The refinery of the future.

Fossil fuels-coal, oil and gas-supply most of the world's energy and also form the basis of many products essential for everyday life. Their use is the largest contributor to the carbon dioxide emissions that drive global climate change, prompting joint efforts to find renewable alternatives that might enable a carbon-neutral society by as early as 2050. There are clear paths for renewable electricity to replace fossil-fuel-based energy, but the transport fuels and chemicals produced in oil refineries will still be needed. We can attempt to close the carbon cycle associated with their use by electrifying refinery processes and by changing the raw materials that go into a refinery from fossils fuels to carbon dioxide for making hydrocarbon fuels and to agricultural and municipal waste for making chemicals and polymers. We argue that, with sufficient long-term commitment and support, the science and technology for such a completely fossil-free refinery, delivering the products required after 2050 (less fuels, more chemicals), could be developed. This future refinery will require substantially larger areas and greater mineral resources than is the case at present and critically depends on the capacity to generate large amounts of renewable energy for hydrogen production and carbon dioxide capture.

Correction: Unravelling potential reaction intermediates during catalytic pyrolysis of polypropylene with microscopy and spectroscopy.

[This corrects the article DOI: 10.1039/D3CY01473H.].

Alternative nano-lithographic tools for shell-isolated nanoparticle enhanced Raman spectroscopy substrates.

Chemically synthesized metal nanoparticles (MNPs) have been widely used as surface-enhanced Raman spectroscopy (SERS) substrates for monitoring catalytic reactions. In some applications, however, the SERS MNPs, besides being plasmonically active, can also be catalytically active and result in Raman signals from undesired side products. The MNPs are typically insulated with a thin (∼3 nm), in principle pin-hole-free shell to prevent this. This approach, which is known as shell-isolated nanoparticle-enhanced Raman spectroscopy (SHINERS), offers many advantages, such as better thermal and chemical stability of the plasmonic nanoparticle. However, having both a high enhancement factor and ensuring that the shell is pin-hole-free is challenging because there is a trade-off between the two when considering the shell thickness. So far in the literature, shell insulation has been successfully applied only to chemically synthesized MNPs. In this work, we alternatively study different combinations of chemical synthesis (bottom-up) and lithographic (top-down) routes to obtain shell-isolated plasmonic nanostructures that offer chemical sensing capabilities. The three approaches we study in this work include (1) chemically synthesized MNPs + chemical shell, (2) lithographic substrate + chemical shell, and (3) lithographic substrate + atomic layer deposition (ALD) shell. We find that ALD allows us to fabricate controllable and reproducible pin-hole-free shells. We showcase the ability to fabricate lithographic SHINER substrates which report an enhancement factor of 7.5 × 103 ± 17% for our gold nanodot substrates coated with a 2.8 nm aluminium oxide shell. Lastly, by introducing a gold etchant solution to our fabricated SHINER substrate, we verified that the shells fabricated with ALD are truly pin-hole-free.

Green Additives in Chitosan-based Bioplastic Films: Long-term Stability Assessment and Aging Effects.

Although biomass-based alternatives for the manufacturing of bioplastic films are an important aspect of a more sustainable future, their physicochemical properties need to be able to compete with the existing market to establish them as a viable alternative. One important factor that is often neglected is the long-term stability of renewables-based functional materials, as they should neither degrade after a day or week, nor last forever. One material showing high potential in this regard, also due to its intrinsic biodegradability and antibacterial properties, is chitosan, which can form stable, self-standing films. We previously showed that green additives introduce a broad tunability of the chitosan-based material properties. In this work, we investigate the long-term stability and related degradation processes of chitosan-based bioplastics by assessing their physicochemical properties over 400 days. It was found that the film properties change similarly for samples stored in the fridge (4 °C, dark) as at ambient conditions (20 °C, light/dark cycles of the day). Additives with high vapor pressure, such as glycerol, evaporate and degrade, causing both brittleness and discoloration. In contrast, films with the addition of crosslinking additives, such as citric acid, show high stability also over a long time, bearing great preconditions for practical applications. This knowledge serves as a stepping-stone to utilizing chitosan as an alternative material for renewable-resourced bioplastic products.

Unravelling potential reaction intermediates during catalytic pyrolysis of polypropylene with microscopy and spectroscopy.

