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Heterogeneous Catalysis
Heterogeneous Catalysis
Fundamentals, Engineering, and
Characterizations (with accompanying
presentation slides and instructor’s manual)
Giovanni Palmisano
Department of Chemical Engineering, Khalifa University, Abu Dhabi,
United Arab Emirates
Samar Al Jitan
Department of Chemical Engineering, Khalifa University, Abu Dhabi,
United Arab Emirates
Corrado Garlisi
Luxembourg Institute of Science and Technology, Luxembourg
Contents
Preface.................................................................................................................. ix
v
vi Contents
Index ..................................................................................................................315
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Elsevier
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Copyright © 2022 Elsevier Inc. All rights reserved.
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arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found
at our website: www.elsevier.com/permissions.
This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may
be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and experience broaden our
understanding, changes in research methods, professional practices, or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any
information, methods, compounds, or experiments described herein. In using such information or methods they should be
mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any
injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or
operation of any methods, products, instructions, or ideas contained in the material herein.
ix
x Preface
Chapter 3, Adsorption Models, Surface Reaction, and Catalyst Architectures, describes the
traditional adsorption models with an overview on recent developments covered in the
Focus sections, which are found throughout the book and point mostly to the correlation
between materials preparation/properties and catalytic performance, along with numerical
examples. The chapter ends with the models for surface reaction and the role of cocatalysts
and supports.
Chapter 4, Surface Area and Porosity, deals with the assessment of the surface area and
porosity, with insights on the old and more recent hysteresis classifications and models to
estimate porosity and pore size distribution. This chapter presents a significant number of
examples taken from recent literature that are intended to develop the reader’s skills on the
interpretation of isotherms with hysteresis loops and pore size distributions. Focus sections
describe the working principles and the equipment used for the assessment of the textural
properties of catalysts, numerical examples on the BET equation, tortuosity and diffusivity,
along with a case study on the design of catalysts for the enhancement of diffusion.
Overall, the first four chapters give a unique overview of the fundamentals of catalysis,
inclusive of all the kinetic and thermodynamic aspects related to adsorption/desorption,
followed by a detailed and updated presentation on the assessment of surface area and
porosity.
Chapter 5, Catalytic Reaction Engineering, covers the reaction engineering topics of
heterogeneous catalysts, particularly useful for readers without a background in chemical
engineering who did not study catalytic reaction engineering and reactor modeling. The
Focus sections describe different types of catalytic reactors, the modeling of diffusion and
transport in porous catalysts, the design and preparation of catalyst pellets for fixed bed
reactors, and they also include solved reaction engineering problems.
Chapter 6, Green Heterogeneous Catalysis, is a survey on green catalysis, ranging from
electrocatalysis to photocatalysis and the catalytic conversion of biomass to biofuel. The
chapter is focused on the applications after a quick introduction to the principles of these
three green approaches. Focus sections cover the preparation aspects of recently developed
catalysts and the connection between catalyst properties and activity/selectivity.
To conclude, the most popular characterization techniques used for solid catalysts are
discussed in Chapter 7, Characterization Techniques, where the fundamentals of all
techniques are explained followed by examples of their applications. This chapter is
approachable by both a newcomer and a more expert reader who would like to be
introduced to a characterization technique he/she is not familiar with and analyze few data
describing catalysts reported in the literature. The application of in-situ techniques, the
characterization of catalysts during their synthesis, and the description of a synchrotron
facility are among the topics covered in the Focus sections.
Preface xi
The book, which is reader friendly and accessible to a heterogeneous readership ranging
from senior undergraduate students up to Master’s and PhD level students, along with
experienced scholars and practitioners, is supplemented with Presentation Slides for each
chapter, useful for classes, seminars, workshops. An Instructor’s Manual is also available
upon request with the answers to the proposed questions and problems. Case studies
addressing materials preparation among other topics and numerical examples can be found
in the Focus sections of each chapter. End of chapter Questions and Problems are proposed
for self-tests and as a reference for assignments/exams to be arranged by instructors.
