Waleeporn Donphaiab,
Naphaphan Kunthakudeea,
Sirapat Munpollasriab,
Pariyawalee Sangteantongab,
Surangrat Tonlublaoc,
Wanwisa Limphiratc,
Yingyot Poo-arpornc,
Sirapassorn Kiatphuengpornd and
Metta Chareonpanich*ab
aKU-Green Catalysts Group, Department of Chemical Engineering, Faculty of Engineering, Kasetsart University, Bangkok 10900, Thailand. E-mail: fengmtc@ku.ac.th
bNanocatalysts and Nanomaterials for Sustainable Energy and Environment Research Network of NANOTEC, Kasetsart University, Bangkok 10900, Thailand
cSynchrotron Light Research Institute, Nakhon Ratchasima 30000, Thailand
dNational Nanotechnology Center, National Science and Technology Development Agency, Pathumthani 12120, Thailand
First published on 21st January 2021
An external magnetic field has recently been applied in reaction processes to promote movement and avoid agglomeration of magnetic particles, and also reduce the activation energy through improving the gas–solid contact. In this work, the effect of an external magnetic field on reactant gas diffusivity and reactivity in CO hydrogenation within a confined-space catalyst was investigated for the first time using a conventional reactor packed with a bimetallic 5Fe–5Co/ZSM-5 molecular sieve catalyst. The synergistic effect between magnetic field and limited mass transfer within zeolite cavities improved the mass transfer ability and reaction phenomena of the reactant molecules, leading to enhancement of catalytic activity with tailored reaction pathways. As a result, CO conversion and CH4 selectivity were increased by factors of 1.9 and 1.3 compared to those without a magnetic field. These synergistic interactions are able to provide an innovative challenge for green and sustainable chemical processes and separation processes by means of selective reactant and product mass transfer designed for selective catalytic conversion in the future.
In addition to the catalyst and support, various key parameters, such as reactant gas pressure, reaction temperature, and space velocity, also strongly influence the CO hydrogenation reaction. Recently, an external magnetic field has been applied for the first time in CO2 reforming,16 photocatalytic reaction,17 Fischer–Tropsch synthesis,18,19 hydrogen production,20 in order to control and improve the movement of magnetic particles, avoid agglomeration of magnetic particles, and reduce the activation energy through improving gas–solid contact, respectively.21–23 In previous work,24–26 we fitted a catalytic packed bed reactor with an external magnetic field and observed significant improvement in CO2 hydrogenation over Fe–Cu based catalysts by means of increased adsorption ability and selectivity to longer hydrocarbon products.
Accordingly, it is of a great interest to apply an external magnetic field to the CO hydrogenation reaction especially that in a conventional reactor packed with a confined-space bimetallic 5Fe–5Co/ZSM-5 catalyst. The mass transfer ability and reaction phenomena of reactant molecules are expected to be improved under magnetic field and magnified within a confined-space ZSM-5 molecular sieve, leading to enhancement of catalytic activity with tailored reaction pathways. These synergistic interactions are able to provide an innovation challenge for simultaneous separation–reaction processes in the future.
In this study, 5 wt% Fe and 5 wt% Co were loaded onto ZSM-5 zeolite support using iron nitrate (Fe(NO3)3·6H2O: 98%, Univar) and cobalt nitrate hexahydrate (Co(NO3)2·6H2O: 99.95%, Univar) as metal precursors via incipient wetness impregnation method. The obtained mixture was dried using microwave irradiation at 560 W for 2 min, and consecutively calcined in air at 500 °C for 5 h using a heating rate of 5 °C min−1. The obtained catalyst was denoted as 5Fe–5Co/ZSM-5.
The crystallographic structures of ZSM-5 zeolite support and 5Fe–5Co/ZSM-5 catalyst were analyzed by X-ray diffraction spectroscopy (XRD: TTRAX III) using Cu Kα radiation at high angle in the 2θ range of 5–60°.
The surface morphology of ZSM-5 zeolite support and 5Fe–5Co/ZSM-5 catalyst were observed by using field emission scanning electron microscopy (FE-SEM: JEOL, JSM-7600F) operated at 15 keV with Pt-coated on the samples. Fe and Co elements on the catalyst surface were mapped by using energy-dispersive X-ray spectroscopy (EDS: OXFORD, XMaxN). The catalyst structure was examined by using transmission electron microscopy (TEM: JEOL JEM-2010) with an acceleration voltage of 200 kV.
The reducing temperatures of Fe and Co catalysts and interaction with ZSM-5 zeolite support were examined by using H2 temperature programmed reduction (H2-TPR: Micromeritics AutoChem II chemisorption analyzer). In the TPR experiment, 0.2 g of catalyst was heated in a flow of H2/Ar mixture gas (10% H2) using a total flow rate of 30 ml min−1. The experiment was carried out in temperature range of 50–1000 °C with a heating rate of 5 °C min−1.
