Capillary microreactors wall-coated with mesoporous titania thin film catalyst supports

Selective Hydrogenation of 2-Methyl-3-butyn-2-ol in Microcapillary Reactor on Supported Intermetallic PdZn Catalyst, Effect of Support Doping on Stability and Kinetic Parameters

The development of active, selective, and stable multicrystalline catalytic coatings on the inner surface of microcapillary reactors addresses environmental problems of fine organic synthesis, in particular by reducing the large quantities of reagents and byproducts. Thin-film nanosized bimetallic catalysts based on mesoporous pure titania and doped with zirconia, ceria, and zinc oxide, for use in microreactors, were developed, and the regularities of their formation were studied. The efficiency of PdZn/TixM1−xO2±y (M = Ce, Zr, Zn) in the hydrogenation of 2-methyl-3-butyn 2-ol was studied with an emphasis on the stability of the catalyst during the reaction. The catalytic parameters depend on the adsorption properties and activity of PdZn and Pd(0) active centers. Under reaction conditions, resistance to the decomposition of PdZn is a factor that affects the stability of the catalyst. The zinc-doped coating proved to be the most selective and stable in the reaction of selective hydrogenation of acetylenic alcohols in a microcapillary reactor. This coating retained a high selectivity of 98.2% during long-term testing up to 168 h. Modification of the morphology and electronic structure of the active component, by doping titania with Ce and Zr, is accompanied by a decrease in stability.

4-Amino-TEMPO-Immobilized Polymer Monolith: Preparations, and Recycling Performance of Catalyst for Alcohol Oxidation

Continuous flow reactors with immobilized catalysts are in great demand in various industries, to achieve easy separation, regeneration, and recycling of catalysts from products. Oxidation of alcohols with 4-amino-TEMPO-immobilized monolith catalyst was investigated in batch and continuous flow systems. The polymer monoliths were prepared by polymerization-induced phase separation using styrene derivatives, and 4-amino-TEMPO was immobilized on the polymer monolith with a flow reaction. The prepared 4-amino-TEMPO-immobilized monoliths showed high permeability, due to their high porosity. In batch oxidation, the reaction rate of 4-amino-TEMPO-immobilized monolith varied with stirring. In flow oxidation, the eluent permeated without clogging, and efficient flow oxidation was possible with residence times of 2-8 min. In the recycling test of the flow oxidation reaction, the catalyst could be used at least six times without catalyst deactivation.

Microfluidic assisted low-temperature and speedy synthesis of TiO2/ZnO/GOx with bio/photo active cites for amoxicillin degradation

For the first time, a bio-photo-catalyst is synthesized in a microfluidic platform. The microchannel, which is wall-coated by in situ synthesized bio-photo-catalyst is used as an opto-fluidic reactor for amoxicillin degradation. Analyses including SEM, XRD, FTIR, Raman, UV–Vis spectra, and DLS have been used to characterize samples. The structure and morphology of TiO2 in microfluidic assisted synthesis are studied at 70–120 °C. The results show that both single-crystalline anatase sample and two-phase samples of anatase and rutile can be attained. According to SEM images, the smallest size and the narrowest particle size distribution (0.86 nm $$\pm \hspace{0.17em}0.14$$ ± 0.14 ) is achieved by synthesis at 70 °C. Elemental mapping of Ti shows a uniform coating layer on inner walls. Raman signals besides the primary amines in FTIR results show the biological activity of the cross-linked Glucose oxidase (GOx), which is aimed for situ generation of H2O2. FTIR comparison of bulk and spiral microfluidic synthesized ZnO indicates identical bonds. SEM-coupled with performance experimentation reveal that by regulating the flowrate of spiral micromixer for ZnCl2 at 25 µl/min and NaOH at 50 µl/min, the narrowest size distribution and best the bio-photo-catalytic performance of ZnO nanoparticles is observed.

Homogeneous catalyst modifier for alkyne semi-hydrogenation: systematic screening in an automated flow reactor and computational study on mechanisms

21 types of modifiers are screened for palladium catalysed semi-hydrogenation of alkynes with varying catalyst type, reaction time, and target substrate using an automated flow reactor system.

