Effect of Phosphine on Coke Formation during Steam Cracking of Propane.

In conventional steam cracking feedstocks, contaminants such as sulfur, phosphine, and heavy metal components, present in trace levels, are believed to affect coke formation on high temperature alloys. To gain an understanding of the role of phosphine coking rates on 25/35, CrNi and Al-containing reactor materials were determined in a plug flow reactor during cracking of a propane feedstock doped with ppb levels of PH3 in the presence of DMDS. The presence of phosphine decreased the asymptotic coking rates by more than 20%, while it had a smaller influence on the catalytic coking rate. The coking rate was more severely reduced for the 25/35 CrNi alloy in comparison to the Al-containing alloy. The ppm levels of phosphine did not affect the olefin yields nor the production of undesired carbon monoxide. The morphology of the coked alloys were studied using an off-line Scanning Electron Microscope with Energy Dispersive X-ray detector (SEM with EDX) images of coked coupons. Two types of coke morphology are observed, i.e., filamentous coke with DMDS as an additive and globular coke in the presence of phosphine. The effect of phosphine on the material has a positive impact on the oxide scale homogeneity of 25/35 CrNi alloy, whereas the Al-containing alloy remained unchanged.

Going Beyond the Carothers, Flory and Stockmayer Equation by Including Cyclization Reactions and Mobility Constraints.

A challenge in the field of polymer network synthesis by a step-growth mechanism is the quantification of the relative importance of inter- vs. intramolecular reactions. Here we use a matrix-based kinetic Monte Carlo (kMC) framework to demonstrate that the variation of the chain length distribution and its averages (e.g., number average chain length xn), are largely affected by intramolecular reactions, as mostly ignored in theoretical studies. We showcase that a conventional approach based on equations derived by Carothers, Flory and Stockmayer, assuming constant reactivities and ignoring intramolecular reactions, is very approximate, and the use of asymptotic limits is biased. Intramolecular reactions stretch the functional group (FG) conversion range and reduce the average chain lengths. In the likely case of restricted mobilities due to diffusional limitations because of a viscosity increase during polymerization, a complex xn profile with possible plateau formation may arise. The joint consideration of stoichiometric and non-stoichiometric conditions allows the validation of hypotheses for both the intrinsic and apparent reactivities of inter- and intramolecular reactions. The kMC framework is also utilized for reverse engineering purposes, aiming at the identification of advanced (pseudo-)analytical equations, dimensionless numbers and mechanistic insights. We highlight that assuming average molecules by equally distributing A and B FGs is unsuited, and the number of AB intramolecular combinations is affected by the number of monomer units in the molecules, specifically at high FG conversions. In the absence of mobility constraints, dimensionless numbers can be considered to map the time variation of the fraction of intramolecular reactions, but still, a complex solution results, making a kMC approach overall most elegant.

Computational prediction of the molecular configuration of three-dimensional network polymers.

The three-dimensional arrangement of natural and synthetic network materials determines their application range. Control over the real-time incorporation of each building block and functional group is desired to regulate the macroscopic properties of the material from the molecular level onwards. Here we report an approach combining kinetic Monte Carlo and molecular dynamics simulations that chemically and physically predicts the interactions between building blocks in time and in space for the entire formation process of three-dimensional networks. This framework takes into account variations in inter- and intramolecular chemical reactivity, diffusivity, segmental compositions, branch/network point locations and defects. From the kinetic and three-dimensional structural information gathered, we construct structure-property relationships based on molecular descriptors such as pore size or dangling chain distribution and differentiate ideal from non-ideal structural elements. We validate such relationships by synthesizing organosilica, epoxy-amine and Diels-Alder networks with tailored properties and functions, further demonstrating the broad applicability of the platform.

Alumina-based Coating for Coke Reduction in Steam Crackers.

Alumina-based coatings have been claimed as being an advantageous modification in industrial ethylene furnaces. In this work, on-line experimentally measured coking rates of a commercial coating (CoatAlloy™) have pointed out its superiority compared to an uncoated reference material in an electrobalance set-up. Additionally, the effects of presulfiding with 500 ppmw DMDS per H2O, continuous addition of 41 ppmw S per HC of DMDS, and a combination thereof were evaluated during ethane steam cracking under industrially relevant conditions (Tgasphase = 1173 K, Ptot = 0.1 MPa, XC2H6 = 70%, dilution δ = 0.33 kgH2O/kgHC). The examined samples were further evaluated using online thermogravimetry, scanning electron microscopy and energy diffractive X-ray for surface and cross-section analysis together with X-ray photoelectron spectroscopy and wavelength-dispersive X-ray spectroscopy for surface analysis. The passivating coating illustrated a better performance than the reference Ni-Cr Fe-base alloy after application of an improved pretreatment, followed by piddling changes on the product distribution. Presulfiding of the coating affected negatively the observed coking rates in comparison with the reference alloy, so alternative presulfiding and sulfur addition strategies are recommended when using this barrier coating.

