Heterogeneous catalysis plays a pivotal role in the current chemical and energy vectors production. Notably, to fully utilize the intrinsic activity and selectivity of a catalyst, the chemical reactor has to be designed and operated optimally to achieve enhanced heat/mass transfer, well-defined contact time of reactants, uniform flow pattern, and high permeability. Structured catalysts are a promising strategy to overcome the major drawbacks encountered in the traditional packed-bed reactor technology due to the improved hydrodynamics in combination with enhanced heat/mass transfer. Newly emerged fiber/foam-substrates, with an entirely open 3D network structure, bring distinct advantages over the honeycomb and micro-channel contacting methods, including free radial diffusion, eddy-mixing driven heat/mass transfer, large area-to-volume ratio, and high contacting efficiency. However, how to place the nanocatalysts onto the fiber/foam-substrates is a challenging problem because the commercial washcoating method has great limitations such as the nonuniformity and easy exfoliation of coatings. This review discusses the newly developed non-dip-coating methods for the fiber/foam-structured catalysts and their promising applications in the strongly exo-/endo-thermic and/or high throughput reaction processes.

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The feasibility of gas phase deposition using a Ti alkoxide precursor for precise surface modification of catalysts was demonstrated by modifying a mesoporous alumina support with a Ti oxide overcoat. Titanium tetra-isopropoxide yields a Ti oxide layer that covers homogeneously the alumina surface. Uniformity of the deposited TiO₂ was verified by SEM-EDX, on both intra-particle and inter-particle levels. Only a few atomic layer deposition (ALD) cycles were required in order to obtain Ti contents with a relevance for industrial application. The pore size distribution of the overcoated catalyst support was barely affected by the coating process. Synthesized CoMo catalysts based on the Ti-alumina carrier showed up to 40% higher activity compared to a catalyst supported on pristine alumina, in hydroprocessing under industrial testing conditions. The TiO₂ coating appeared to be stable, showing no agglomeration characteristics after reaction as corroborated by TEM-EDX. ALD provides a scalable route with low waste generation for the production of precisely structured TiO₂-Al₂O₃ hydroprocessing catalyst supports.

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The authors regret that the original graphical abstract contained an error by accident. In particular, the values of the OH density for the calcined SBA-15 and solvent-&-Fenton-treated SBA-15 were swapped. These values contradict the main message of the study. The values contained in the paper are however correct. In summary, the paper's data are correct but the graphical abstract contained swapped data leading to a contradiction. Below, an amended graphical abstract can be found, as well as in the online journal website. The authors would like to apologise for any inconvenience caused. [Figure presented]

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Deactivation of a Pd/alumina catalyst has been observed during the hydrogenation of α-methylstyrene and styrene. In both feedstocks, deactivation is caused by an additive, 4-tert-butylcatechol (TBC), a polymerization inhibitor, commonly employed at the ppm concentration level in the formulation of commercial monomers. It was found that the reaction rate in the α-methylstyrene fluctuated notably among the reactant vendors, and this was ascribed to the varying concentration of TBC, although other factors, such as the concentration of water, may play a role. The study was extended into the hydrogenation of styrene using a trickle bed reactor. The negative impact of the TBC present at the ppm level was obvious. The deactivation mechanism was complex to rationalize. A two-stage behavior was observed: a first stage of a relatively fast deactivation followed by a second stage of slow deactivation. A tentative explanation considers the presence of two types of Pd-sites, which are poisoned by TBC: the more active α-Pd-H sites and the less active β-Pd-H sites. Finally, in practical terms, it is important to emphasize that such an additive must be removed from the reactant to maximize the catalyst performance. This can be achieved by adsorption using a commercial F-200 Alcoa alumina.

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In this perspective paper a brief overview is given of the past developments in the field of structured catalysts and reactors, the potential for process intensification, energy and materials efficiency. Current exciting new developments for demanding processes are highlighted and directions indicated that contribute to a future sustainable chemical industry.

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We describe the co-current flow pattern of gas and liquid through micro-fabricated beds of solid and pillars under variable (i) capillary number, (ii) contact angle or wettability and (iii) pillar arrangement, i.e. modifying the distance between pillars or their size and comparing regular with more chaotic systems. Laser-induced fluorescent microscopy and image analysis are used to study the hydrodynamic interactions in terms of dynamics, liquid hold-up, and gas-liquid interfacial area per reactor volume. Those parameters provide insights into the multiphase flow patterns in these systems, how to control them, maximize mass transfer rate and unlock the potential of microreactors to reveal further intrinsic information.