While plastics-to-plastics recycling via melting and re-extrusion is often the preferred option due to a relatively low CO2 footprint, this technique requires a highly sorted waste stream and plastic properties can often not be maintained. Obtaining aromatics, such as benzene, toluene, and xylene (BTX), via catalytic pyrolysis of polyolefins, such as polypropylene and polyethylene, offers another attractive recycling technology. In this process, a discarded crude oil refinery catalyst (ECAT) was previously shown to lower the unwanted formation of deactivating coke species compared to a fresh crude oil refinery catalyst (FCC-cat), while yielding 20 wt% aromatics from polypropylene. In this work, we study the underlying reaction mechanism for this chemical recycling process over the fresh and used refinery catalyst as well as a model system, not containing any zeolite material, using a combination of microscopy and spectroscopy. More specifically, by using in situ fluorescence microscopy, in situ infrared spectroscopy, in situ ultraviolet-visible spectroscopy as well as ex situ solid-state nuclear magnetic resonance, we observe highly fluorescent methylated aromatic intermediates that differ for the three catalyst materials under study both in their fluorescence, IR, UV-vis, and NMR spectroscopy features. This detailed micro-spectroscopic comparison informs which potential reaction intermediates lead to increased coke formation. Our results suggests that a next generation of catalyst materials for this process would profit from a higher accessibility and a milder acidity compared to an FCC-cat and shows the great potential of using ECAT to reduce coking and obtain a BTX stream, which could be become the chemical building blocks for the manufacturing of e.g., plastics and coating materials.

Fluorescent-Probe Characterization for Pore-Space Mapping with Single-Particle Tracking.

Porous solids often contain complex pore networks with pores of various sizes. Tracking individual fluorescent probes as they diffuse through porous materials can be used to characterize pore networks at tens of nanometers resolution. However, understanding the motion behavior of fluorescent probes in confinement is crucial to reliably derive pore network properties. Here, we introduce well-defined lithography-made model pores developed to study probe behavior in confinement. We investigated the influence of probe-host interactions on diffusion and trapping of confined single-emitter quantum-dot probes. Using the pH-responsiveness of the probes, we were able to largely suppress trapping at the pore walls. This enabled us to define experimental conditions for mapping of the accessible pore space of a one-dimensional pore array as well as a real-life polymerization-catalyst-support particle.

Molecular Accessibility and Diffusion of Resorufin in Zeolite Crystals.

Invited for the cover of this issue is the group of Professor Bert Weckhuysen at Utrecht University. The image depicts the change in fluorescence color of a resorufin dye molecule when it is protonated and confined inside the micropores of zeolite-ß. Read the full text of the article at 10.1002/chem.202302553.

Molecular Accessibility and Diffusion of Resorufin in Zeolite Crystals.

We have used confocal laser scanning microscopy on the small, fluorescent resorufin dye molecule to visualize molecular accessibility and diffusion in the hierarchical, anisotropic pore structure of large (~10 µm-sized) zeolite-ß crystals. The resorufin dye is widely used in life and materials science, but only in its deprotonated form because the protonated molecule is barely fluorescent in aqueous solution. In this work, we show that protonated resorufin is in fact strongly fluorescent when confined within zeolite micropores, thus enabling fluorescence microimaging experiments. We find that J-aggregation guest-guest interactions lead to a decrease in the measured fluorescence intensity that can be prevented by using non-fluorescent spacer molecules. We characterized the pore space by introducing resorufin from the outside solution and following its diffusion into zeolite-ß crystals. The eventual homogeneous distribution of resorufin molecules throughout the zeolite indicates a fully accessible pore network. This enables the quantification of the diffusion coefficient in the straight pores of zeolite-ß without the need for complex analysis, and we found a value of 3×10-15  m2  s-1 . Furthermore, we saw that diffusion through the straight pores of zeolite-ß is impeded when crossing the boundaries between zeolite subunits.

Visualizing the Structure, Composition and Activity of Single Catalyst Particles for Olefin Polymerization and Polyolefin Decomposition.

The structural and morphological characterization of individual catalyst particles for olefin polymerization, as well as for the reverse process of polyolefin decomposition, can provide an improved understanding for how these catalyst materials operate under relevant reaction conditions. In this review, we discuss an emerging analytical toolbox of 2D and 3D chemical imaging techniques that is suitable for investigating the chemistry and reactivity of related catalyst systems. While synchrotron-based X-ray microscopy still provides unparalleled spatial resolutions in 2D and 3D, a number of laboratory-based techniques, most notably focused ion beam-scanning electron microscopy, confocal fluorescence microscopy, infrared photoinduced force microscopy and laboratory-based X-ray nano-computed tomography, have helped to significantly expand the arsenal of analytical tools available to scientists in heterogeneous catalysis and polymer science. In terms of future research, the review outlines the role and impact of in situ and operando (spectro-)microscopy experiments, involving sophisticated reactors as well as online reactant and product analysis, to obtain real-time information on the formation, decomposition, and mobility of polymer phases within single catalyst particles. Furthermore, the potential of fluorescence microscopy, X-ray microscopy and optical microscopy is highlighted for the high-throughput characterization of olefin polymerization and polyolefin decomposition catalysts. By combining these chemical imaging techniques with, for example, chemical staining methodologies, selective probe molecules as well as particle sorting approaches, representative structure-activity relationships can be derived at the level of single catalyst particles.