Evolution of Thin-Liquid Films Surrounding Bubbles in Microfluidics and Their Impact on the Pressure Drop and Fluid Movement

The evolution of thin-liquid films in a microchannel is one of the most critical and intricate phenomena to understand two-phase movement, evaporation, micromixing, heat transfer, chemical synthesis, biological processes, and efficient energy devices. In this paper, we demonstrate experimentally the effect of a liquid film on the removal of an initially dry and lodged bubble in laser-etched poly(methyl methacrylate) microfluidic networks and discuss the evolution of the liquid film in accordance with the bubble superficial velocity and the effect of liquid properties and branch angle on the evolution of the liquid film and the pressure drop. During the removal of a dry bubble, four stages have been observed in the bubble velocity profile and they directly relate to the evolution of the liquid film. The correlation of maximum bubble velocity has been derived as a function of bubble length, fluid viscosity, surface tension, geometry of the cross-sectional area, and dimensions of the microchannel and agrees with the experimental results. The bubble moving distance required for the full deposition of a continuous and stable thin-liquid film is affected by the liquid viscosity and network branch angle. The liquid with a higher viscosity will increase the pressure drop for removing dry bubbles from microfluidic networks, while this effect will be hampered by increasing the microfluidic network complexity. The deposition of the thin-liquid film surrounding bubbles significantly decreases the pressure drop required to remove bubbles from microfluidics. Compared with deionized water, the glycerol solution is prone to acting as the lubricating liquid due to its strong H-bond interaction with the channel wall and the reduction in interfacial energy of the gas-water interface.

Continuous Flow Synthesis of a ZSM-5 Film in Capillary Microchannel for Efficient Production of Solketal

This work presented the microfluidic preparation of zeolite film in a capillary microchannel with different length-to-diameter ratios. In the quartz capillary with an inner diameter of 0.53 and 0.32 mm, Zeolite Socony Mobil-5 (ZSM-5) film was prepared by a continuous flow hydrothermal method. Considering the chemically inert surface of quartz capillary and the difficulty of preparing uniform and continuous zeolite film by conventional static synthesis, the ZSM-5 seed layer was precoated as active sites to induce film growth. The parameters of length-to-diameter ratio, seed coating, feed flow rate, and synthesis time were investigated. It revealed that the crystallinity of the ZSM-5 film was significantly affected by the capillary length-to-diameter ratio and seed coating in this flow system. The film morphology and thickness could be precisely controlled by adjusting the feed flow rate and synthesis time. This hydrogen form of the ZSM-5 (HZSM-5) film capillary microreactor was applied in the ketalization reaction of glycerol with acetone to produce solketal. The single-pass yield of solketal could reach ∼30% under mild conditions. This work provided a convenient stratagem of preparing zeolite catalytic coating or other support coatings in closed microchannels with a high length-to-diameter ratio and the potential application in valuable transformation of biomass glycerol.

Amperometric Flow-Injection Analysis of Phenols Induced by Reactive Oxygen Species Generated under Daylight Irradiation of Titania Impregnated with Horseradish Peroxidase

Titanium dioxide (TiO₂) is a unique material for biosensing applications due to its capability of hosting enzymes. For the first time, we show that TiO₂ can accumulate reactive oxygen species (ROS) under daylight irradiation and can support the catalytic cycle of horseradish peroxidase (HRP) without the need of H₂O₂ to be present in the solution. Phenolic compounds, such as hydroquinone (HQ) and 4-aminophenol (4-AP), were detected amperometrically in flow-injection analysis (FIA) mode via the use of an electrode modified with TiO₂ impregnated with HRP. In contrast to the conventional detection scheme, no H₂O₂ was added to the analyte solution. Basically, the inherited ability of TiO₂ to generate reactive oxygen species is used as a strategy to avoid adding H₂O₂ in the solution during the detection of phenolic compounds. Electron paramagnetic resonance (EPR) spectroscopy indicates the presence of ROS on titania which, in interaction with HRP, initiate the electrocatalysis toward phenolic compounds. The amperometric response to 4-AP was linear in the concentration range between 0.05 and 2 μM. The sensitivity was 0.51 A M^-1 cm^-2, and the limit of detection (LOD) 26 nM. The proposed sensor design opens new opportunities for the detection of phenolic traces by HRP-based electrochemical biosensors, yet in a more straightforward and sensitive way following green chemistry principles of avoiding the use of reactive and harmful chemical, such as H₂O₂.