Evaluation of a Ti-Base Alloy as Steam Cracking Reactor Material.

Low-coking reactor material technologies are key for improving the performance and sustainability of steam crackers. In an attempt to appraise the coking performance of an alternative Ti-base alloy during ethane steam cracking, an experimental study was performed in a jet stirred reactor under industrially relevant conditions using thermogravimetry (Tgasphase = 1173 K, Ptot = 0.1 MPa, XC2H6 = 70%, and dilution δ = 0.33 kgH2O/kgHC). Initially, a typical pretreatment used for Fe-Ni-Cr alloys was utilized and compared with a pretreatment at increased temperature, aiming at better surface oxidation and thus suppressing coke formation. The results revealed a decrease in coking rates upon high temperature pretreatment of the Ti-base alloy, however, its coking performance was significantly worse compared to the typically used Fe-Ni-Cr alloys, and carbon oxides formation increased by a factor of 30 or more. Moreover, the analyzed coupons showed crack propagation after coking/decoking and cooling down to ambient temperature. Scanning electron microscopy combined with energy-dispersive X-ray spectroscopy indicated that the prompt and unsystematic oxidation of the surface and bulk caused observable crack initiation and propagation due to alloy brittleness. Hence, the tested Ti-base alloy cannot be considered an industrially noteworthy steam cracking reactor alloy.

Visualization and design of the functional group distribution during statistical copolymerization.

Even though functional copolymers with a low percentage of functional comonomer units (up to 20 mol%) are widely used, for instance for the development of polymer therapeutics and hydrogels, insights in the functional group distribution over the actual chains are lacking and the average composition is conventionally used to describe the functionalization degree. Here we report the visualization of the monomer distribution over the different polymer chains by a synergetic combination of experimental and theoretical analysis aiming at the construction of functionality-chain length distributions (FUNC-CLDs). A successful design of the chemical structure of the comonomer pair, the initial functional comonomer amount (13 mol%), and the temperature (100 °C) is performed to tune the FUNC-CLD of copoly(2-oxazoline)s toward high functionalization degree for both low (100) and high (400) target degrees of polymerization. The proposed research strategy is generic and extendable to a broad range of copolymerization chemistries, including reversible deactivation radical polymerization.

Modeling of Miniemulsion Polymerization of Styrene with Macro-RAFT Agents to Theoretically Compare Slow Fragmentation, Ideal Exchange and Cross-Termination Cases.

A 5-dimensional Smith-Ewart based model is developed to understand differences for reversible addition-fragmentation chain transfer (RAFT) miniemulsion polymerization with theoretical agents mimicking cases of slow fragmentation, cross-termination, and ideal exchange while accounting for chain length and monomer conversion dependencies due to diffusional limitations. The focus is on styrene as a monomer, a water soluble initiator, and a macro-RAFT agent to avoid exit/entry of the RAFT leaving group radical. It is shown that with a too low RAFT fragmentation rate coefficient it is generally not afforded to consider zero-one kinetics (for the related intermediate radical type) and that with significant RAFT cross-termination the dead polymer product is dominantly originating from the RAFT intermediate radical. To allow the identification of the nature of the RAFT retardation it is recommended to experimentally investigate in the future the impact of the average particle size (dp) on both the monomer conversion profile and the average polymer properties for a sufficiently broad dp range, ideally including the bulk limit. With decreasing particle size both a slow RAFT fragmentation and a fast RAFT cross-termination result in a stronger segregation and thus rate acceleration. The particle size dependency is different, allowing further differentiation based on the variation of the dispersity and end-group functionality. Significant RAFT cross-termination is specifically associated with a strong dispersity increase at higher average particle sizes. Only with an ideal exchange it is afforded in the modeling to avoid the explicit calculation of the RAFT intermediate concentration evolution.

Effect of Long-Term High Temperature Oxidation on the Coking Behavior of Ni-Cr Superalloys.