Local geometry changes of Fe and Co species in catalyst during reduction stage with H2 gas at a temperature range of 30–400 °C and holding stage of 400 °C for 6 h were investigated by time resolved X-ray absorption spectroscopy (TR-XAS) at Beamline 2.2 of the Synchrotron Light Research Institute (SLRI), Thailand. XANES spectra of Fe K-edge and Co K-edge were collected in energy ranges of 6975–7525 eV and 7690–7840 eV, respectively, in the transmission detection mode using ionization chamber.
Magnetic properties were measured using a vibrating sample magnetometer (VSM: Lake-Shore7404) with an external magnetic field of 5 kOe at room temperature.
In this study, magnetic flux intensities at the catalyst bed were −20.8, −25.1 and −27.4 mT for two pairs, three pairs, and four pairs of magnets, respectively, with magnetic field orientation of N–S alignment. Prior to each experiment, 0.2 g catalyst packed at the center of magnetic pairs was reduced at 400 °C for 6 h using a H2 flow rate of 50 ml min−1 at atmospheric pressure. After catalyst activation, the reactor was cooled down to room temperature using He gas, then reactant gases (H2 and CO with molar ratio of 2) were introduced into the reactor. The reaction was performed at 320 °C at a total pressure of 10 bar.
Effluent gases including H2, CO, CO2, and CH4 were analyzed by using Shimadzu gas chromatograph (GC-2014) with a thermal conductivity detector (TCD) and a Unibead-C packed column, while hydrocarbon products (C1–C5+) were analyzed by Shimadzu gas chromatograph (GC-8A) with a flame ionization detector (FID). A Porapak-Q packed column and OV-1 Uniport HP packed column were used to analyze C1–C4 and C5+ hydrocarbons, respectively. Activity and selectivity of 5Fe–5Co/ZSM-5 catalyst without an external magnetic field were also examined in comparison.
Fig. 2 N2 adsorption–desorption isotherm (a) and pore size distribution (b) of ZSM-5 support and 5Fe–5Co/ZSM-5 catalyst. |
Fig. 3 SEM images of 5Fe–5Co/ZSM-5 catalyst (a) with EDS mapping of Fe (b), Co (c) dispersions and EDS spectrum (d). |
The reducibility of the catalysts was evaluated by H2-TPR, and the reduction profiles are presented in Fig. 4. Three deconvolution peaks of reduction in the temperature range of 200–800 °C are observed in 5Fe–5Co/ZSM-5 catalyst. The first peak at lower temperature (317 °C) can be assigned to transformations of Fe2O3 to Fe3O4 and of Co3O4 to CoO.5,6,12 The second peak (414 °C) is attributed to the reduction of Fe3O4 and FeO to metallic Fe and of CoO to metallic Co, while the last peak (452 °C) can be ascribed to the reduction of remaining FeO or of hardly reducible Fe species.7,29
Fig. 4 H2-TPR profile of (a) 5Fe–5Co/ZSM-5, (b) 5Fe/ZSM-5 and (c) 5Co/ZSM-5 catalysts. TPR profile (experiment); TPR profile (program); deconvoluted profile of Fe and Cu oxide species. |
In situ XANES technique was applied to confirm the transformation of Fe and Co species on 5Fe–5Co/ZSM-5 (Fig. 5). The XANES spectra in the range 50–340 °C exhibited absorption edge energy at 7127 eV, indicating the presence of Fe2O3 and Fe3O4. Increasing the reduction temperature to above 340 °C under a flow of H2, a gradual shift of the absorption edge energy towards lower energy was observed, indicating the reduction of oxidation state of Fe species. In the case of Co species, the reduction of oxidation state occurred when increasing the reduction temperature to those higher than 300 °C. In order to determine the evolution of the oxidation states of Fe and Co species on ZSM-5 support, linear combination fitting was performed on each XANES spectrum at the reduction temperature of 400 °C, and compared to the XANES spectra of the references consisting Fe2O3, Fe3O4, FeO and Fe for Fe species, as well as Co3O4, CoO and Co for Co species. As shown in Fig. 6, the metal oxide catalysts were transformed to approximately 20% FeO and 70% Fe, and approximately 20% CoO and 80% Co, after the reduction process.
Fig. 5 In situ Fe K-edge and Co K-edge XANES spectra of 5Fe–5Co/ZSM-5 catalyst reduction from 50–400 °C and for 4 h holding time. |
The magnetic properties of 5Fe–5Co/ZSM-5 catalyst before and after the reduction process at 400 °C were investigated using a vibrating sample magnetometer (VSM) (Fig. 7). Before the reduction process, 5Fe–5Co/ZSM-5 catalyst exhibited a small magnetic hysteresis loop, indicating paramagnetic nature of the catalyst.30,31 After the reduction process, a narrower hysteresis loop was clearly observed. The saturation (Ms) and remanence (Mr) magnetizations of the reduced 5Fe–5Co/ZSM-5 catalyst both significantly increased, indicating higher magnetic responses compared to the unreduced catalyst due to the existence of α-Fe phase with ferromagnetic property within the catalyst. In addition, a higher saturation magnetization of 19.0 emu g−1 was observed on the reduced catalyst, compared to 3.6 emu g−1 for the catalyst before reduction.