The authors are thankful to Mr. Mujeeb Oladipupo Kareem for his contribution to the
Instructor’s Manual and his useful suggestions.
Giovanni Palmisano
Samar Al Jitan
Corrado Garlisi
To access the Instructor’s Manual including answers to proposed questions and problems
please go to the following website and register to use: https://textbooks.elsevier.com/web/
Login.aspx?MREDIR=../web/Manuals.aspx?isbn=9780323898454
CHAPTER 1
Introduction
Catalytic reactions are subdivided into two distinct categories depending on the phases of
both the catalyst and the reacting mixture. If the catalyst is in solution with at least one of
the reactants, then the process is defined as homogenous catalysis. On the contrary, if the
process involves more than one phase (e.g., solid catalyst with reactants in the liquid or gas
phase), then it is defined as heterogeneous catalysis. Of these two types, heterogeneous
catalysis is more common. This is mainly attributed to the simple and complete separation
of the reaction products from the solid catalyst. Catalysts are quite valuable and their reuse
is in high demand. Hence, the possibility of catalyst recycling makes heterogeneous
catalysis economically much more attractive.
Today, heterogeneous catalysis plays a key role in many important industrial processes,
since it involves c. 80% of the industrial chemical conversions. As such, it is applied in
(1) the production of organic and inorganic chemicals, (2) crude oil refining and
petrochemistry, (3) environmental protection, and (4) energy-conversion processes.
Heterogeneous catalysis takes place through surface reactions, with adsorption of at least
one of the reactants on the catalyst surface as the initial step.
A catalyst is defined as a substance that increases the rate of a chemical reaction without
itself undergoing a chemical change. A good catalyst must possess high activity, the desired
selectivity, and long-term stability. The activity of a catalyst may be assessed via different
parameters, including its turnover frequency (TOF), conversion, yield, and, most
importantly, selectivity. These fundamental catalysis terms will be thoroughly defined and
explained within this chapter after a historical account of heterogeneous catalysis.
Heterogeneous Catalysis.
DOI: https://doi.org/10.1016/B978-0-323-89845-4.00001-1 1
© 2022 Elsevier Inc. All rights reserved.
2 Chapter 1
concept of catalysis were the transformation of starch to sugar by acids observed by Gustav
Kirchhoff, the enhanced combustion of a variety of gases in the presence of platinum
observed by Humphry Davy, and the oxidation of alcohol to acetic acid in the presence of
fine platinum powder [1].
In 1834 Michael Faraday observed the catalytic action of platinum that catalyzed the
spontaneous combustion of hydrogen and oxygen in water electrolysis. He was the first to
introduce the concept of what we know as adsorption and hypothesize that catalytic
reaction occurs on the catalyst surface following the simultaneous adsorption of the
reactants involved in the process [2]. Presently, water electrocatalysis is being widely
applied in the industrial production of high-purity hydrogen [3].
An important contribution to catalysis as we know it now was given by Wilhelm Ostwald
in 1897, who defined a catalyst as a material that modifies the reaction rate without
appearing in the final products, thereby recognizing catalysis as a kinetic phenomenon for
the first time [4]. In the same years, Paul Sabatier investigated the hydrogenation reaction
catalyzed by metals, such as nickel, other than platinum. He proposed the formation and
decomposition of intermediate complexes with the surface catalysts, resulting in a lowering
of the Gibbs energy of the system [5].
A fundamental step in catalysis occurred in 1909, when the chemist Fritz Haber discovered
that a significant amount of ammonia could be generated from hydrogen and nitrogen in the
presence of osmium and uranium catalysts. The potential for industrial application of these
processes could be increased by working at high pressure, and to that end, the Haber’s
laboratory apparatus was converted to a high-pressure large-scale industrial apparatus by
Carl Bosh. Afterward, Badische Anilin und Soda Fabrik (BASF) started a large program to
develop a cheaper and effective catalyst. Alvin Mittasch, together with his colleagues, Wolf
and Stern, identified magnetite (Fe3O4) as the best candidate for ammonia production [6].
