Neetika
Madaan
,
N. Raveendran
Shiju
and
Gadi
Rothenberg
*
Van't Hoff Institute for Molecular Sciences, University of Amsterdam, Science Park 904, 1098XH, Amsterdam, The Netherlands. E-mail: g.rothenberg@uva.nl; Web: http://hims.uva.nl/hcsc
First published on 19th August 2015
Practical solutions in catalysis require catalysts that are active and stable. Mixed metal oxides are robust materials, and as such are often used as industrial catalysts. The problem is that predicting their performance a priori is difficult. Following our work on simple descriptors for supported metals based on Slater-type orbitals, we show here that a similar paradigm holds also for metal oxides. Using the oxidative dehydrogenation of butane to 1,3-butadiene as a model reaction, we synthesised and tested 15 bimetallic mixed oxides supported on alumina. We then built a descriptor model for these oxides, and projected the model's results on a set of 1711 mixed oxide catalysts in silico. Based on the model's predictions, six new bimetallic oxides were then synthesised and tested. Experimental validation showed impressive results, with Q2 > 0.9, demonstrating the power of these low-cost predictive models. Importantly, no interaction terms were included in the model, showing that even if we think that bimetallic oxide catalysts are highly complex materials, their performance can be predicted using simplistic models. The implications of these findings to catalyst optimisation practices in academia and industry are discussed.
However, the bulk of the industrial applications in real life require robust and hardy materials, and the most common are metal oxides.6 These are already “burned” and have a high chemical and mechanical resistance, which is a must for large-scale processing. But appearances can be deceiving: the molecular formula of a mixed oxide may look simple, but the actual structure is highly complex. What's more, unlike the uniformity of homogneous complexes,7,8 the catalytic activity of solids often stems from breaks and kinks on the surface, that in turn depend on minute changes in the synthesis and pre-treatment conditions.9 Predicting the performance of such catalysts successfully is thus a mammoth task.
There are two approaches for making such predictions. The first uses high-power computing and intricate algorithms, that combine quantum and classical mechanics. Great advances were made in this field in the past decade,10 and catalyst performance can actually be predicted, but at a high cost.11,12 The second approach is data-driven, based on modelling catalyst performance using a few simple descriptors. Such models may be less intuitive, but they are highly practical.13–15 Ultimately, both approaches are needed for finding new catalysts and optimising existing ones.
Recently, we demonstrated the feasibility and effectiveness of using simplified radial distribution functions (RDFs) as descriptors for supported metal(0) catalysts.16 These models can predict the performance of heterogeneous catalysts under a reducing environment (e.g. for catalytic hydrogenation). Here, we take these descriptor models an important step further, into the realm of oxidation reactions. The interactions of the active site with the support are different for an oxide and a metal.17,18 Oxides bind differently and react differently, so the catalytic performance of a metallic element is usually very different from that of its oxo or peroxo species. Nevertheless, we show here that by tuning the RDF descriptors to the corresponding metal ions, one can predict well the performance of supported catalysts under oxidative conditions. The theoretical principles are first demonstrated using an experimental set of 15 catalysts in the oxidative dehydrogenation of butane to 1,3-butadiene. Subsequently, we generate a large set of 1711 bimetallic oxides in silico, and use descriptor models to project the experimental results onto this dataset. Six promising catalysts from the virtual set are then synthesised and tested, validating the model and demonstrating the power of data-driven predictive modelling in oxidation catalysis.
