Proceedings of MATSUS Spring 2025 Conference (MATSUSSpring25)
Publication date: 16th December 2024
Catalyst materials can drive sustainable production of base chemicals by means of catalytic fixation of CO2.[1-6] Aiming for an industrial level, these materials should be available with high purity and in sufficient quantities for the respective application. Application-wise, further prerequisites may be more specific, such as an intense contact between different compounds within the catalyst or different levels of homogeneity. For continuous co-precipitation, rapid mixing of reactants for rapid nucleation is critical to tune such properties or reach the target phase with sufficient subsequent induction (= suspension ageing) periods.[7-9]
In this work, two examples of scaling up catalyst material production are discussed, demonstrating the versatility of this continuous co-precipitation method coupled with batch-wise ageing.[10] Firstly, methanol synthesis catalysts based on Cu, ZnO and ZrO2 (CZZ) are capable of converting higher CO2/CO ratios than typical Cu/Zn/Al catalysts at comparable activity. For CZZ, we could show that temporal and spatial separation of initial nucleation and suspension ageing is necessary to assess suspension ageing kinetics.[11] In turn, this contributes to full control over material properties (e.g. porosity, crystal phase) in the case of methanol synthesis, also showing that tested catalytic performance is inherited by the initial synthesis steps. Furthermore, the mentioned procedure reveals to be highly scalable, which is why a production capacity of up to 1 kg could be reached.[12] The second example is Bi2O2CO3 (BOC), an electrocatalyst known for its high selectivity towards formic acid.[13] The method described above was applied for its production, which was scaled up to 50 g while maintaining the crucial material properties as well as catalytic activity. This step in scale-up already involves the consideration of synthesis, (spray-)coating and catalytic testing as whole process chain, a concept which will be applied in future work.
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The authors ackknowledge the financial support of the "Karlsruhe House of Young Scientists" (KHYS) and the Helmholtz association for funding in the topic "Chemical Energy Carriers - Power-based Fuels and Chemicals".
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