The service time of an industrial cracker is strongly dependent on the long-term coking behavior and microstructure stability of the reactor coil alloy. Super alloys are known to withstand temperatures up to even 1400 K. In this work, several commercially available alloys have been first exposed to a long term oxidation at 1423 K for 500 h, so-called metallurgic aging. Subsequently, their coking behavior was evaluated in situ in a thermogravimetric setup under ethane steam cracking conditions (Tgasphase = 1173 K, Ptot = 0.1 MPa, XC2H6 = 70%, continuous addition of 41 ppmw S/HC of DMDS, dilution δ = 0.33 kgH2O/kgHC) and compared with their unaged coking behavior. The tested samples were also examined using scanning electron microscopy and energy diffractive X-ray for surface and cross-section analysis. The alloys characterized by increased Cr-Ni content or the addition of Al showed improved stability against bulk oxidation and anti-coking behavior after application of metallurgic aging due to the formation of more stable oxides on the top surface.

Ab initio derived group additivity model for intramolecular hydrogen abstraction reactions.

A set of group additivity values for intramolecular hydrogen abstraction reactions of alkanes, alkenes and alkynes is reported. Calculating 448 reaction rate coefficients at the CBS-QB3 level of theory for 1-2 up to 1-7 hydrogen shift reactions allowed the estimation of ΔGAV° values for 270 groups. The influence of substituents on (1) the attacking radical, (2) the attacked carbon atom, and (3) the carbon chain between the attacking and attacked reactive atom has been systematically studied. Substituents have been varied between hydrogen atoms and sp3, sp2 and sp hybridized carbon atoms. It has been assumed that substituents further away from the reactive atoms or their connecting carbon chain have negligible influences on the kinetics. This group additivity model is applicable to a wide variety of reactions in the 300-1800 K temperature range. Correlations for tunneling coefficients have been generated which are complementary to the ΔGAV°'s to obtain accurate rate coefficients without the need for imaginary frequencies or electronic energies of activation. These correlations depend on the temperature and activation energy of the exothermic step. The group additivity model has been successfully applied to a test set of reactions also calculated at the CBS-QB3 level of theory. A mean absolute deviation of 1.18 to 1.71 has been achieved showing a good overall accuracy of the model.

Ab-Initio-Based Kinetic Modeling to Understand RAFT Exchange: The Case of 2-Cyano-2-Propyl Dodecyl Trithiocarbonate and Styrene.

Ab-initio-calculated rate coefficients for addition and fragmentation in reversible-addition fragmentation chain transfer (RAFT) polymerization of styrene with 2-cyano-2-propyl dodecyl trithiocarbonate initiated by azobisisobutyronitrile allow the reliable simulation of the experimentally observed conversion, number average chain length, and dispersity. The rate coefficient for addition of a macroradical Ri to the macroRAFT agent Ri X at 333 K (6.8 104 L mol-1 s-1 ) is significantly lower than to the initial RAFT agent R0 X (3.2 106 L mol-1 s-1 ), mainly due to a difference in activation energy (15.4 vs 3.0 kJ mol-1 ), which causes the dispersity to spike in the beginning of the polymerization.

Quantitative First-Principles Kinetic Modeling of the Aza-Michael Addition to Acrylates in Polar Aprotic Solvents.

This work presents a detailed computational study and kinetic analysis of the aza-Michael addition of primary and secondary amines to acrylates in an aprotic solvent. Accurate rate coefficients for all elementary steps in the various competing mechanisms are calculated using an ONIOM-based approach in which the full system is calculated with M06-2X/6-311+G(d,p) and the core system with CBS-QB3 corrected for solvation using COSMO-RS. Diffusional contributions are taken into account using the coupled encounter pair model with diffusion coefficients calculated based on molecular dynamics simulations. The calculated thermodynamic and kinetic parameters for all forward and reverse elementary reactions are fed to a microkinetic model giving excellent agreement with experimental data obtained using GC analysis. Rate analysis reveals that for primary and secondary amines, the aza-Michael addition to ethyl acrylate occurs preferentially according to a 1,2-addition mechanism, consisting of the pseudoequilibrated formation of a zwitterion followed by a rate controlling amine assisted proton transfer toward the singly substituted product. The alternative 1,4-addition becomes competitive if substituents are present on the amine or double bond of the acrylate. Primary amines react faster than secondary amines due to increased solvation of the zwitterionic intermediate and less sterically hindered proton transfer.

Computational Investigation of the Aminolysis of RAFT Macromolecules.

