sulfur compounds emissions have been, on the late years, subject to more severe environmental laws due to its impact on the environment (causing the acid rain phenomena) and on human health. It has also been object of much attention from the refiners worldwide due to its relationship with equipment’s life, which is decreased by corrosion, and also with products’ quality, as the later may have its color, smell and stability altered by the presence of such compounds. Sulfur removal can be carried out by hydrotreating (HDT) which is a catalytic process. Catalysts for HDS are traditionally based on Co(Ni)-Mo(W)/Al2O3. However, in face of the increased contaminants’ content on crude oil, and stricter legislation on emissions, the development of new, more active and efficient catalysts is pressing. Carbides of refractory material have been identified as potential materials for this use. The addition of a second metal to carbides may enhance catalytic activities by increasing the density of active sites. In the present thesis Mo2C with Co addition was produced in a fixed bed reactor via gas-solid reaction of CH4 (5%) and H2(95%) with a precursor made of a mix of ammonium heptamolybdate [(NH4)6[Mo7O24].4H2O] and cobalt nitrate[Co(NO3)2.6H2O] at stoichiometric amounts. Precursors’ where analyzed by XRF, XRD, SEM and TG/DTA. Carboreduction reactions were carried out at 700 and 750°C with two cobalt compositions (2,5 and 5%). Reaction’s products were characterized by XRF, XRD, SEM, TOC, BET and laser granulometry. It was possible to obtain Mo2C with 2,5 and 5% cobalt addition as a single phase at 750°C with nanoscale crystallite sizes. At 700°C, however, both MoO2 and Mo2C phases were found by XRD. No Co containing phases were found by XRD. XRF, however, confirmed the intended Co content added. SEM images confirmed XRD data. The increase on Co content promoted a more severe agglomeration of the produced powder. The same effect was noted when the reaction temperature was increased. The powder synthesized at 750°C with 2,5% Co addition TOC analysis indicated the complete conversion from oxide material to carbide, with a 8,9% free carbon production. The powder produced at this temperature with 5% Co addition was only partially converted (86%)

Desenvolvimento de material BaCexPr1-xO3 (0 ≤ X ≤ 1) com estrutura perovskita para oxidação catalítica do CO a CO2 em reator de leito fixo

Barium Cerate (BaCeO3) is perovskite type structure of ABO3, wherein A and B are metal cations. These materials, or doped, have been studied by having characteristics that make them promising for the application in fuel cells solid oxide, hydrogen and oxygen permeation, as catalysts, etc .. However, as the ceramic materials mixed conductivity have been produced by different synthesis methods, some conditions directly influence the final properties, one of the most important doping Site B, which may have direct influence on the crystallite size, which in turn directly influences their catalytic activity. In this study, perovskite-type (BaCexO3) had cerium gradually replaced by praseodymium to obtain ternary type materials BaCexPr1-xO3 and BaPrO3 binaries. These materials were synthesized by EDTA/Citrate complexing method and the material characterized via XRD, SEM and BET for the identification of their structure, morphology and surface area. Moreover were performed on all materials, catalytic test in a fixed bed reactor for the identification of that person responsible for complete conversion of CO to CO2 at low operating temperature, which step can be used as the subsequent production of synthesis gas (CO + H2) from methane oxidation. In the present work the crystalline phase having the orthorhombic structure was obtained for all compositions, with a morphology consisting of agglomerated particles being more pronounced with increasing praseodymium in the crystal structure. The average crystal size was between 100 nm and 142,2 nm. The surface areas were 2,62 m²g-1 for the BaCeO3 composition, 3,03 m²g-1 to BaCe0,5Pr0,5O3 composition and 2,37 m²g-1 to BaPrO3 composition. Regarding the catalytic tests, we can conclude that the optimal flow reactor operation was 50 ml / min and the composition regarding the maximum rate of conversion to the lowest temperature was BaCeO3 to 400° C. Meanwhile, there was found that the partially replaced by praseodymium, cerium, there was a decrease in the catalytic activity of the material.