Oxidative Conversion of Polyethylene Towards Di-Carboxylic Acids: A Multi-Analytical Approach.

To reduce the pressure on the environment created by the increasing amount of plastic waste, the need to develop suitable plastic recycling methods has become more evident. However, the chemical recycling toolbox for polyethylene (PE), the most abundant type of plastic waste, remains underdeveloped. In this work, analytical methods were developed to explore the possibility to oxidatively convert PE into di-carboxylic acids as reaction products. A multi-analytical approach including gas chromatography-mass spectrometry, gas chromatography-flame ionization detection, several (2D) nuclear magnetic resonance methods as well as in-situ transmission infrared spectroscopy was used. This led to a thorough qualitative and quantitative analysis on the product mixture, which extends and clarifies the existing literature. Without a catalyst (thermally) already up to 7 mol % di-carboxylic acids can be formed. Furthermore, it was found that the majority of the oxidized functionalities are carboxylic acids, (methyl) ketones, γ-lactones, γ-ketones and esters. An intra-molecular hydrogen shift seemed key in the cleavage step and the formation of late-stage side products. In addition, crosslinking reactions due to esterification reactions seem to limit the di-carboxylic acid yield. Therefore, these two handles can be taken into account to study and design similar (catalytic) systems for the oxidative conversion of plastic waste.

Operando time-gated Raman spectroscopy of solid catalysts.

Operando Raman spectroscopy is a powerful analytical tool to provide new insights in the working and deactivation principles of solid catalysts. Intense fluorescence can obscure Raman spectra to the extent that they become uninterpretable. Time-gated Raman spectroscopy, based on pulsed excitation and time-gated detection, suppresses background fluorescence based on its slower time dynamics compared to Raman scattering. In this work, we demonstrate and quantify the benefit of time gating for operando Raman spectroscopy, using the propane dehydrogenation reaction over Pt-Sn-based catalyst materials as a case study. Experimental time-gated Raman spectroscopy data are fitted to a time-trace model that is used to optimize time gating for the maximum signal-to-background-noise ratio. Time-gated Raman spectra of a spent propane dehydrogenation catalyst material show lower background fluorescence compared to the time-integrated Raman spectra counterparts. Simultaneous operando time-gated and time-integrated Raman spectroscopy experiments demonstrate the benefit of time gating to obtain more distinct Raman features, especially in the early coking stages where spectra are dominated by background fluorescence.

Mapping Temperature Heterogeneities during Catalytic CO2 Methanation with Operando Luminescence Thermometry.

Controlling and understanding reaction temperature variations in catalytic processes are crucial for assessing the performance of a catalyst material. Local temperature measurements are challenging, however. Luminescence thermometry is a promising remote-sensing tool, but it is cross-sensitive to the optical properties of a sample and other external parameters. In this work, we measure spatial variations in the local temperature on the micrometer length scale during carbon dioxide (CO2) methanation over a TiO2-supported Ni catalyst and link them to variations in catalytic performance. We extract local temperatures from the temperature-dependent emission of Y2O3:Nd3+ particles, which are mixed with the CO2 methanation catalyst. Scanning, where a near-infrared laser locally excites the emitting Nd3+ ions, produces a temperature map with a micrometer pixel size. We first designed the Y2O3:Nd3+ particles for optimal temperature precision and characterized cross-sensitivity of the measured signal to parameters other than temperature, such as light absorption by the blackened sample due to coke deposition at elevated temperatures. Introducing reaction gases causes a local temperature increase of the catalyst of on average 6-25 K, increasing with the reactor set temperature in the range of 550-640 K. Pixel-to-pixel variations in the temperature increase show a standard deviation of up to 1.5 K, which are attributed to local variations in the catalytic reaction rate. Mapping and understanding such temperature variations are crucial for the optimization of overall catalyst performance on the nano- and macroscopic scale.

Probing nearby molecular vibrations with lanthanide-doped nanocrystals.