This work presents a detailed computational study and kinetic analysis of the aminolysis of dithioates, dithiobenzoates, trithiocarbonates, xanthates, and thiocarbamates, which are frequently used as chain-transfer agents for reversible addition-fragmentation chain-transfer (RAFT) polymerization. Rate coefficients were obtained from ab initio calculations, taking into account a diffusional contribution according to the encounter pair model. A kinetic model was constructed and reveals a reaction mechanism of four elementary steps: (i) formation of a zwitterionic intermediate, (ii) formation of a complex intermediate in which an assisting amine molecule takes over the proton from the zwitterionic intermediate, (iii) breakdown of the complex into a neutral tetrahedral intermediate with release of the assisting amine molecule, and (iv) amine-assisted breakdown of the neutral intermediate to the products. Furthermore, a comparative analysis indicates that the alkanedithioates and dithiobenzoates react the fastest, followed, respectively, by xanthates and trithiocarbonates, which react almost equally fast, and dithiocarbamates, which are not reactive at typical experimentally used conditions.

Insights into the Reaction Mechanism of Ethanol Conversion into Hydrocarbons on H-ZSM-5.

Ethanol dehydration to ethene is mechanistically decoupled from the production of higher hydrocarbons due to complete surface coverage by adsorbed ethanol and diethyl ether (DEE). The production of C3+ hydrocarbons was found to be unaffected by water present in the reaction mixture. Three routes for the production of C3+ hydrocarbons are identified: the dimerization of ethene to butene and two routes involving two different types of surface species categorized as aliphatic and aromatic. Evidence for the different types of species involved in the production of higher hydrocarbons is obtained via isotopic labeling, continuous flow and transient experiments complemented by UV/Vis characterization of the catalyst and ab initio microkinetic modeling.

Improved Livingness and Control over Branching in RAFT Polymerization of Acrylates: Could Microflow Synthesis Make the Difference?

The superior capabilities of structured microreactors over batch reactors are demonstrated for reversible addition-fragmentation chain transfer (RAFT) solution polymerization of n-butyl acrylate with the aid of simulations, explicitly accounting for the chain length distribution of all macrospecies types. Since perfect isothermicity can be established in a microreactor, less side products due to backbiting and ß-scission are formed compared to the batch operation in which ineffective heat removal leads to an undesirable temperature spike. For a given RAFT chain transfer agent (CTA), additional microstructural control results under microflow conditions by optimizing the reaction temperature, lowering the dilution degree, or decreasing the initial molar ratio of monomer to RAFT CTA.

Computational Study and Kinetic Analysis of the Aminolysis of Thiolactones.

The aminolysis of three differently α-substituted γ-thiolactones (C4H5OSX, X = H, NH2, and NH(CO)CH3) is modeled based on CBS-QB3 calculated free energies corrected for solvation using COSMO-RS. For the first time, quantitative kinetic and thermodynamic data are provided for the concerted path and the stepwise path over a neutral tetrahedral intermediate. These paths can take place via an unassisted, an amine-assisted, or a thiol-assisted mechanism. Amine assistance lowers the free energy barriers along both paths, while thiol assistance only lowers the formation of the neutral tetrahedral intermediate. Based on the ab initio calculated rate coefficients, a kinetic model is constructed that is able to reliably describe experimental observations for the aminolysis of N-acetyl-dl-homocysteine thiolactone with n-butylamine in THF and CHCl3. Reaction path analysis shows that for all conditions relevant for applications in polymer synthesis and postpolymer modification, an assisted stepwise mechanism is operative in which the formation of the neutral tetrahedral intermediate is rate-determining and which is mainly amine-assisted at low conversions and thiol-assisted at high conversions.

Group Additive Kinetics for Hydrogen Transfer Between Oxygenates.

Hydrogen abstraction reactions involving oxygenates in gaseous phase play an important role in many biomass-related conversion processes. In this work, group additivity is used to provide Arrhenius parameters in a temperature range of 300-2500 K for hydrogen abstractions between oxygenate compounds such as alcohols, ethers, esters, acids, ketones, diketones, aldehydes, hydroxyperoxides, alkyl peroxides, and unsaturated ethers and ketones. The group additive values for Arrhenius parameters of hydrogen transfer reactions of the type O--H--C and O--H--O are derived from CBS-QB3 calculations in the high-pressure limit. From a total set of 118 reactions, 43 group additivity values are determined. Inclusion of an additional 37 corrections accounting for cross-resonance effects in the transition state further improves the accuracy of the model. For a set of 25 ab initio calculated and 60 experimental rate coefficients, group additive modeling reproduces rate coefficients within a mean factor of deviation of ∼3. Hence, the developed group additive models can be reliably used for an accurate and fast prediction of the kinetics of hydrogen abstractions involving oxygenates.