Catalizzatori polifunzionali per la sintesi di Metil Isobutil Chetone

In this work, we have examined the activity and selectivity of new catalysts for the single-stage production of methyl isobutyl ketone (MIBK, 4- methyl-2-pentanone) from acetone (both in liquid and gas phase), using a fixed bed reactor operated in the temperature range between 373 and 473 K. The main reaction pathways for the synthesis of MIBK from acetone are given in Fig.1. The first step is the self condensation of acetone to diacetone alcohol (DAA, 4-hydroxy-4-methyl-2-pentanone); the second step is the dehydration of DAA to mesityl oxide (MO, 4-methyl-3-penten-2-one); the final step is the selective hydrogenation of the carbon–carbon double bond of MO to form MIBK. The most commonly observed side reactions are over-condensations and unselective hydrogenations (also shown in Fig.1). Two types of catalysts were studied: i)Pd supported on MgO-SiO2 mixed oxides with ratio of Mg to Si, synthetized using Ohnishi’s method and ii)Pd supported on alumina doped with 5% or 10% of MgO. The different Mg-Si and Mg-Al catalysts were characterized by different techniques (XRD, BET, SEM, NH3-TPD and CO2-TPD) and tested under different conditions in the condensation of acetone to diacetone alcohol and its dehydration to mesityl oxide to enhance the activity. Palladium was chosen as metal component, and its hydrogenation activity was studied. A low hydrogenation activity negatively affects the acetone conversion and promotes the production of mesityl oxide. Hydrogenation conditions being too severe may favor the unwanted hydrogenation of acetone to 2-propanol and of MIBK to methyl isobutyl carbinol (MIBC, 4-methyl-2-pentanol) but this effect is less detrimental to the MIBK selectivity than an unsufficient hydrogenation activity.

Características de cinzas e sua aplicação no tratamento de gases durante a gasificação de biomassa

Na procura de melhores combustíveis para a produção de energia térmica e energia elétrica, a biomassa apresenta-se como uma das fontes de energia renováveis menos prejudiciais ao meio ambiente, esta é considerada como um recurso neutro do ponto de vista de emissões de dióxido de carbono. Atualmente, a tecnologia predominante no domínio da conversão energética de biomassa por via termoquímica é a combustão. Contudo, verifica-se a procura de combustíveis de melhor qualidade produzidos a partir de biomassa, como por exemplo na forma gasosa (gás de combustível). A produção deste tipo de combustíveis gasosos envolvendo processos de gasificação carece do desenvolvimento de tecnologia que permita obter um gás combustível com características adequadas às utilizações pretendidas. Os problemas mais relevantes relacionados com a conversão termoquímica da biomassa incluem a produção de cinzas e de alcatrões, estes podem levar a vários problemas operatórios. O presente trabalho teve dois objetivos, a caracterização das cinzas resultantes do processo de combustão de biomassa e o estudo do efeito da aplicação das cinzas para melhorar as propriedades do gás produzido durante o processo de gasificação de biomassa, principalmente na redução de compostos condensáveis (alcatrões). As cinzas volantes da combustão de biomassa analisadas apresentam na sua constituição elementos químicos característicos da biomassa, onde o cálcio apresenta-se em concentrações mais elevadas. Em menores concentrações encontram-se sódio, magnésio, fósforo, enxofre, cloro, potássio, manganês e ferro. As cinzas de fundo, pelo contributo que a areia do leito tem, são caracterizadas por conterem grandes concentrações de silício. Durante os processos de gasificação de biomassa a concentração de compostos condensáveis diminuiu com o aumento da razão de equivalência. As cinzas, colocadas no reator de leito fixo, apresentam um efeito positivo sobre a qualidade do gás, nomeadamente um aumento de 47,8% no teor de H2 e de 11% de CO, consequentemente obteve-se um gás combustível com PCI (poder calorífico inferior) mais elevado.