The photoluminescence (PL) of lanthanide-doped nanocrystals can be quenched by energy transfer to vibrations of molecules located within a few nanometers from the dopants. Such short-range electronic-to-vibrational energy transfer (EVET) is often undesired as it reduces the photoluminescence efficiency. On the other hand, EVET may be exploited to extract information about molecular vibrations in the local environment of the nanocrystals. Here, we investigate the influence of solvent and gas environments on the PL properties of NaYF4:Er3+,Yb3+ upconversion nanocrystals. We relate changes in the PL spectrum and excited-state lifetimes in different solvents and their deuterated analogues to quenching of specific lanthanide levels by EVET to molecular vibrations. Similar but weaker changes are induced when we expose a film of nanocrystals to a gas environment with different amounts of H2O or D2O vapor. Quenching of green- and red-emitting levels of Er3+ can be explained in terms of EVET-mediated quenching that involves molecular vibrations with energies resonant with the gap between the energy levels of the lanthanide. Quenching of the near-infrared-emitting level is more complex and may involve EVET to combination-vibrations or defect-mediated quenching. EVET-mediated quenching holds promise as a mechanism to probe the local chemical environment-both for nanocrystals dispersed in a liquid and for nanocrystals exposed to gaseous molecules that adsorb onto the nanocrystal surface.

Transport limitations in polyolefin cracking at the single catalyst particle level.

Catalytic cracking is a promising approach to chemically recycle polyolefins by converting them into smaller hydrocarbons like naphtha, and important precursors of various platform chemicals, such as aromatics. Cracking catalysts, commonly used in the modern refinery and petrochemical industry, are tailored to process gaseous or liquid feedstock. Polyolefins, however, are very large macromolecules that form highly viscous melts at the temperatures required to break their backbone C-C bonds. Therefore, mass transport is expected to limit the performance of traditional cracking catalysts when applied to the conversion of polymers. In this work, we study these effects during the cracking of polypropylene (PP) over catalysts utilized in the fluid catalytic cracking (FCC) process. Thermogravimetric experiments using PP of varying molecular weight (Mw) and catalysts of varying accessibility showed that low Mw model polymers can be cracked below 275 °C, while PP of higher Mw required a 150 °C higher temperature. We propose that this difference is linked to different degrees of mass transport limitations and investigated this at length scales ranging from milli- to nanometers, utilizing in situ optical microscopy and electron microscopy to inspect cut open catalyst-polymer composites. We identified the main cause of transport limitations as the significantly higher melt viscosity of high Mw polymers, which prohibits efficient catalyst-polymer contact. Additionally, the high Mw polymer does not enter the inner pore system of the catalyst particles, severely limiting utilization of the active sites located there. Our results demonstrate that utilizing low Mw polymers can lead to a significant overestimation of catalyst activity, and suggest that polyolefins might need to undergo a viscosity reducing pre-treatment in order to be cracked efficiently.

Correction to "Correlating the Morphological Evolution of Individual Catalyst Particles to the Kinetic Behavior of Metallocene-Based Ethylene Polymerization Catalysts".

[This corrects the article DOI: 10.1021/jacsau.1c00324.].

Green Additives in Chitosan-Based Bioplastic Films: Physical, Mechanical, and Chemical Properties.

To switch to alternatives for fossil-fuel-based polymer materials, renewable raw materials from green resources should be utilized. Chitosan is such a material that is a strong, but workable derivative from chitin, obtained from crustaceans. However, various applications ask for specific plastic properties, such as certain flexibility, hardness and transparency. With different additives, also obtainable from green resources, chitosan-based composites in the form of self-supporting films, ranging from very hard and brittle to soft and flexible were successfully produced. The additives turned out to belong to one of three categories, namely linear, non-linear, or crosslinking additives. The non-linear additives could only be taken up to a certain relative amount, whereas the uptake of linear additives was not limited within the range of our experiments. Additives with multiple functional groups tend to crosslink chitosan even at room temperature in an acidic medium. Finally, it was shown that dissolving the chitosan in acetic acid and subsequently drying the matrix as a film results in reacetylation compared to the starting chitosan source, resulting in a harder material. With these findings, it is possible to tune the properties of chitosan-based polymer materials, making a big step towards application of this renewable polymer within consumer goods.

Elucidating the Structure and Composition of Individual Bimetallic Nanoparticles in Supported Catalysts by Atom Probe Tomography.

