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Stable catalyst design for the viable activation of methane to syngas, hydrogen, and chemicals

Problem statement

Methane and light alkanes are surplus species and by-products with relatively poor economic interest. Our goal is to activate C–H σ-bond to produce hydrogen, olefins, carbon monoxide, and carbon nanofibers, following different process strategies such as oxidative coupling (for olefins), CO2 dry reforming (for syngas), cracking or catalytic decomposition (for hydrogen-free of COx and sequestrated carbon nanotubes/nanofibers), cracking/co-cracking with CO or methanol. We work on developing, synthesizing, characterizing, and testing innovative catalysts with a twist of reaction engineering concepts, looking at multi-scale implications.

We delve into the mechanistic insights of a series of in-house synthesized metal-supported heterogeneous catalysts by combining them with dynamic reactors and ab initio calculations. We explore catalysts with promoted lifetime, activity, selectivity, and heat exchange.

We investigate novel reactor designs grounded on forced dynamic (operando) fluidized-bed reactors at high pressures to amplify the kinetic information and hydrogen.

Goals

  • Develop a microkinetic-based modeling framework to analyze the catalyst performance
  • Scale the technical catalyst for its application in demanding exothermic (oxidative coupling of methane using SiC and spray drying) or fluidized-bed (catalytic decomposition of methane) conditions
  • Develop new catalytic concepts based on Ni-alloys (Ni-Fe, -Co, -Zn…)
  • Improve the catalyst structure-function correlations using in-situ, operando, and dynamic techniques and reactors
CHA2023

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Related Publications

Robust data curation for improved kinetic modeling in oxidative coupling of methane using high-throughput reactors
Chem. Eng. Sci. Year: 2024 DOI:https://doi.org/10.1016/j.ces.2023.119412
Authors: Lezcano, Gobouri, Realpe, Kulkarni, Velisoju, Castaño
  • MKM
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Overcoming the kinetic and deactivation limitations of Ni catalyst by alloying it with Zn for the dry reforming of methane
J. CO2 Util. Year: 2023 DOI:https://doi.org/10.1016/j.jcou.2023.102573
Authors: Velisoju, Virpurwala, Yerrayya, Bai, Davaasuren, Hassine, Yao, Lezcano, Kulkarni, Castaño
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Multi-technique operando methods and instruments for simultaneous assessment of thermal catalysis structure, performance, dynamics, and kinetics
Chem Catal. Year: 2023 DOI:https://doi.org/10.1016/j.checat.2023.100666
Authors: Velisoju, Kulkarni, Cui, Rabee, Paalanen, Rabeah, Maestri, Brückner, Ruiz-Martinez, Castaño
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Post-Synthetic Surface Modification of Metal–Organic Frameworks and Their Potential Applications
Small Methods Year: 2023 DOI:https://doi.org/10.1002/smtd.202201413
Authors: Figueroa-Quintero, Villalgordo-Hernández, Delgado-Marín, Narciso, Velisoju, Castaño, Gascon, Ramos-Fernandez
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Atypical stability of exsolved Ni-Fe alloy nanoparticles on double layered perovskite for CO2 dry reforming of methane
Appl. Catal. B: Environ. Year: 2023 DOI:https://doi.org/10.1016/j.apcatb.2023.122479
Authors: Yao, Cheng, Yerrayya, Ould-Chikh, Ramirez, Bai, Mohamed, Li, Shterk, Zheng, Gascon, Han, Bakr, Castaño
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Maximizing Active Fe Species in ZSM-5 Zeolite Using Organic-Template-Free Synthesis for Efficient Selective Methane Oxidation
J. Am. Chem. Soc. Year: 2023 DOI:https://doi.org/10.1021/jacs.2c13351
Authors: Cheng, Yao, Zheng, Wang, Emwas, Castaño, Ruiz-Martinez, Han
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Silicon carbide in catalysis: from inert bed filler to catalytic support and multifunctional material
Catal. Rev. Year: 2023 DOI:https://doi.org/10.1080/01614940.2022.2025670
Authors: Kulkarni, Velisoju, Tavares, Dikhtiarenko, Gascon, Castaño
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Effect of the particle blending-shaping method and silicon carbide crystal phase for Mn-Na-W/SiO2-SiC catalyst in oxidative coupling of methane
Mol. Catal. Year: 2022 DOI:https://doi.org/10.1016/j.mcat.2022.112399
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Engineering Thermally Resistant Catalytic Particles for Oxidative Coupling of Methane Using Spray-Drying and Incorporating SiC
Ind. Eng. Chem. Res. Year: 2021
Authors: Lezcano, Velisoju, Kulkarni, Ramirez, Castaño
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Activation of n-pentane while prolonging HZSM-5 catalyst lifetime during its combined reaction with methanol or dimethyl ether
Catal. Today Year: 2022 DOI:https://doi.org/10.1016/j.cattod.2020.09.015
Authors: Cordero-Lanzac, Martinez, Aguayo, Castaño, Bilbao, Corma
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