Catalytic Membrane Reactors for Partial Oxidation Using Perovskite Hollow Fiber Membranes and for Partial Hydrogenation Using a Catalytic Membrane Contactor

In Situ Performance Monitoring of Electrochemical Oxygen and Hydrogen Peroxide Sensors in an Additively Manufactured Modular Microreactor

Miniaturized and microstructured reactors in process engineering are essential for a more decentralized, flexible, sustainable, and resilient chemical production. Modern, additive manufacturing methods for metals enable complex reactor-geometries, increased functionality, and faster design iterations, a clear advantage over classical subtractive machining and polymer-based approaches. Integrated microsensors allow online, in situ process monitoring to optimize processes like the direct synthesis of hydrogen peroxide. We developed a modular tube-in-tube membrane reactor fabricated from stainless steel via 3D printing by laser powder bed fusion of metals (PBF-LB/M). The reactor concept enables the spatially separated dosage and resaturation of two gaseous reactants across a membrane into a liquid process medium. Uniquely, we integrated platinum-based electrochemical sensors for the online detection of analytes to reveal the dynamics inside the reactor. An advanced chronoamperometric protocol combined the simultaneous concentration measurement of hydrogen peroxide and oxygen with monitoring of the sensor performance and self-calibration in long-term use. We demonstrated the highly linear and sensitive monitoring of hydrogen peroxide and dissolved oxygen entering the liquid phase through the membrane. Our measurements delivered important real-time insights into the dynamics of the concentrations in the reactor, highlighting the power of electrochemical sensors applied in process engineering. We demonstrated the stable continuous measurement over 1 week and estimated the sensor lifetime for months in the acidic process medium. Our approach combines electrochemical sensors for process monitoring with advanced, additively manufactured stainless steel membrane microreactors, supporting the power of sensor-equipped microreactors as contributors to the paradigm change in process engineering and toward a greener chemistry.

Recent Advances in Membrane-Based Biogas and Biohydrogen Upgrading

Biogas and biohydrogen, due to their renewable nature and zero carbon footprint, are considered two of the gaseous biofuels that will replace conventional fossil fuels. Biogas from anaerobic digestion must be purified and converted into high-quality biomethane prior to use as a vehicle fuel or injection into natural gas networks. Likewise, the enrichment of biohydrogen from dark fermentation requires the removal of CO2, which is the main pollutant of this new gaseous biofuel. Currently, the removal of CO2 from both biogas and biohydrogen is carried out by means of physical/chemical technologies, which exhibit high operating costs and corrosion problems. Biological technologies for CO2 removal from biogas, such as photosynthetic enrichment and hydrogenotrophic enrichment, are still in an experimental development phase. In this context, membrane separation has emerged as the only physical/chemical technology with the potential to improve the performance of CO2 separation from both biogas and biohydrogen, and to reduce investment and operating costs, as a result of the recent advances in the field of nanotechnology and materials science. This review will focus on the fundamentals, potential and limitations of CO2 and H2 membrane separation technologies. The latest advances on membrane materials for biogas and biohydrogen purification will be systematically reviewed.

Catalytic Membrane Reactors: The Industrial Applications Perspective

Catalytic membrane reactors have been widely used in different production industries around the world. Applying a catalytic membrane reactor (CMR) reduces waste generation from a cleaner process perspective and reduces energy consumption in line with the process intensification strategy. A CMR combines a chemical or biochemical reaction with a membrane separation process in a single unit by improving the performance of the process in terms of conversion and selectivity. The core of the CMR is the membrane which can be polymeric or inorganic depending on the operating conditions of the catalytic process. Besides, the membrane can be inert or catalytically active. The number of studies devoted to applying CMR with higher membrane area per unit volume in multi-phase reactions remains very limited for both catalytic polymeric and inorganic membranes. The various bio-based catalytic membrane system is also used in a different commercial application. The opportunities and advantages offered by applying catalytic membrane reactors to multi-phase systems need to be further explored. In this review, the preparation and the application of inorganic membrane reactors in the different catalytic processes as water gas shift (WGS), Fisher Tropsch synthesis (FTS), selective CO oxidation (CO SeLox), and so on, have been discussed.

Preparation and Application of Palladium Nanoparticle Impregnated Chloromethylated Polysulfone Matrix as an Efficient Catalytic Membrane for Oxidation of Alcohols

The use of palladium nanoparticles embedded in a chloromethylated Polysulfone (CMPSf) matrix was developed for highly efficient oxidation of primary and secondary alcohols to corresponding aldehyde and ketone in organic solvent free condition. Pd (Π)/bis (2, 4-dihydroxybenzaldehyde) chelate chemically incorporated onto CMPSf was used to prepare beneficial catalytic membranes. Chemical structure and thermal properties of resulting membranes were characterized via FTIR, 1HNMR, UV-vis, TGA and DSC techniques. Morphology and particle distribution throughout the catalytic membranes was elucidated using FE-SEM. An average particle size of Pd nanoparticles was estimated about 20 nm by XRD technique. ICP technique proved that no Pd particles were leached out of the membrane into the solutions; hence the as-prepared catalytic membranes could be used several times without significant loss in their activities. This is in good accordance with formation of chemical bond between Pd and polymer matrix.