Microfluidic processing of HZSM-5 films in a capillary microreactor for the continuous acetalisation reaction of glycerol with acetone

This work presented microfluidic processing of zeolite films in a capillary microreactor and its potential application for biomass conversion.

Designing Microflowreactors for Photocatalysis Using Sonochemistry: A Systematic Review Article

Use of sonication for designing and fabricating reactors, especially the deposition of catalysts inside a microreactor, is a modern approach. There are many reports that prove that a microreactor is a better setup compared with batch reactors for carrying out catalytic reactions. Microreactors have better energy efficiency, reaction rate, safety, a much finer degree of process control, better molecular diffusion, and heat-transfer properties compared with the conventional batch reactor. The use of microreactors for photocatalytic reactions is also being considered to be the appropriate reactor configuration because of its improved irradiation profile, better light penetration through the entire reactor depth, and higher spatial illumination homogeneity. Ultrasound has been used efficiently for the synthesis of materials, degradation of organic compounds, and fuel production, among other applications. The recent increase in energy demands, as well as the stringent environmental stress due to pollution, have resulted in the need to develop green chemistry-based processes to generate and remove contaminants in a more environmentally friendly and cost-effective manner. It is possible to carry out the synthesis and deposition of catalysts inside the reactor using the ultrasound-promoted method in the microfluidic system. In addition, the synergistic effect generated by photocatalysis and sonochemistry in a microreactor can be used for the production of different chemicals, which have high value in the pharmaceutical and chemical industries. The current review highlights the use of both photocatalysis and sonochemistry for developing microreactors and their applications.

Emerging porous materials in confined spaces: from chromatographic applications to flow chemistry

Porous materials confined within capillary columns/microfluidic devices are discussed, and progress in chromatographic and membrane separations and catalysis is reviewed.

Photocatalytic Oxidation of VOCs in Gas Phase Using Capillary Microreactors with Commercial TiO₂ (P25) Fillings

The elimination of volatile organic compounds (VOCs) at low concentration is a subject of great interest because these compounds are very harmful for the environment and human health. In this work, we have developed an easy methodology to immobilize a benchmark photocatalyst (P25) inside a capillary microreactor (Fused silica capillary with UV transparent coating) without any previous treatment. For this purpose, a dispersion of the sample (P25) in EtOH was used obtaining a packed bed configuration. We have improved the immobilization of the benchmark photocatalyst (P25) inside the capillary incorporating a surfactant (F-127) to generate porosity inside the microreactor to avoid severe pressure drops (∆P < 0.5 bar). The resulting capillaries were characterized by Scanning Electron Microscopy (SEM). These microreactors show a good performance in the abatement of propene (VOC) under flow conditions per mol of active phase (P25) due to an improved mass transfer when the photocatalyst is inside the capillary. Moreover, the prepared microreactors present a higher CO₂ production rate (mole CO₂/(mole P25·s)) with respect to the same TiO₂ operating in a conventional reactor. The microreactor with low pressure drop is very interesting for the abatement of the VOCs since it improves the photoactivity of P25 per mol of TiO₂ operating at near atmospheric pressure.

OpenFlowChem – a platform for quick, robust and flexible automation and self-optimisation of flow chemistry

OpenFlowChem – an open-access platform for automation of process control and monitoring optimised for flexibility.