Catalyst | Compositiona |
---|---|
a In all cases, the loading of each metal is 1 wt%. | |
1 | AgOx:SrOx/Al2O3 |
2 | CrOx:ZrOx/Al2O3 |
3 | PbOx:InOx/Al2O3 |
4 | NbOx:NiOx/Al2O3 |
5 | MgOx:CrOx/Al2O3 |
6 | GaOx:MoOx/Al2O3 |
7 | LaOx:BiOx/Al2O3 |
8 | LiOx:WOx/Al2O3 |
9 | YOx:KOx/Al2O3 |
10 | CuOx:TeOx/Al2O3 |
11 | VOx:MgOx/Al2O3 |
12 | WOx:MnOx/Al2O3 |
13 | CoOx:MnOx/Al2O3 |
14 | VOx:MoOx/Al2O3 |
15 | PtOx:InOx/Al2O3 |
Conditions set | Catalyst amount (mg) | O2:nBu ratio | Reaction T (°C) |
---|---|---|---|
A | 100 | 0.25 | 550 |
B | 100 | 0.25 | 650 |
C | 100 | 1 | 550 |
D | 100 | 1 | 650 |
E | 20 | 0.25 | 550 |
F | 20 | 0.25 | 650 |
G | 20 | 1 | 550 |
H | 20 | 1 | 650 |
The bimetallic mixed oxide catalysts 1–15 were prepared using wet impregnation (for details see the Experimental section). X-ray diffraction and BET surface area analysis of several samples (CoOx:MnOx/Al2O3, MgOx:CrOx/Al2O3, LaOx:BiOx/Al2O3, and VOx:MoOx/Al2O3) confirmed that the crystal structure of the alumina remained unchanged. The BET surface area values of these catalysts were all in the range of 200–240 m2 g−1. This is what we would expect considering the low metal loadings and high surface area of alumina support. The 15 bimetallic oxide catalysts were then tested in the oxidative dehydrogenation of n-butane (eqn (1)). This reaction has an interesting history: it was a popular subject of research following WW II, when synthetic rubber was in short supply. The interest subsided in the 1960s, when large-scale cracking of naphtha provided a steady stream of 1,3-butadiene. It then resumed around 2010, with the advent of shale gas and the political unrest in the Persian Gulf. Following our work on ethane24 and propane25 oxidative dehydrogenation, we were approached by Lanxess Deutchland GmbH, one of the main users of 1,3-butadiene, to collaborate on using predictive modelling methods for finding new butane oxidative dehydrogenation catalysts.
(1) |
Table 3 shows the conversion and butadiene selectivity results for the four reaction conditions A–D. Running the reactions using lower catalyst loadings (conditions E–H) yielded lower conversions, but very similar selectivity results (results shown in Fig. 1 only). The reactions at lower catalyst loadings were run to confirm that the same mechanism is in effect at both regimes. This was confirmed by the similar product selectivity at lower conversions. Fig. 1 shows the conversion and total butenes selectivity results for all 15 catalysts at all eight condition sets. The remaining difference to 100% is due to oxidation to CO and CO2. No deactivation was observed over 24 h on stream, and control experiments on three different catalysts running for 100 h showed also no deactivation.
Conditions | 550 °C | 650 °C | ||||||
---|---|---|---|---|---|---|---|---|
A | B | C | D | |||||
0.25:1:8.75 (nBu:O2:Ar) | 1:1:8 (nBu:O2:Ar) | 0.25:1:8.75 (nBu:O2:Ar) | 1:1:8 (nBu:O2:Ar) | |||||
Catalyst | χ butane (%) | S butadiene (%) | χ butane (%) | S butadiene (%) | χ butane (%) | S butadiene (%) | χ butane (%) | S butadiene (%) |
1 | 4.7 | 3.8 | 18.5 | 1.2 | 16.5 | 2.2 | 40.0 | 2.0 |
2 | 9.0 | 4.0 | 26.5 | 3.3 | 13.7 | 6.0 | 36.2 | 3.7 |
3 | 5.3 | 8.5 | 10.0 | 0.3 | 12.5 | 12.8 | 29.5 | 7.5 |
4 | 8.5 | 8.0 | 14.4 | 5.2 | 15.5 | 13.7 | 37.0 | 6.0 |
5 | 9.0 | 5.3 | 27.0 | 3.2 | 14.2 | 8.2 | 35.5 | 5.5 |
6 | 4.5 | 5.0 | 10.0 | 3.5 | 15.0 | 5.0 | 34.8 | 4.0 |
7 | 14.0 | 6.0 | 36.0 | 4.0 | 17.5 | 5.0 | 40.0 | 2.2 |
8 | 15.2 | 6.0 | 40.0 | 5.0 | 20.6 | 3.5 | 43.5 | 1.6 |
9 | 6.0 | 1.6 | 16.0 | 1.1 | 15.0 | 1.9 | 36.5 | 1.7 |
10 | 7.8 | 11.2 | 22.3 | 6.5 | 11.7 | 8.2 | 30.5 | 6.2 |