Fig. 7 Magnetic hysteresis loops of 5Fe–5Co/ZSM-5 catalyst before and after reduction process at 400 °C. |
The performances of 5Fe–5Co/ZSM-5 catalyst in CO hydrogenation reaction were examined using a magnetic field-assisted packed bed reactor operated at 320 °C and 10 bar with a total flow rate of 30 ml min−1; the results are shown in Fig. 8 and 9. Magnetic flux intensities were varied in the range of 0–27.7 mT (the geomagnetic field thereby being approx. 0.03–0.06 mT). It was found that CO conversion under external magnetic field increased by a factor of 1.9 compared to that without magnetic field. Compared to the reaction over Co/Al2O3 catalyst, CO conversion at 15 mT increased by a factor of 1.1.19 However, the CO conversion showed no significant variation using magnetic flux intensities ranging from 20.8–27.4 mT.
Fig. 8 Catalytic performances in terms of H2 and CO conversion over 5Fe–5Co/ZSM-5 using different magnetic flux intensities. |
Fig. 9 Product distributions from CO hydrogenation over 5Fe–5Co/ZSM-5 catalyst for different magnetic flux intensities. |
It was noted that methane yield significantly increased, while CO2 obviously decreased with increasing magnetic flux intensities in the range of 0–27.4 mT. These results indicated that the external magnetic field facilitated the activity of 5Fe–5Co/ZSM-5 catalyst through increasing the reverse water–gas shift reaction.32 This may attributed to the effective diffusion of reactant molecules and their interaction with the catalyst surface under magnetic field.
Based on the above results, it was suggested that the selective CO conversion and product selectivities under external magnetic field could possibly rely not only on the improvement of catalyst active surfaces, but also on the diffusion rate of the reactants into and the product gases from the confined-space ZSM-5 zeolite based catalyst. In order to confirm the synergistic effect of the external magnetic field and limited mass transfer within zeolite cavities, the diffusion of CO and H2 reactant molecules through 5Fe–5Co/ZSM-5 catalyst bed under external magnetic field were observed and compared to that without magnetic field, as shown in Fig. 10.
As shown in Fig. 10, the diffusion rates of both CO and H2 reactant gases were significantly lowered principally due to the interaction with –OH functional group on ZSM-5 zeolite surfaces and limited mass transfer within zeolite cavities compared to inert silica. In addition, H2 diffusivity improved considerably, more than that of CO under external magnetic field as its kinetic diameter (289 pm) is 1.3 times smaller than that of CO (376 pm). The synergistic effect of the external magnetic field and limited mass transfer within zeolite cavities therefore led to selective CO conversion to methane and larger hydrocarbon products.
In order to understand the effect of external magnetic field on the reactant gas diffusion within the confined space catalyst, the effective diffusion coefficients (De) of CO and H2 were calculated using eqn (1)–(5);33 the results are shown in Table 1.
De = Dporeε/τ | (1) |
(2) |
(3) |
(4) |
Magnetic flux intensity (mT) | Diffusivities in pores × 10−3 (cm2 s−1) | Effective diffusion coefficient × 10−4 (cm2 s−1) | ||
---|---|---|---|---|
CO | H2 | CO | H2 | |
0 | 0.89 | 3.30 | 4.29 | 15.97 |
20.8 | 1.75 | 4.83 | 8.49 | 23.41 |
25.1 | 2.33 | 9.57 | 11.30 | 46.32 |
27.4 | 1.84 | 6.71 | 8.92 | 32.51 |
The tortuosity (τ) of 5Fe–5Co/ZSM-5 catalyst in eqn (1), can be calculated by using eqn (5).34
(5) |
Table 1 shows that effective diffusion coefficients of CO and H2 in pores of 5Fe–5Co/ZSM-5 catalyst under external magnetic field were improved by approximately 2.6 and 2.9 times, respectively, compared to those without magnetic field. This is in good agreement with the experimental results observed in Fig. 10. As a result, it can be concluded that the application of an external magnetic field to catalytic CO hydrogenation over a confined-space ZSM-5 zeolite based catalyst can facilitate the synergy between the external magnetic field and limited mass transfer within zeolite cavities. These phenomena consequently led to differences in effective diffusion abilities of CO and hydrogen during the reaction within the catalyst pores, leading to significant improvement in CO conversion.
As the reactor system consisting an external magnetic field in cooperation with a confined-space zeolite catalyst can facilitate different mass transfer abilities of reactant gases and products, the potential application for reactive separation processes by means of selective reactant and product mass transfers designed for separation—selective catalytic conversion with tailored reaction pathways are therefore able to provide a potential challenge for larger—scale green and sustainable chemical processes in the future.
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