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Reactor and chemical process development for CO2 hydrogenation and FTS

Dr. Ali Shan Malik

Thin film catalysis represents a cutting-edge and emerging frontier in the field of gas-phase catalytic reactions, offering unparalleled opportunities for enhancing reaction efficiency and selectivity to desired end products. By depositing catalytic materials as ultra-thin layers on substrates, precise control over catalyst properties, such as composition, morphology, and active site density could be achieved. This level of control enables the design of highly efficient catalysts tailored for specific applications, such as the production of sustainable fuels and chemicals through Fischer-Tropsch and CO₂ conversion processes. The use of thin films also minimizes material waste and reduces costs, aligning with the principles of green chemistry and sustainability.

The work focuses on creating innovative thin film architectures (with prime focus on 3D hierarchical structures) using a mix of state-of-the-art techniques like photolithography, Reactive ion etching (RIE) atomic layer deposition (ALD), sputtering, and chemical vapor deposition (CVD). These methods allow to engineer nanostructured surfaces with enhanced reactivity, improved mass transfer, increased active site exposure and stability under reaction conditions. Subsequent characterization employs a suite of advanced tools, including X-ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM), and operando spectroscopy, to probe the material's structure-property relationships. 

To fully unlock the potential of thin film catalysts, novel reactor concepts are essential for their performance evaluation under realistic industrial conditions. Traditional reactors often fail to provide the necessary precision and flexibility required to assess the unique characteristics of thin films. Advanced reactors must be capable of operating under well-defined gas flow conditions, ensuring accurate measurement of reaction kinetics and product distributions and accommodate various substrate geometries, ensuring versatility and scalability. In this regard, we are building thin film performance evaluation infrastructure by building reactor set ups suitable for thin films testing.

Such capabilities are crucial for optimizing thin film catalysts and advancing our understanding of their behaviour in complex gas-phase reactions aimed at producing sustainable fuels.
By integrating synthesis, characterization, and reactor testing, we aim to accelerate the development of robust thin film catalysts that drive the transition toward a carbon-neutral energy future. 

Patents

Zaman, S. F., Malik, A. S., Alzahrani, A. A., Daous, M. A., & Petrov, L. A. (2020). U.S. Patent No. 10,710,056. Washington, DC: U.S. Patent and Trademark Office.

Selected Publications

1.     Malik, A. S., Van der Verren, M., Aprile, C., & Debecker, D. P. (2024). Hafnosilicate microspheres as effective catalysts for the conversion of dihydroxyacetone to ethyl lactate. Catalysis Today.

2.     Van der Verren, M., Vykoukal, V., Styskalik, A., Malik, A. S., Aprile, C., & Debecker, D. P. (2022). Airborne Preparation of Small Gold Nanoparticles Dispersed on Mesoporous Silica for the Catalytic Oxidation of Glycerol to Dihydroxyacetone. ACS Applied Nano Materials.

3.     Malik, Ali Shan, et al. "Turning CO₂ to CH₄ and CO over CeO₂ and MCF-17 supported Pt, Ru and Rh nanoclusters–Influence of nanostructure morphology, supporting materials and operating conditions." Fuel 326 (2022): 124994.

4.     Malik, Ali Shan, et al. "Turning CO₂ into di-methyl ether (DME) using Pd based catalysts–Role of Ca in tuning the activity and selectivity." Journal of Industrial and Engineering Chemistry (2021).

5.     Malik, A. S., Zaman, S. F., Al-Zahrani, A. A., Daous, M. A., Driss, H., & Petrov, L. A. (2020). Selective hydrogenation of CO₂ to CH₃OH and in-depth DRIFT analysis for PdZn/ZrO₂ and CaPdZn/ZrO₂ catalysts. Catalysis Today, 357, 573-582