Understanding and controlling the structure and composition of nanoparticles in supported metal catalysts are crucial to improve chemical processes. For this, atom probe tomography (APT) is a unique tool, as it allows for spatially resolved three-dimensional chemical imaging of materials with sub-nanometer resolution. However, thus far APT has not been applied for mesoporous oxide-supported metal catalyst materials, due to the size and number of pores resulting in sample fracture during experiments. To overcome these issues, we developed a high-pressure resin impregnation strategy and showcased the applicability to high-porous supported Pd-Ni-based catalyst materials, which are active in CO2 hydrogenation. Within the reconstructed volume of 3 × 105 nm3, we identified over 400 Pd-Ni clusters, with compositions ranging from 0 to 16 atom % Pd and a size distribution of 2.6 ± 1.6 nm. These results illustrate that APT is capable of quantitatively assessing the size, composition, and metal distribution for a large number of nanoparticles at the sub-nm scale in industrial catalysts. Furthermore, we showcase that metal segregation occurred predominately between nanoparticles, shedding light on the mechanism of metal segregation. We envision that the presented methodology expands the capabilities of APT to investigate porous functional nanomaterials, including but not limited to solid catalysts.

Spatiotemporal Mapping of Local Heterogeneities during Electrochemical Carbon Dioxide Reduction.

The activity and selectivity of a copper electrocatalyst during the electrochemical CO2 reduction reaction (eCO2RR) are largely dominated by the interplay between local reaction environment, the catalyst surface, and the adsorbed intermediates. In situ characterization studies have revealed many aspects of this intimate relationship between surface reactivity and adsorbed species, but these investigations are often limited by the spatial and temporal resolution of the analytical technique of choice. Here, Raman spectroscopy with both space and time resolution was used to reveal the distribution of adsorbed species and potential reaction intermediates on a copper electrode during eCO2RR. Principal component analysis (PCA) of the in situ Raman spectra revealed that a working electrocatalyst exhibits spatial heterogeneities in adsorbed species, and that the electrode surface can be divided into CO-dominant (mainly located at dendrite structures) and C-C dominant regions (mainly located at the roughened electrode surface). Our spectral evaluation further showed that in the CO-dominant regions, linear CO was observed (as characterized by a band at ∼2090 cm-1), accompanied by the more classical Cu-CO bending and stretching vibrations located at ∼280 and ∼360 cm-1, respectively. In contrast, in the C-C directing region, these three Raman bands are suppressed, while at the same time a band at ∼495 cm-1 and a broad Cu-CO band at ∼2050 cm-1 dominate the Raman spectra. Furthermore, PCA revealed that anodization creates more C-C dominant regions, and labeling experiments confirmed that the 495 cm-1 band originates from the presence of a Cu-C intermediate. These results indicate that a copper electrode at work is very dynamic, thereby clearly displaying spatiotemporal heterogeneities, and that in situ micro-spectroscopic techniques are crucial for understanding the eCO2RR mechanism of working electrocatalyst materials.

How Temperature Affects the Selectivity of the Electrochemical CO2 Reduction on Copper.

Copper is a unique catalyst for the electrochemical CO2 reduction reaction (CO2RR) as it can produce multi-carbon products, such as ethylene and propanol. As practical electrolyzers will likely operate at elevated temperatures, the effect of reaction temperature on the product distribution and activity of CO2RR on copper is important to elucidate. In this study, we have performed electrolysis experiments at different reaction temperatures and potentials. We show that there are two distinct temperature regimes. From 18 up to ∼48 °C, C2+ products are produced with higher Faradaic efficiency, while methane and formic acid selectivity decreases and hydrogen selectivity stays approximately constant. From 48 to 70 °C, it was found that HER dominates and the activity of CO2RR decreases. Moreover, the CO2RR products produced in this higher temperature range are mainly the C1 products, namely, CO and HCOOH. We argue that CO surface coverage, local pH, and kinetics play an important role in the lower-temperature regime, while the second regime appears most likely to be related to structural changes in the copper surface.

Restructuring of titanium oxide overlayers over nickel nanoparticles during catalysis.

Reducible supports can affect the performance of metal catalysts by the formation of suboxide overlayers upon reduction, a process referred to as the strong metal-support interaction (SMSI). A combination of operando electron microscopy and vibrational spectroscopy revealed that thin TiOx overlayers formed on nickel/titanium dioxide catalysts during 400°C reduction were completely removed under carbon dioxide hydrogenation conditions. Conversely, after 600°C reduction, exposure to carbon dioxide hydrogenation reaction conditions led to only partial reexposure of nickel, forming interfacial sites in contact with TiOx and favoring carbon-carbon coupling by providing a carbon species reservoir. Our findings challenge the conventional understanding of SMSIs and call for more-detailed operando investigations of nanocatalysts at the single-particle level to revisit static models of structure-activity relationships.