Nanocatalysis in Flow

Nanocatalysis in flow is catalysis by metallic nanoparticles (NPs; 1-50 nm) performed in microstructured reactors. These catalytic processes make use of the enhanced catalytic activity and selectivity of NPs and fulfill the requirements of green chemistry. Anchoring catalytically active metal NPs within a microfluidic reactor enhances the reagent/catalyst interaction, while avoiding diffusion limitations experienced in classical approaches. Different strategies for supporting NPs are reviewed herein, namely, packed-bed reactors, monolithic flow-through reactors, wall catalysts, and a selection of novel approaches (NPs embedded on nanotubes, nanowires, catalytic membranes, and magnetic NPs). Through a number of catalytic reactions, such as hydrogenations, oxidations, and cross-coupling reactions, the advantages and possible drawbacks of each approach are illustrated.

Novel synthesis of thick wall coatings of titania supported Bi poisoned Pd catalysts and application in selective hydrogenation of acetylene alcohols in capillary microreactors

Catalysis in microreactors allows reactions to be performed in a very small volume, reducing the environmental problems and greatly intensifying the processes through easy pressure control and the elimination of heat- and mass-transfer limitations. In this study, we report a novel method for the controlled synthesis of micrometre-thick mesoporous TiO2 catalytic coatings on the walls of long channels (>1 m) of capillary microreactors in a single deposition step. The method uses elevated temperature and introduces a convenient control parameter of the deposition rate (displacement speed controlled by a stepper motor), which allows deposition from concentrated and viscous sols without channel clogging. A capillary microreactor wall-coated with titania supported Bi-poisoned Pd catalyst was obtained using the method and used for the semihydrogenation of 2-methyl-3-butyn-2-ol providing 93 ± 1.5% alkene yield for 100 h without deactivation. Although the coating method was applied only for TiO2 deposition, it is nonetheless suitable for the deposition of volatile sols.

A catalytic chiral gel microfluidic reactor assembled via dynamic covalent chemistry

A novel dynamic covalent gel strategy is reported to immobilize an asymmetric catalyst within the channels of a microfluidic flow reactor. A layer of a catalytically active Mn-salen dynamic covalent imine gel matrix was coated onto a functionalized capillary. Mn-salen active moiety was incorporated into dynamic covalent imine gel matrix via the reaction of a chiral Mn-salen dialdehyde unit with a tetraamine linker. The catalytic activity of the capillary reactor has been demonstrated in enantioselective kinetic resolution of secondary alcohols.

Synthesis of robust hierarchical silica monoliths by surface-mediated solution/precipitation reactions over different scales: designing capillary microreactors for environmental applications

A synthetic procedure to prepare novel materials (surface-mediated fillings) based on robust hierarchical monoliths is reported. The methodology includes the deposition of a (micro- or mesoporous) silica thin film on the support followed by growth of a porous monolithic SiO2 structure. It has been demonstrated that this synthesis is viable for supports of different chemical nature with different inner diameters without shrinkage of the silica filling. The formation mechanism of the surface-mediated fillings is based on a solution/precipitation process and the anchoring of the silica filling to the deposited thin film. The interaction between the two SiO2 structures (monolith and thin film) depends on the porosity of the thin film and yields composite materials with different mechanical stability. By this procedure, capillary microreactors have been prepared and have been proved to be highly active and selective in the total and preferential oxidation of carbon monoxide (TOxCO and PrOxCO).

Highly efficient TiO2-based microreactor for photocatalytic applications

A photocatalytic, TiO2-based microreactor is designed and fabricated on a metal-titanium foil. The microchannel is mechanically engraved in the substrate foil, and a double-layered TiO2 anatase film is immobilized on its inner walls with a two-step synthesis, which included anodization and a hydrothermal treatment. X-ray diffraction (XRD) and scanning electron microscopy (SEM) confirm the presence of an approximately 10-μm-thick layer of titania nanotubes and anatase nanoparticles. The SEM and transmission electron microscopy (TEM) of the cross sections show a dense interface between the titanium substrate and the TiO2 nanotubes. An additional layer of TiO2-anatase nanoparticles on the top of the film provides a large, photocatalytic surface area. The metal-titanium substrate with a functionalized serpentine channel is sealed with UV-transparent Plexiglas, and four 0.8-mW UV LEDs combined with a power controller on a small printed-circuit board are fixed over the substrate. The photocatalytic activity and the kinetic properties for the degradation of caffeine are provided, and the longer-term stability of the TiO2 film is evaluated. The results show that after 6 months of use and 3600 working cycles the microreactor still exhibits 60% of its initial efficiency.