In the wake of these results, in 1923, BASF also developed the first plant for the synthesis
of methanol from syngas produced from coal in the presence of ZnO/Cr2O3 catalysts
operating at c. 400 C and 200 bar [7].
In 1938 Fischer and Tropsch studied the conversion of syngas to hydrocarbons and alcohols
catalyzed by metals such as cobalt and iron (i.e., FischerTropsch synthesis) [8].
In the early 20th century, a greater understanding of the mechanisms behind the catalytic
processes was gained thanks to the studies conducted by Irving Langmuir on adsorption
and Hugh Stott Taylor on surface active sites. The latter especially focused on the
heterogeneity of the catalyst surface, which usually presents vacancies, kinks, terraces,
ledges, etc., being hosting sites where metal atoms have different coordination numbers and
thus catalytic activities [2]. Meanwhile, Stephen Brunauer, Paul Hugh Emmett, and Edward
Teller explained the physical adsorption of gas molecules on a solid surface; Eric Rideal,
Introduction 3
Mikhail Temkin, Michel Boudart, and many others provided a valuable contribution to a
greater understanding of the kinetics of catalytic reactions [9].
In the 1930s catalytic cracking was introduced in the petroleum refining industry. This
process allowed to break the CaC bonds in large petroleum molecules, converting them
into high-octane fuels using an aluminum chloride catalyst (i.e., FriedelCrafts catalysts).
Yet, the foundation of modern petroleum refining was established in 1942 with the
commercialization of fluid catalytic cracking (FCC). These processes enabled to maintain
the catalyst particles in suspension by a stream of vaporized hydrocarbons blown through
the reactor and successively passed through the regenerator [7].
An important landmark was the advent of synthetic zeolites, aluminosilicate catalysts, in the
1960s, when amorphous silicaalumina catalysts used in FCC were gradually replaced by
synthetic faujasites (zeolites X and Y) (Fig. 1.1). The zeolite catalysts were orders of
magnitude more active than the conventional ones and ensured a much higher yield of
gasoline, the key product in FCC plants. This type of catalyst, characterized by a broad
variety of structures, rapidly found applications in further processes in petroleum refining
and basic petrochemistry. Fig. 1.1 shows some of the typical structures, along with the
distinctive micropore systems and dimensions of zeolites. Among these, the synthetic
zeolite ZSM-5 is one of the most used industrially, being the prototype of shape-selective
catalysts and finding application in the synthesis of ethylbenzene, conversion of methanol
to gasoline, and isomerization of xylenes [10].
Figure 1.1
Four examples of zeolite structures with their micropore system and dimensions. Source: Reproduced
from [10].
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4 Chapter 1
From the 1960s, the evolution of the transportation industry, the increase in industrial
activity, and the severe rise in air-born pollutants have led to the establishment of new laws
that regulate vehicle and stationary emissions [11]. Driven by these regulations, global
attention and widespread interest in environmental catalysis grew substantially.
Environmental catalysis addresses problems relating directly to emission control, NOx
removal, volatile organic compound conversion, and waste treatment. Presently, the
research focus of environmental catalysis has expanded from pollutant abatement to include
pollutant prevention. Accordingly, new catalytic routes have been explored for the synthesis
of value-added products without the formation of undesirable pollutants and for the
production of new clean fuels with low sulfur content [12].
