Droplet microreactor for high-throughput fluorescence-based measurements of single catalyst particle acidity.

The particles of heterogeneous catalysts differ greatly in size, morphology, and most importantly, in activity. Studying these catalyst particles in batch typically results in ensemble averages, without any information at the level of individual catalyst particles. To date, the study of individual catalyst particles has been rewarding but is still rather slow and often cumbersome1. Furthermore, these valuable in-depth studies at the single particle level lack statistical relevance. Here, we report the development of a droplet microreactor for high-throughput fluorescence-based measurements of the acidities of individual particles in fluid catalytic cracking (FCC) equilibrium catalysts (ECAT). This method combines systematic screening of single catalyst particles with statistical relevance. An oligomerization reaction of 4-methoxystyrene, catalyzed by the Brønsted acid sites inside the zeolite domains of the ECAT particles, was performed on-chip at 95 °C. The fluorescence signal generated by the reaction products inside the ECAT particles was detected near the outlet of the microreactor. The high-throughput acidity screening platform was capable of detecting ~1000 catalyst particles at a rate of 1 catalyst particle every 2.4 s. The number of detected catalyst particles was representative of the overall catalyst particle population with a confidence level of 95%. The measured fluorescence intensities showed a clear acidity distribution among the catalyst particles, with the majority (96.1%) showing acidity levels belonging to old, deactivated catalyst particles and a minority (3.9%) exhibiting high acidity levels. The latter are potentially of high interest, as they reveal interesting new physicochemical properties indicating why the particles were still highly acidic and reactive.

Structure Sensitivity of CO2 Conversion over Nickel Metal Nanoparticles Explained by Micro-Kinetics Simulations.

Nickel metal nanoparticles are intensively researched for the catalytic conversion of carbon dioxide. They are commercially explored in the so-called power-to-methane application in which renewably resourced H2 reacts with CO2 to produce CH4, which is better known as the Sabatier reaction. Previous work has shown that this reaction is structure-sensitive. For instance, Ni/SiO2 catalysts reveal a maximum performance when nickel metal nanoparticles of ∼2-3 nm are used. Particularly important to a better understanding of the structure sensitivity of the Sabatier reaction over nickel-based catalysts is to understand all relevant elementary reaction steps over various nickel metal facets because this will tell as to which type of nickel facets and which elementary reaction steps are crucial for designing an efficient nickel-based methanation catalyst. In this work, we have determined by density functional theory (DFT) calculations and micro-kinetics modeling (MKM) simulations that the two terrace facets Ni(111) and Ni(100) and the stepped facet Ni(211) barely show any activity in CO2 methanation. The stepped facet Ni(110) turned out to be the most effective in CO2 methanation. Herein, it was found that the dominant kinetic route corresponds to a combination of the carbide and formate reaction pathways. It was found that the dissociation of H2CO* toward CH2* and O* is the most critical elementary reaction step on this Ni(110) facet. The calculated activity of a range of Wulff-constructed nickel metal nanoparticles, accounting for varying ratios of the different facets and undercoordinated atoms exposed, reveals the same trend of activity-versus-nanoparticle size, as was observed in previous experimental work from our research group, thereby providing an explanation for the structure-sensitive nature of the Sabatier reaction.

Single catalyst particle diagnostics in a microreactor for performing multiphase hydrogenation reactions.

Since inter- and intra-particle heterogeneities in catalyst particles are more the rule than the exception, it is advantageous to perform high-throughput screening for the activity of single catalyst particles. A multiphase system (gas/liquid/solid) is developed, where droplet-based microfluidics and optical detection are combined for the analysis of single catalyst particles by safely performing a hydrogenation study on in-house synthesized hollow Pd/SiO2 catalyst microparticles, in a polydimethylsiloxane (PDMS) microreactor. A two-phase segmented flow system of particle-containing droplets is combined with a parallel gas-reactant channel separated from the flow channel by a 50 µm thick gas permeable PDMS wall. In this paper, the developed microreactor system is showcased by monitoring the Pd-catalyzed hydrogenation of methylene blue. A discoloration of blue to brown visualizes the hydrogenation activity happening in a high-throughput fashion on the single Pd/SiO2 spherical catalyst microparticles, which are encapsulated in 50 nL-sized droplets. By measuring the reagent concentration at various spots along the length of the channel the reaction time can be determined, which is proportional to the residence time in the channel. The developed experimental platform opens new possibilities for single catalyst particle diagnostics in a multiphase environment.

Continuous Flow Pickering Emulsion Catalysis in Droplet Microfluidics Studied with In Situ Raman Microscopy.

Pickering emulsions (PEs), emulsions stabilized by solid particles, have shown to be a versatile tool for biphasic catalysis. Here, we report a droplet microfluidic approach for flow PE (FPE) catalysis, further expanding the possibilities for PE catalysis beyond standard batch PE reactions. This microreactor allowed for the inline analysis of the catalytic process with in situ Raman spectroscopy, as demonstrated for the acid-catalyzed deacetalization of benzaldehyde dimethyl acetal to form benzaldehyde. Furthermore, the use of the FPE system showed a nine fold improvement in yield compared to the simple biphasic flow system (FBS), highlighting the advantage of emulsification. Finally, FPE allowed an antagonistic set of reactions, the deacetalization-Knoevenagel condensation, which proved less efficient in FBS due to rapid acid-base quenching. The droplet microfluidic system thus offers a versatile new extension of PE catalysis.