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An efficient process is reported for preparing a state-of-the-art Fe-ferrierite catalyst for N₂O decomposition under industrial tail-gas conditions. In the synthesis procedure, we evaluate the very demanding constraints for scale-up; i.e. large reactor volumes are typically needed, and long processing times and considerable amounts of wastewater are generated. The proposed synthesis minimizes the amount of water used, and therefore, the amount of produced wastewater is minimal; in this approach there is no liquid residual water stream that would need intensive processing. This has remarkable benefits in terms of process design, since the volume of equipment is reduced and the energy-intensive filtration is eliminated. This route exemplifies the concept of process intensification, with the ambition to re-engineer an existing process to make the industrial catalyst manufacture more sustainable. The so-obtained catalyst is active, selective, and very stable under tail-gas conditions containing H₂O, NO, and O₂, together with N₂O, keeping a high conversion during 70 h time on stream at 700 K, with a decay of 0.01%/h, while the standard reference catalyst decays at 0.06%/h; hence, it deactivates 6 times more slowly, with ∼5% absolute points of higher conversion. The excellent catalytic performance is preliminarily ascribed to the differential speciation.

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In industrial catalysis, the sintering of supported nanoparticles (NPs) is often associated with the loss of catalyst activity and thus with periodic plant downtime and economic burdens. Yet, sintering mechanisms are at play also during the synthesis of the catalyst itself. They can, in fact, determine the size distribution of the NPs, and thus the activity and the stability of the catalyst. Here, we examine the role of nanoparticle sintering in a technique borrowed from the semiconductor industry that promises to reconcile atomic-scale precision with scalability: atomic layer deposition. By modeling the cyclic influx of single atoms in concomitance with NP sintering via either dynamic coalescence or Ostwald ripening, we establish the "signature" of different growth regimes: the size distribution. In contrast, we show that integral quantities such as the mean diameter, the number of NPs per unit area, and the material loading are poor indicators of the underlying growth mechanism. In particular, a constant number of NPs cannot be interpreted as a sign of no sintering. Finally, we argue that NP sintering, if properly understood, can open up new avenues for the control over the size distribution of NPs, and thus over their catalytic activity and stability.

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We tailored the size distribution of Pt nanoparticles (NPs) on graphene nanoplatelets at a given metal loading by using low-temperature atomic layer deposition carried out in a fluidized bed reactor operated at atmospheric pressure. The Pt NPs deposited at low temperature (100 °C) after 10 cycles were more active and stable towards the propene oxidation reaction than their high-temperature counterparts. Crucially, the gap in the catalytic performance was retained even after prolonged periods of time (>24 hours) at reaction temperatures as high as 450 °C. After exposure to such harsh conditions the Pt NPs deposited at 100 °C still retained a size distribution that is narrower than the one of the as-synthesized NPs obtained at 250 °C. The difference in performance correlated with the difference in the number of facet sites as estimated after the catalytic test. Our approach provides not only a viable route for the scalable synthesis of stable supported Pt NPs with tailored size distributions but also a tool for studying the structure-function relationship.

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A novel route to prepare highly active and stable N₂O decomposition catalysts is presented, based on Fe-exchanged beta zeolite. The procedure consists of liquid phase Fe(III) exchange at low pH. By varying the pH systematically from 3.5 to 0, using nitric acid during each Fe(III)-exchange procedure, the degree of dealumination was controlled, verified by ICP and NMR. Dealumination changes the presence of neighbouring octahedral Al sites of the Fe sites, improving the performance for this reaction. The so-obtained catalysts exhibit a remarkable enhancement in activity, for an optimal pH of 1. Further optimization by increasing the Fe content is possible. The optimal formulation showed good conversion levels, comparable to a benchmark Fe-ferrierite catalyst. The catalyst stability under tail gas conditions containing NO, O₂ and H₂O was excellent, without any appreciable activity decay during 70 h time on stream. Based on characterisation and data analysis from ICP, single pulse excitation NMR, MQ MAS NMR, N₂ physisorption, TPR(H₂) analysis and apparent activation energies, the improved catalytic performance is attributed to an increased concentration of active sites. Temperature programmed reduction experiments reveal significant changes in the Fe(III) reducibility pattern with the presence of two reduction peaks; tentatively attributed to the interaction of the Fe-oxo species with electron withdrawing extraframework AlO₆ species, causing a delayed reduction. A low-temperature peak is attributed to Fe-species exchanged on zeolitic AlO₄ sites, which are partially charged by the presence of the neighbouring extraframework AlO₆ sites. Improved mass transport phenomena due to acid leaching is ruled out. The increased activity is rationalized by an active site model, whose concentration increases by selectively washing out the distorted extraframework AlO₆ species under acidic (optimal) conditions, liberating active Fe species.