Hydrogen production through aqueous-phase reforming of ethylene glycol in a washcoated microchannel

Aqueous-phase reforming (APR) of biocarbohydrates is conducted in a catalytically stable washcoated microreactor where multiphase hydrogen removal enhances hydrogen efficiency. Single microchannel experiments are conducted following a simplified model based on the microreactor concept. A coating method to deposit a Pt-based catalyst on the microchannel walls is selected and optimized. APR reactivity tests are performed by using ethylene glycol as the model compound. Optimum results are achieved with a static washcoating technique; a highly uniform and well adhered 5 μm layer is deposited on the walls of a 320 μm internal diameter (ID) microchannel in one single step. During APR of ethylene glycol, the catalyst layer exhibits high stability over 10 days after limited initial deactivation. The microchannel presents higher conversion and selectivity to hydrogen than a fixed-bed reactor. The benefits of using a microreactor for APR can be further enhanced by utilizing increased Pt loadings, higher reaction temperatures, and larger carbohydrates (e.g., glucose). The use of microtechnology for aqueous-phase reforming will allow for a great reduction in the reformer size, thus rendering it promising for distributed hydrogen production.

Ordered Porous Nanomaterials: The Merit of Small

This paper will introduce the reader to some of the “classical” and “new” families of ordered porous materials which have arisen throughout the past decades and/or years. From what is perhaps the best-known family of zeolites, which even now to this day is under constant research, to the exciting new family of hierarchical porous materials, the number of strategies, structures, porous textures, and potential applications grows with every passing day. We will attempt to put these new families into perspective from a synthetic and applied point of view in order to give the reader as broad a perspective as possible into these exciting materials.

New triblock copolymer templates, PEO-PB-PEO, for the synthesis of titania films with controlled mesopore size, wall thickness, and bimodal porosity

The synthesis and properties of a series of new structure-directing triblock copolymers with PEO-PB-PEO structure (PEO = poly(ethylene oxide) and PB = polybutadiene) and their application as superior pore-templates for the preparation of mesoporous titania coatings are reported. Starting from either TiCl4 or from preformed TiO2 nanocrystalline building blocks, mesoporous crystalline titanium oxide films with a significant degree of mesoscopic ordered pores are derived, and the pore size can be controlled by the molecular mass of the template polymer. Moreover, the triblock copolymers form stable micelles already at very low concentration, i.e., prior to solvent evaporation during the evaporation-induced self-assembly process (EISA). Consequently, the thickness of pore walls can be controlled independently of pore size by changing the polymer-to-precursor ratio. Thus, unprecedented control of wall thickness in the structure of mesoporous oxide coatings is achieved. In addition, the micelle formation of the new template polymers is sufficiently distinct from that of typical commercial PPO-PEO-PPO polymers (Pluronics; PPO = poly(propylene oxide)), so that a combination of both polymers facilitates bimodal porosity via dual micelle templating.

Nanoparticulate PdZn--pathways towards the synthetic control of nanosurface properties

This paper reports an in-depth structural investigation of PdZn nanoparticulates prepared over an entire compositional range. By using a combination of HRTEM, ICP-OES, EDX and XPS alongside PXRD, we are able to show how a liquid-type reduction process can be exploited to target different PdZn bimetallic structures while maintaining reproducibly narrow particle size distributions and average particle diameters of approximately 3 nm. Samples have been further analyzed by quantitative phase analysis of the Rietveld refined diffraction data, providing indications as to how variations in specific surface compositions are obtained when Zn is used as the alloying metal. The influence of nanolattice strain is investigated by geometric analysis of TEM data. Results suggest, in conjunction with previously published catalytic data, how different compositions of this specific bimetallic system may be exploited in catalytic processes to control substrate/product affinity. We thus demonstrate a new and simplified approach to PdZn bimetallics, which may offer novel perspectives for applications in industrial catalysis.