Symmetry calculation for molecules and transition states.

The symmetry of molecules and transition states of elementary reactions is an essential property with important implications for computational chemistry. The automated identification of symmetry by computers is a very useful tool for many applications, but often relies on the availability of three-dimensional coordinates of the atoms in the molecule and hence becomes less useful when these coordinates are a priori unavailable. This article presents a new algorithm that identifies symmetry of molecules and transition states based on an augmented graph representation of the corresponding structures, in which both topology and the presence of stereocenters are accounted for. The automorphism group order of the graph associated with the molecule or transition state is used as a starting point. A novel concept of label-stereoisomers, that is, stereoisomers that arise after labeling homomorph substituents in the original molecule so that they become distinguishable, is introduced and used to obtain the symmetry number. The algorithm is characterized by its generic nature and avoids the use of heuristic rules that would limit the applicability. The calculated symmetry numbers are in agreement with expected values for a large and diverse set of structures, ranging from asymmetric, small molecules such as fluorochlorobromomethane to highly symmetric structures found in drug discovery assays. The new algorithm opens up new possibilities for the fast screening of the degree of symmetry of large sets of molecules.

Thermodynamic study of benzene and hydrogen coadsorption on Pd(111).

Periodic density functional theory (DFT) has been used to study the coadsorption of hydrogen and benzene on Pd(111). The most stable coverages are predicted by constructing the thermodynamic phase diagram as a function of gas-phase temperature and pressure. The common approximation that neglects vibrational contributions to the surface Gibbs free energy, using the PW91 functional, is compared to the one that includes vibrational contributions. Higher coverages are predicted to be thermodynamically the most stable including vibrational frequencies, mainly due to the different entropy contributions. The first approach is also compared to the one using a (optPBE-vdW) vdW-DF functional without vibrational contributions, which predicts higher benzene coverages for benzene adsorption, and lower hydrogen coverages for hydrogen adsorption and coadsorption with a fixed benzene coverage. Inclusion of vibrational contributions using the vdW-DF method has not been implemented due to computational constraints. However, an estimate of the expected result is proposed by adding PW91 vibrational contributions to the optPBE-vdW electronic energies, and under typical hydrogenation conditions high coverages of about θH = 0.89 are expected. Inclusion of vibrational contributions to the surface Gibbs free energy and a proper description of van der Waals interaction are recommended to predict the thermodynamically most stable surface coverage.

Kinetic modeling of α-hydrogen abstractions from unsaturated and saturated oxygenate compounds by hydrogen atoms.

Hydrogen-abstraction reactions play a significant role in thermal biomass conversion processes, as well as regular gasification, pyrolysis, or combustion. In this work, a group additivity model is constructed that allows prediction of reaction rates and Arrhenius parameters of hydrogen abstractions by hydrogen atoms from alcohols, ethers, esters, peroxides, ketones, aldehydes, acids, and diketones in a broad temperature range (300-2000 K). A training set of 60 reactions was developed with rate coefficients and Arrhenius parameters calculated by the CBS-QB3 method in the high-pressure limit with tunneling corrections using Eckart tunneling coefficients. From this set of reactions, 15 group additive values were derived for the forward and the reverse reaction, 4 referring to primary and 11 to secondary contributions. The accuracy of the model is validated upon an ab initio and an experimental validation set of 19 and 21 reaction rates, respectively, showing that reaction rates can be predicted with a mean factor of deviation of 2 for the ab initio and 3 for the experimental values. Hence, this work illustrates that the developed group additive model can be reliably applied for the accurate prediction of kinetics of α-hydrogen abstractions by hydrogen atoms from a broad range of oxygenates.

Experimental and theoretical methods in kinetic studies of heterogeneously catalyzed reactions.

This review aims to illustrate the potential of kinetic analysis in general and microkinetic modeling in particular for rational catalyst design. Both ab initio calculations and experiments providing intrinsic kinetic data allow us to assess the effects of catalytic properties and reaction conditions on the activity and selectivity of the targeted reactions. Three complementary approaches for kinetic analysis of complex reaction networks are illustrated, using select examples of acid zeolite-catalyzed reactions from the authors' recent work. Challenges for future research aimed at defining targets for synthesis strategies that enable us to tune zeolite properties are identified.