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Small-scale parallel trickle-bed reactors were used to evaluate the performance of a commercial hydrodesulfurization catalyst under industrially relevant conditions. Catalyst extrudates were loaded as a single string in reactor tubes. It is demonstrated that product sulfur levels and densities obtained with the single-pellet-string reactor are close to the results obtained in a bench-scale fixed-bed reactor operated under the same conditions. Moreover, parallel single-pellet-string reactors show high reproducibility. To study the hydrodynamic effects of the catalyst-bed packing, the catalyst-bed length was varied by loading different amounts of catalysts, and crushed catalyst was also loaded.

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Traditional industrial chemical processes have a reactor (or series of reactors) and a sequence of separations. Combining the reaction and separation into a single unit represents an opportunity for more sustainable processes which reduce the amount of materials and land used in plant construction, save significant energy inputs associated with separation, and normally increase yields. This approach is particularly useful with equilibrium processes since one can often force the reaction to the desired product by separating a reaction product. This article provides an overview of the types of technologies and then provides a more detailed discussion and examples of the three most common types of reactive separations including reactive distillation, coupling reactions with membrane separations, and coupling reaction with adsorption.

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We present an atomistic understanding of the evolution of the size distribution with temperature and number of cycles in atomic layer deposition (ALD) of Pt nanoparticles (NPs). Atomistic modeling of our experiments teaches us that the NPs grow mostly via NP diffusion and coalescence rather than through single-atom processes such as precursor chemisorption, atom attachment, and Ostwald ripening. In particular, our analysis shows that the NP aggregation takes place during the oxygen half-reaction and that the NP mobility exhibits a size- and temperature-dependent scaling. Finally, we show that contrary to what has been widely reported, in general, one cannot simply control the NP size by the number of cycles alone. Instead, while the amount of Pt deposited can be precisely controlled over a wide range of temperatures, ALD-like precision over the NP size requires low deposition temperatures (e.g., T < 100 °C) when growth is dominated by atom attachment.@en

A few decades ago a general feeling developed that the discipline of chemical engineering was reaching maturity. New breakthrough-type developments should not be expected anymore and it would be sufficient to be open to new branches that might prove to be useful such as life sciences and new functional materials. However, this static picture has changed profoundly. Considering the world with its increasing need for space due to the desire of increased safety, a healthier environment, and a higher standard of living, the footprint of every industrial sector has to be critically assessed. A parallel might be drawn between the chemical industry and other major production sectors such as the agricultural sector, the automotive industry, and the computer production industry. In all these sectors, the production has been strongly increased without proportionally increasing their footprint. Thus, the normal situation is that upon reaching a certain maturity an industrial sector has to drastically reduce its impact (Stankiewicz and Moulijn, 2000). Also in the chemical industry real progress has been realized: although the production volumes have increased dramatically, the space used only modestly increased. However, we might go a step further. Imagine that we could give back to the society 50% of the space we currently use. Because many petrochemical complexes lie in areas of high natural value, this would be fantastic. Think of the industrial complexes built in harbor areas, part of estuaries. Should these complexes shrink, sea life and tourism would benefit enormously. For drastic changes in this direction, a revolutionary approach is called for. We believe that a transformation of the chemical industrial sector into one with a lower footprint is possible. The timing for disruptive breakthroughs is right.

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ZnCl2 hydrate, the main molten salt used in biomass conversion, combined with low concentration HCl is an excellent solvent for the dissolution and hydrolysis of the carbohydrates present in lignocellulosic biomass. The most recalcitrant carbohydrate, cellulose, is dissolved in a residence time less than 1 h under mild conditions without significant degradation. This technology is referred to as BIOeCON-solvent technology. Separation of the sugars from the solution is the main challenge. The earlier conclusion regarding the potential of zeolite beta for selective adsorption has been used as the basis of a scale-up study. The technology of choice is continuous chromatographic separation (e.g., simulated moving bed, SMB). The sugar monomers are separated from the sugar oligomers, allowing the production of monosugars at high yield, using water as an eluent. Results of a pilot plant study are presented showing a stable operation at high selectivity. Several process designs are discussed, and the techno-economic performance of the BIOeCON-solvent technology is demonstrated by comparison with the state-of-the-art technology of NREL (National Renewable Energy Laboratory), which is based on enzymatic conversion of cellulose. It is concluded that the BIOeCON-solvent technology is technically and economically viable and is competitive to the NREL process. Because the BIOeCON-solvent process is in an early stage of development and far from fully optimized, it has the potential to outperform the existing processes@en