Estudo da gasificação do glicerol em reator de leito fixo

As metas da União Europeia para 2020 em termos de biocombustíveis e biolíquidos traduziram-se, na última década, num destaque da indústria de biodiesel em Portugal. Inerente ao processo de produção biodiesel está um subproduto, o glicerol bruto, cujo estudo tem vindo a ser alvo de interesse na comunidade científica. O objetivo principal deste trabalho consistiu no estudo da gasificação do glicerol técnico e do glicerol bruto, usando vapor como agente oxidante. Pretendeu-se avaliar a composição do gás de produção obtido e os parâmetros de gasificação, como a percentagem de conversão de carbono e de hidrogénio, o rendimento de gás seco, a eficiência de gás frio e o poder calorífico do gás produzido. No estudo da gasificação do glicerol técnico avaliou-se o efeito da temperatura na performance do processo, entre 750 – 1000 ºC, e estudou-se ainda o efeito do caudal de alimentação ao reator (3,8 mL/min, 6,5 mL/min e 10,0 mL/min). Para o caudal mais baixo, estudou-se o efeito da razão de mistura glicerol/água (25/75, 40/60, 60/40 e 75/25) e para a razão de mistura 60/40 foi avaliada a influência da adição de ar como agente gasificante. O estudo da gasificação do glicerol bruto foi feito realizando ensaios de gasificação numa gama de temperaturas de 750 ºC a 1000 ºC, para uma razão de mistura glicerol/água (60/40) com o caudal de 3,8 mL/min e usando apenas vapor de água como agente de gasificação. Os ensaios foram realizados num reator de leito fixo de 500 mm de comprimento e 90 mm de diâmetro interno, composto por um leito de alumina com partículas de 5 mm de diâmetro. O aquecimento foi realizado com um forno elétrico de 4 kW. A amostra de gás de produção recolhida foi analisada por cromatografia gasosa com detector de termocondutividade. Os resultados obtidos na gasificação do glicerol técnico, revelaram que a temperatura é uma variável preponderante no desempenho do processo de gasificação. À exceção do poder calorífico superior, para o qual se obteve uma ligeira diminuição de valores com o aumento da temperatura, os valores mais elevados dos parâmetros de gasificação foram obtidos para temperaturas superiores a 900 ºC. Esta temperatura parece ser determinante no modelo cinético de gasificação do glicerol, condicionando a composição do gás de produção obtido. Concluiu-se ainda que, na gama de caudais testada, o caudal de alimentação ao reator não teve influência no processo de gasificação. Os ensaios realizados para avaliar o efeito da razão de mistura permitiram verificar que, o aumento da adição de água à alimentação se traduz na redução do teor de CO e de CH4 e no aumento do teor de H2 e CO2, no gás de produção. Para a razão de mistura 25/75 foram obtidos valores de 1,3 para o rácio H2/CO para temperaturas superiores a 900 ºC. A influência da adição de água tornou-se mais evidente nos ensaios de gasificação realizados a temperaturas superiores a 900 ºC. Verificou-se um aumento da conversão de carbono, do rendimento de gás seco e da eficiência do gás frio e uma ligeira diminuição do poder calorífico e da potência disponível, no gás de produção. Para as razões de misturas 60/40 e 40/60 obtiveram-se resultados, para os parâmetros de gasificação, da mesma ordem de grandeza e com valores intermédios entre os obtidos para as razões de mistura 25/75 e 75/25. Porém, quanto maior o teor de água alimentado maior o consumo de energia associado à vaporização da água. Assim, o aumento do teor de água na mistura só apresentará interesse industrial se o objetivo passar pela produção de hidrogénio. Quanto ao efeito da adição de ar como agente de gasificação, os resultados obtidos dão indicação que se poderão potenciar algumas reações exotérmicas que contribuirão para a redução do consumo energético global do processo. Por outro lado, o gás de produção apresentou um rácio H2/CO interessante do ponto de vista da sua aplicação industrial, superior em 35 % ao verificado para a gasificação efetuada apenas na presença de vapor. À exceção do decréscimo no valor do poder calorífico superior do gás de produção, os restantes parâmetros estudados apresentaram a mesma ordem de grandeza, dos obtidos para o estudo da mesma razão de mistura na ausência de ar. Relativamente ao estudo da gasificação do glicerol bruto, obtiveram-se valores de rácio H2/CO e eficiência de gás frio mais elevados que os valores obtidos para a mesma razão de mistura usando glicerol técnico. Os demais parâmetros de gasificação avaliados mostraram-se semelhantes entre as duas matérias-primas, verificando-se apenas uma ligeira diminuição no valor do poder calorífico superior do gás produzido com glicerol bruto. Os resultados obtidos demonstram a possibilidade de valorização energética do glicerol bruto resultante da produção de biodiesel.