Catalytic mixed conducting ceramic membrane reactors for methane conversion

Schematic of catalytic mixed conducting ceramic membrane reactors for various reactions: (a) O₂ permeable ceramic membrane reactor; (b) H₂ permeable ceramic membrane reactor; (c) CO₂ permeable ceramic membrane reactor.

High-flux oxygen-transporting membrane Pr(0.6)Sr(0.4)Co(0.5)Fe(0.5)O(3-δ): CO2 stability and microstructure

High oxygen permeability and good thermochemical stability of oxygen-transporting membranes (OTMs) are two main requirements concerning the applicability of these devices in chemical processes, such as CO2 capture using the oxyfuel concept or catalytic membrane reactors. In this work, a single-phase perovskite-type membrane Pr0.6Sr0.4Co0.5Fe0.5O3-δ (PSCF) with 0.6-mm thickness was subjected to periodic thermal cycling in the temperature range between 850 and 1000 °C in a 1000-h long-term permeation test with pure CO2 as the sweep gas. The results of this long-term permeation operation revealed a stepwise increase in oxygen permeation values at 1000 °C after each thermal cycle, reaching from 1.38 cm(3) (STP) min(-1) cm(-2) in the first cycle to 1.75 cm(3) (STP) min(-1) cm(-2) in the fourth cycle. Furthermore, the membrane showed very good CO2 stability at 900 °C and above. Despite a partial decrease in oxygen permeation fluxes at 850 °C, a steady state of 0.25 cm(3) (STP) min(-1) cm(-2) was reached and maintained for more than 100 h. The newly developed PSCF membrane also exhibited a higher oxygen permeation flux with He and CO2 sweeping at all measured temperatures compared to a similar La0.6Sr0.4Co0.8Fe0.2O3-δ (LSCF) membrane.

Enhancing the oxygen permeation rate of Zr(0.84)Y(0.16)O(1.92)-La(0.8)Sr(0.2)Cr(0.5)Fe(0.5)O(3-δ) dual-phase hollow fiber membrane by coating with Ce(0.8)Sm(0.2)O(1.9) nanoparticles

Zr0.84Y0.16O1.92-La0.8Sr0.2Cr0.5Fe0.5O3-δ (YSZ-LSCrF) dual-phase composite hollow fiber membranes were prepared by a combined phase-inversion and sintering method. The shell surface of the hollow fiber membrane was modified with Ce0.8Sm0.2O1.9 (SDC) via a drop-coating method. As the rate of oxygen permeation of the unmodified membrane is partly controlled by the surface exchange kinetics, coating of a porous layer of SDC on the shell side (oxygen reduction side) of the hollow fiber membrane was found to improve its oxygen permeability. Rate enhancements up to 113 and 48% were observed, yielding a maximum oxygen flux of 0.32 and 4.53 mL min(-1) cm(-2) under air/helium and air/CO gradients at 950 °C, respectively. Excess coating of SDC was found to induce significant gas phase transport limitations and hence lower the rate of oxygen permeation. A model was proposed to calculate the length of triple phase boundaries (TPBs) for the coated dual-phase composite membrane and to explain the effect of coating on the oxygen permeability.

Selective hydrogenation over Pd nanoparticles supported on a pore-flow-through silica monolith microreactor with hierarchical porosity

Well-dispersed Pd nanoparticles have been synthesized inside the mesoporosity of a silica monolith featuring hierarchical porosity of homogeneous interconnected macropores (4 microns) and mesopores (11 nm). These monoliths have been implemented as microreactors for selective hydrogenation reactions. Conversion and selectivity can be tuned by adjusting the flow rates of hydrogen and substrates. In the selective hydrogenation of cyclooctadiene, a conversion of 95% and a selectivity of 90% in the monohydrogenated product, constant over a period of 70 h, have been reached. These figures correspond to a productivity of 4.2 mmol s(-1) g(-1)(MonoSil) (or 0.32 mol s(-1) g(-1)(Pd)). In the stereoselective hydrogenation of 3-hexyn-1-ol a constant conversion of 85% was observed, with however moderate selectivity into the cis isomer, over a test period of 7 h. These results open the route to the synthesis of important chemicals and intermediates via safe and green processes.

Wet air oxidation of formic acid using nanoparticle-modified polysulfone hollow fibers as gas-liquid contactors

Catalytic wet air oxidation (CWAO) using membrane contactors is attractive for remediation of aqueous pollutants, but previous studies of even simple reactions such as formic acid oxidation required multiple passes through tubular ceramic membrane contactors to achieve high conversion. This work aims to increase single-pass CWAO conversions by using polysulfone (PS) hollow fibers as contactors to reduce diffusion distances in the fiber lumen. Alternating adsorption of polycations and citrate-stabilized platinum colloids in fiber walls provides catalytically active PS hollow fibers. Using a single PS fiber, 50% oxidation of a 50 mM formic acid feed solution results from a single pass through the fiber lumen (15 cm length) with a solution residence time of 40 s. Increasing the number of PS fibers to five while maintaining the same volumetric flow rate leads to over 90% oxidation, suggesting that further scale up in the number of fibers will facilitate high single pass conversions at increased flow rates. The high conversion compared to prior studies with ceramic fibers stems from shorter diffusion distances in the fiber lumen. However, the activity of the Pt catalyst is 20-fold lower than in previous ceramic fibers. Focusing the Pt deposition near the fiber lumen and limiting pore wetting to this region might increase the activity of the catalyst.