Single Particle Assays to Determine Heterogeneities within Fluid Catalytic Cracking Catalysts.

Invited for the cover of this issue is the group of Bert M. Weckhuysen at Utrecht University. The image depicts an artistic impression of catalyst particles in full color: by combining multiple characterization techniques per single Fluid Catalytic Cracking (FCC) particle, insights are provided into the heterogeneity of an industrially used catalyst. Read the full text of the article at 10.1002/chem.201905880.

Single Particle Assays to Determine Heterogeneities within Fluid Catalytic Cracking Catalysts.

Fluid catalytic cracking (FCC) is an important process in oil refinery industry to produce gasoline and propylene. Due to harsh reaction conditions, FCC catalysts are subject to deactivation through for example, metal accumulation and zeolite framework collapse. Here, we perform a screening of the influence of metal poisons on the acidity and accessibility of an industrial FCC catalyst material using laboratory-based single particle characterization that is, µ-XRF and fluorescence microscopy in combination with probe molecules. These methods have been performed on density-separated FCC catalyst fractions, allowing to determine interparticle heterogeneities in the catalyst under study. It was found that with increasing catalyst density and metal content, the acidity and accessibility of the catalyst particles decreased, while their distribution narrowed with catalyst age. For example, particles containing high Ni level possessed very low acidity and were hardly accessible by a Nile Blue dye. Single catalyst particle mapping identifies minority species like the presence of a phosphated zeolite ZSM-5-containing FCC additive for selective propylene formation, catalyst particles without any zeolite phase and catalyst particles, which act as a trap for SOx .

Luminescence thermometry for in situ temperature measurements in microfluidic devices.

Temperature control for lab-on-a-chip devices has resulted in the broad applicability of microfluidics to, e.g., polymerase chain reaction (PCR), temperature gradient focusing for electrophoresis, and colloidal particle synthesis. However, currently temperature sensors on microfluidic chips either probe temperatures outside the channel (resistance temperature detector, RTD) or are limited in both the temperature range and sensitivity in the case of organic dyes. In this work, we introduce ratiometric bandshape luminescence thermometry in which thermally coupled levels of Er3+ in NaYF4 nanoparticles are used as a promising method for in situ temperature mapping in microfluidic systems. The results, obtained with three types of microfluidic devices, demonstrate that temperature can be monitored inside a microfluidic channel accurately (0.34 °C) up to at least 120 °C with a spot size of ca. 1 mm using simple fiber optics. Higher spatial resolution can be realized by combining luminescence thermometry with confocal microscopy, resulting in a spot size of ca. 9 µm. Further improvement is anticipated to enhance the spatial resolution and allow for 3D temperature profiling.

Magnetophoretic Sorting of Single Catalyst Particles.

A better understanding of the deactivation processes taking place within solid catalysts is vital to design better ones. However, since inter-particle heterogeneities are more a rule than an exception, particle sorting is crucial to analyse single catalyst particles in detail. Microfluidics offers new possibilities to sort catalysts at the single particle level. Herein, we report a first-of-its-kind 3D printed magnetophoretic chip able to sort catalyst particles by their magnetic moment. Fluid catalytic cracking (FCC) particles were separated based on their Fe content. Magnetophoretic sorting shows that large Fe aggregates exist within 20 % of the FCC particles with the highest Fe content. The availability of Brønsted acid sites decreases with increasing Fe content. This work paves the way towards a high-throughput catalyst diagnostics platform to determine why specific catalyst particles perform better than others.

In Situ Luminescence Thermometry To Locally Measure Temperature Gradients during Catalytic Reactions.

Bandshape luminescence thermometry during in situ temperature measurements has been reported by preparing three catalytically relevant systems, which show temperature-dependent luminescence. One of these systems was further investigated as a showcase for application. Microcrystalline NaYF4 doped with Er3+ and Yb3+ was mixed with a commercial zeolite H-ZSM-5 to investigate the Methanol-to-Hydrocarbons (MTH) reaction, while monitoring the reaction products with online gas chromatography. Due to the exothermic nature of the MTH reaction, a front of increased temperature migrating down the fixed reactor bed was visualized, showing the potential for various applications of luminescence thermometry for in situ measurements in catalytic systems.

CaO as drop-in colloidal catalysts for the synthesis of higher polyglycerols.

Glycerol is an attractive renewable building block for the synthesis of polyglycerols, which find application in the cosmetic and pharmaceutical industries. The selective etherification of glycerol to higher oligomers was studied in the presence of CaO colloids and the data are compared with those obtained from NaOH and CaO. The materials were prepared by dispersing CaO, CaCO3 , or Ca(OH)2 onto a carbon nanofiber (CNF) support. Colloidal nanoparticles were subsequently dispensed from the CNF into the reaction mixture to give CaO colloids that have a higher activity than equimolar amounts of bulk CaO and NaOH. Optimization of the reaction conditions allowed us to obtain a product with Gardner color number <2, containing no acrolein and minimal cyclic byproducts. The differences in the CaO colloids originating from CNF and bulk CaO were probed using light scattering and conductivity measurements. The results confirmed that the higher activity of the colloids originating from CaO/CNF was due to their more rapid formation and smaller size compared with colloids from bulk CaO. We thus have developed a practical method for the synthesis of polyglycerols containing low amounts of Ca.