Effect of low hydrogen to palladium molar ratios in the direct synthesis of H2O2 in water in a trickle bed reactor

Direct H2O2 Synthesis, without H2 Gas

We report here the direct hydrogenation of O₂ gas to form hydrogen peroxide (H₂O₂) using a membrane reactor without H₂ gas. Hydrogen is sourced from water, and the reactor is driven by electricity. Hydrogenation chemistry is achieved using a hydrogen-permeable Pd foil that separates an electrolysis chamber that generates reactive H atoms, from a hydrogenation chamber where H atoms react with O₂ to form H₂O₂. Our results show that the concentration of H₂O₂ can be increased ∼8 times (from 56.5 to 443 mg/L) by optimizing the ratio of methanol-to-water in the chemical chamber, and through catalyst design. We demonstrate that the concentration of H₂O₂ is acutely sensitive to the H₂O₂ decomposition rate. This decomposition rate can be minimized by using AuPd alloy catalysts instead of pure Pd. This study presents a new pathway to directly synthesize H₂O₂ using water electrolysis without ever using H₂ gas.

Generation of hydroxyl radicals by metal-free bifunctional electrocatalysts for enhanced organics removal

Low yields of H₂O₂ and a narrow range of appropriate pH values have been two major drawbacks for electro-Fenton (EF) process. Herein, metal-free electrochemical advanced oxidation processes (EAOPs) were developed with nitrogen and sulfur co-doped electrochemically exfoliated graphene (N, S-EEGr) electrocatalysts, which was confirmed as an outstanding bifunctional catalyst for synchronous generation and activation of H₂O₂ via (2 + 1) e^- consecutive reduction reactions. Specifically, two elements (N, S) in metal-free N, S-EEGr-CF cathode synergize to promote the formation of H₂O₂ followed by its activation. With N, S-EEGr-CF cathode, phenol of initial 50 mg L^-1 could be effectively removed within pH 3-11 and 6.25 mA cm^-2, and 100% removal efficiency could be achieved within 15-min even at neutral pH. The pseudo-first-order rate constant for phenol removal in metal-free EAOPs with N,S-EEGr-CF at neutral pH was 10 times higher than that with EF process. Detection of active species, coupled with decay kinetics with specific trapping agents, confirmed that OH was the dominant oxidizing species promoting removal efficiencies of organics (phenol, antibiotics and dyes) at pH 3 and pH 7. In the actual wastewater treatment, the synergistic effect of bifunctional catalyst would also be used for improving the degradation efficiency of organics. Thus, the metal-free EAOPs with N,S-EEGr-CF cathode may serve as an alternative in wastewater treatment with a broadened range of solution pH values and avoiding Fe²⁺ (catalyst) addition.

Microsensor Electrodes for 3D Inline Process Monitoring in Multiphase Microreactors

We present an electrochemical microsensor for the monitoring of hydrogen peroxide direct synthesis in a membrane microreactor environment by measuring the hydrogen peroxide and oxygen concentrations. In prior work, for the first time, we performed in situ measurements with electrochemical microsensors in a microreactor setup. However, the sensors used were only able to measure at the bottom of the microchannel. Therefore, only a limited assessment of the gas distribution and concentration change over the reaction channel dimensions was possible because the dissolved gases entered the reactor through a membrane at the top of the channel. In this work, we developed a new fabrication process to allow the sensor wires, with electrodes at the tip, to protrude from the sensor housing into the reactor channel. This enables measurements not only at the channel bottom, but also along the vertical axis within the channel, between the channel wall and membrane. The new sensor design was integrated into a multiphase microreactor and calibrated for oxygen and hydrogen peroxide measurements. The importance of measurements in three dimensions was demonstrated by the detection of strongly increased gas concentrations towards the membrane, in contrast to measurements at the channel bottom. These findings allow a better understanding of the analyte distribution and diffusion processes in the microreactor channel as the basis for process control of the synthesis reaction.

Direct Synthesis of Hydrogen Peroxide under Semi-Batch Conditions over Un-Promoted Palladium Catalysts Supported by Ion-Exchange Sulfonated Resins: Effects of the Support Morphology

Palladium catalysts supported by a mesoporous form of sulfonated poly-divinylbenzene, Pd/µS-pDVB10 (1%, w/w) and Pd/µS-pDVB35 (3.6% w/w), were applied to the direct synthesis of hydrogen peroxide from dihydrogen and dioxygen. The reaction was carried for 4 h out in a semibatch reactor with continuous feed of the gas mixture (H2/O2 = 1/24, v/v; total flow rate 25 mL·min−1), at 25 °C and 101 kPa. The catalytic performances were compared with those of a commercial egg-shell Pd/C catalyst (1%, w/w) and of a palladium catalyst supported by a macroreticular sulfonated ion-exchange resin, Pd/mS-pSDVB10 (1%, w/w). Pd/µS-pDVB10 and Pd/C showed the highest specific activity (H2 consumption rate of about 75–80 h−1), but the resin supported catalyst was much more selective (ca 50% with no promoters). The nanoparticles (NP) size was somewhat larger in Pd/µS-pDVB10, showing that either the reaction was structure insensitive or diffusion limited to some extent over Pd/C, in which the support is microporous. The open pore structure of Pd/µS-pDVB10, possibly ensuring the fast removal of H2O2 from the catalyst, could also be the cause of the relatively high selectivity of this catalyst. In summary, Pd/µS-pDVB10 was the most productive catalyst, forming ca 375 molH2O2·kgPd−1·h−1, also because it retained a constant selectivity, while the other ones underwent a more or less pronounced loss of selectivity after 80–90 min. Ageing experiments showed that for a palladium catalyst supported on sulfonated mesoporous poly-divinylbenzene storage under oxidative conditions implied some deactivation, but a lower drop in the selectivity; regeneration upon a reductive treatment or storage under strictly anaerobic conditions (dry-box) lead to an increase of the activity but to both a lower initial selectivity and a higher drop of selectivity with time.

A review on research progress in the direct synthesis of hydrogen peroxide from hydrogen and oxygen: noble-metal catalytic method, fuel-cell method and plasma method

The direct synthesis of H₂O₂ from H₂ and O₂ using Pd catalyst, fuel cell and plasma methods have been reviewed systematically.