The engineering of semiconductors, especially of titanium oxide, has led to growing
attention toward heterogeneous photocatalysis during the 20th century, which nowadays is a
hot topic in applied catalysis for the possibility to efficiently degrade any organic pollutants
and produce alternative clean fuels by the irradiation of a catalyst. The earliest reference on
photocatalysis dates back to 1911, when Alexander Eibner studied the effect of the
illumination of ZnO on the bleaching of Prussian blue. However, in the absence of practical
applications, these processes remained a curiosity for much of the 20th century. In the
1970s Akira Fujishima and Kenichi Honda [13] observed the electrochemical photolysis of
water in a cell consisting of an ionically conducting separator and a rutile TiO2 electrode
irradiated by near-UV light and connected to a platinum counter electrode via an electrical
load (Fig. 1.2). The HondaFujishima effect attracted the attention of the whole scientific
Figure 1.2
Schematic of the electrochemical cell employed by Fujishima and Honda for the photolysis of
water: (1) rutile electrode, (2) platinum counter electrode, (3) ionically conducting separator,
(4) gas burette, (5) load resistance, and (6) voltmeter. Source: Reproduced from [14].
Introduction 5
Figure 1.3
The main components of a power-to-gas system and the various types of applications for it.
Source: Reproduced from [15].
6 Chapter 1
In the 21st century, catalytic asymmetric synthesis methods, developed by Knowles, Noyori,
and Sharpless, have seen great significance in the industrial production of pharmaceuticals
and agro-chemicals [18]. Catalytic asymmetric synthesis refers to catalytic methods in
which one of the enantiomers is formed in preference to the other. Here, a chiral catalyst is
used to produce large quantities of an optically active compound from a precursor that may
be chiral or achiral. On this basis, many organic chemists have recently developed
numerous methods that convert prochiral substrates into chiral products with high
enantioselectivity.
Pd-catalyzed carboncarbon bond-forming reactions, developed by Heck, Negishi, and
Suzuki, have also had a huge influence on synthetic organic chemistry during the 21st
century [19]. A large number of natural products and biologically active compounds in the
fine chemical and pharmaceutical industries are presently being synthesized by these Pd-
catalyzed cross-coupling reactions. This is mainly attributed to the mild reaction conditions
and the tolerance of a wide range of functional groups. In Pd-catalyzed cross-coupling
reactions, two molecules assemble on Pd via the formation of metalcarbon bonds. The
carbon atoms bound to Pd are, therefore, in very close proximity to one another.
Accordingly, the two carbon atoms couple together and a new carboncarbon single bond
is formed.
Focus 1.1: Effect of Zn:Cr ratio on the structure and reactivity of ZnO/Cr2O3
catalysts for methanol synthesis
Advances on the ZnO/Cr2O3 catalyst developed by BASF in 1923 for the synthesis of
methanol from syngas have been recently achieved by Song et al. [20] who studied the
effect of different Zn:Cr ratios—from 100:0 to 0:100—on the catalytic performance. The
catalysts with ratios from 65:35 to 55:45 consisted of ZnCr2O4 spinel with a low degree of
crystallinity and high surface area. In particular, the sample with 65:35 exhibited the
highest reactivity due to the optimum Zn:Cr ratio corresponding to that of the
hydrotalcite-like precursor Zn4Cr2(OH)12CO3. This precursor, formed during the synthesis
of the catalysts by coprecipitation, decomposed during calcination to the
nonstoichiometric ZnCr spinel, which is the active phase of ZnO/Cr2O3 in methanol
synthesis. On the other hand, the lower activity of Cr-rich catalysts was mainly ascribed to
the formation of chromates during the calcination, having a detrimental impact on
methanol synthesis.
Density functional theory calculations showed that (100) surface of the spinel has favorable
oxygen vacancy formation energies. Fig. 1.4 displays the calculated local structure for the
spinel with excess 60% Zn content (26.66% doping). The nonstoichiometric surface is
terminated by an amorphous-like thin layer of ZnO, which is the active phase for methanol
production, since it possesses a low oxygen vacancy formation energy, as well as not too
strong adsorption of hydrogen and carbon monoxide.
(Continued)
Introduction 7
Focus 1.1: Effect of Zn:Cr ratio on the structure and reactivity of ZnO/Cr2O3
catalysts for methanol synthesis (Continued)
Figure 1.4
Local structure for the spinel structure with 26.66% Zn doping. Source: Reproduced from [20].