Hydrogen production by enhanced methane reforming with membrane reactors or with CO2 capture materials

Pure hydrogen production from methane is a multi-step process run on a large scale for economic reasons. However, hydrogen can be produced in a one-pot continuous process for small scale applications, namely Low Temperature Steam Reforming. Here, Steam Reforming is carried out in a reactor whose walls are composed by a membrane selective toward hydrogen. Pd is the most used membrane material due to its high permeability and selectivity. However, Pd deteriorates at temperatures higher than 500°C, thus the operative temperature of the reaction has to be lowered. However, the employment of a membrane reactor may allow to give high yields thanks to hydrogen removal, which shifts the reaction toward the products. Moreover, pure hydrogen is produced. This work is concentrated on the synthesis of a catalytic system and the investigation of its performances in different processes, namely oxy-reforming, steam reforming and water gas shift, to find appropriate conditions for hydrogen production in a catalytic membrane reactor. The catalyst supports were CeZr and Zr oxides synthesized by microemulsion, impregnated with different noble metals. Pt, Rh and PtRh based catalysts were tested in the oxy reforming process at 500°C, where Rh on CeZr gave the most interesting results. On the opposite, the best performances in low temperature steam reforming were obtained with Rh impregnated on Zr oxide. This catalyst was selected to perform low temperature steam reforming in a Pd membrane reactor. The hydrogen removal given by the membrane allowed to increase the methane conversion over the equilibrium of a classical fixed bed reactor thanks to an equilibrium shift effect. High hydrogen production and recoveries were also obtained, and no other compound permeated through the membrane which proved to be hydrogen selective.

Chemical looping reforming from methane to syngas: investigation on CeO2 oxygen carrier lifetime and optimal process times

Emissions of CO2 are constantly growing since the beginning of industrial era. Interruption of the production of major emitters sectors (energy and agriculture) is not a viable way and reducing all the emission through carbon capture and storage (CCS) is not economically viable and little publicly accepted, therefore, it becomes fundamentals to take actions like retrofitting already developed infrastructure employing cleanest resources, modify the actual processes limiting the emissions, and reduce the emissions already present through direct air capture. The present thesis will deeply discuss the aspects mentioned in regard to syngas and hydrogen production since they have a central role in the market of energy and chemicals. Among the strategies discussed, greater emphasis is given to the application of looping technologies and to direct air capture processes, as they have been the main point of this work. Particularly, chemical looping methane reforming to syngas was studied with Aspen Plus thermodynamic simulations, thermogravimetric analysis characterization (TGA) and testing in a fixed bed reactor. The process was studied cyclically exploiting the redox properties of a Ce-based oxide oxygen carrier synthetized with a simple forming procedure. The two steps of the looping cycles were studied isothermally at 900 °C and 950° C with a mixture of 10 %CH4 in N2 and of 3% O2 in N2, for carrier reduction and oxidation, respectively. During the stay abroad, in collaboration with the EHT of Zurich, a CO2 capture process in presence of amine solid sorbents was investigated, studying the difference in the performance achievable with the use of contactors of different geometry. The process was studied at two concentrations (382 ppm CO2 in N2 and 5.62% CO2 in N2) and at different flow rates, to understand the dynamics of the adsorption process and to define the mass transfer limiting step.

Dynamics of sulfidogenesis associated to methanogenesis in horizontal-flow anaerobic immobilized biomass reactor

Two bench-scale horizontal anaerobic fixed bed reactors were tested to remove both sulfate and organic matter from wastewater. First, the reactors (R1 and R2) were supplied with synthetic wastewater containing sulfate and a solution of ethanol and volatile fatty acids. Subsequently, RI and R2 were fed with only ethanol or acetate, respectively. The substitution to ethanol in R1 increased the sulfate reduction efficiency from 83% to nearly 100% for a chemical oxygen demand to sulfate (COD/sulfate) ratio of 3.0. In contrast, in R2, the switch in carbon source to acetate strongly decreased sulfidogenesis and the maximum sulfate reduction achieved was 47%. Process stability in long-term experiments and high removal efficiencies of both organic matter and sulfate were achieved with ethanol as the sole carbon source. The results allow concluding that syntrophism instead of competition between the sulfate reducing bacteria and acetoclastic methanogenic archaeal populations prevailed in the reactor. (C) 2009 Elsevier Ltd. All rights reserved.