The extent of surface fractional coverage θ indicates the portion of catalytic sites occupied
by an adsorbed species (adsorbate) and it can be defined in the following way:
Number of adsorption sites occupied
θ5 (1.1)
Total number of adsorption sites
This quantity is usually calculated from the volume of adsorbate adsorbed (V) by θ 5 V/Vm,
where Vm is the volume of adsorbate corresponding to a complete monolayer (i.e., a single
layer of atoms or molecules adsorbed on the surface of a catalyst). The volumes V and Vm
are of the free gas measured in the same conditions of temperature and pressure [21]. When
θ reaches the value of 1, the surface catalytic sites are completely occupied, and adsorption
of further layers is possible only on top of the first one (multilayer adsorption), as it will be
widely discussed in the following chapters.
The catalytic activity is related to the ability of a catalyst to change the reaction rate, which, in
turn, can be defined in many ways depending on the reaction system. In general, the reaction rate
(R) is a function of temperature and partial pressure or concentration of the reactants. It can be
8 Chapter 1
expressed as the product of an apparent coefficient (k) and a function ( f ) of the partial pressure
(gassolid system) or concentration (liquidsolid system) of the reactant i:
R 5 k f ðpi Þ ðgas2solid systemÞ (1.2)
R 5 k f ðci Þ ðliquid2solid systemÞ (1.3)
where pi and ci are the partial pressure and concentration of the reactant i, respectively. The
reaction rate expresses a change in the number of moles (of a reactant or product) per unit
time per unit mass (or surface) of a catalyst. The rate constant can be expressed through the
Arrhenius equation:
2 ERT
k 5 Ae (1.4)
where A is the preexponential factor not changing with temperature, R is the universal
gas constant, T is the absolute temperature, and E is the apparent activation energy. E
is usually different from the true activation energy since the concentration of the
reactant at the catalyst surface may be temperature dependent, although the catalyst
structure may not be affected by temperature changes. To avoid resorting to the
activation energy, most of the time catalytic activity is expressed in terms of TOF,
which is defined as the number of molecular reactions or catalytic cycles (n) per active
site of the catalyst per unit time. Being a reaction rate, TOF depends on the reaction
conditions including temperature and composition of the reacting system. In general,
TOF can be expressed as:
1 dn
TOF 5 (1.5)
S dt
where t stands for reaction time and S indicates the number of active sites. For the most
relevant heterogeneous catalytic reactions in industry, TOF is in the range of
1022a102 s21. The main difficulty in determining TOF lies in counting active sites.
Moreover, sites may not be all identical. In such situations, S is usually replaced by the
total exposed area, mass, or volume of the catalyst [7].
Fig. 1.5 presents the results of a study conducted on the catalytic gas-phase hydrogenation
of p-nitrobenzonitrile (p-NBN) to p-aminobenzonitrile (p-ABN) using a series of oxides
as support for the catalyst consisting of gold (Au) particles with a mean size 38 nm.
Different supports resulted in different Au nanoparticle sizes, impacting the hydrogen
chemisorption (Fig. 1.5A) and TOF (Fig. 1.5B). The variation of the TOF with the mean
Au size coincided with that observed for H2 uptake, indicating a strong correlation
between the hydrogenation rate and H2 dissociation capacity. The reduced TOF at small
Au size (,3 nm) is due to the semiconducting properties of the catalysts to the detriment
of the metallic ones [22].
Figure 1.5
Variation of (A) H2 uptake and (B) TOF of p-NBN with metal particle size for the hydrogenation
of p-nitrobenzonitrile over Au catalysts supported on various oxides. Source: Reproduced from [22].
Figure 1.6
Schematic illustration of the HER mechanism over np-Co0.85Se catalyst. HER, Hydrogen evolution
reaction. Source: Readapted from [23].
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