11 | 9.5 | 8.0 | 14.5 | 7.0 | 16.5 | 9.3 | 42.0 | 8.3 |
12 | 13.0 | 9.0 | 37.0 | 6.0 | 15.5 | 6.0 | 40.0 | 5.0 |
13 | 10.3 | 6.3 | 26.5 | 4.5 | 15.0 | 6.0 | 40.0 | 4.5 |
14 | 10.5 | 7.0 | 20.0 | 5.4 | 16.5 | 10.2 | 37.4 | 8.0 |
15 | 9.0 | 14.0 | 20.0 | 3.0 | 12.0 | 14.0 | 22.0 | 6.0 |
Fig. 1 Summary plot showing the percentage total selectivity for butenes vs. the percentage conversion of n-butane for catalysts 1–15 under condition sets A–H. |
The second approach is using purely data-driven models. These “black-box” models are based on statistical analysis, often combined with stochastic optimization methods, such as neural networks or genetic algorithms.23,30 Such models are fast, but connecting their results to ‘chemical intuition’ is difficult, and they cannot adapt well to new factors. Here, we opted for a third approach, using so-called ‘grey models’, that combine simple descriptors based on chemical principles with statistical modelling. As we will show, such models are effective in predicting catalyst performance, giving a good cost-to-benefit ratio.
Previously, we showed that descriptors based on radial distribution functions (RDFs) derived from Slater-type orbitals (STOs) are effective for modelling and predicting the performance of hydrogenation catalysts.31,32 These RDF descriptors are robust. Their calculation is straightforward, and their implementation is easy. Here, we will show that the same approach works also in an oxidative environment, but instead of using the parameters for metals, we now apply the analogous parameters for their oxide salts. This is an important generalizing step – the same paradigm that works well for monometallic and bimetallic catalysts applies also to monometallic oxides and mixed metal oxides.
Basically, we reduce the combined STOs of the frontier orbitals of each metal to four parameters: the distance from the nucleus where the probability of finding the electrons is highest, rapex, the value of the RDF at this distance, Rapex, the peak width at half height, FWHH, and the skewness of the peak, Skew (the latter is calculated as the area on one side of the peak divided by the area on the other side, see Fig. 2). However, considering that the (mixed) oxide system is more complex than the pure metallic one, we introduced three additional parameters as descriptors: electronegativity,33 atomic radius34,35 and ionization potential.36
To construct a statistical model that can predict the performance of these mixed oxide catalysts, we first used principal component analysis (PCA) and partial least squares (PLS) regression for distinguishing important parameters from marginal ones. This must be done to avoid over-fitting and ensure that the model will be based on the simplest and most robust parameters (a tutorial on using PCA and PLS in catalysis research is published elsewhere37). Fig. 3 shows a biplot representation based on the PCA analysis. The symbols on the graph show the distribution of the conversion and selectivity for catalysts 1–15 running under reaction conditions A–H. In this graph, the axes are the two first principal components (PCs, also called ‘latent variables’). These two PCs explain 53% of the variance in the data. The arrows indicate the direction and magnitude of the descriptors, the reaction conditions, and the figures of merit. The direction of the arrows gives the relation between the parameters: if two arrows are close together, it means that the two parameters are highly correlated. Similarly, if two arrows are close together yet pointing at opposite directions, it means that the two parameters are inversely correlated. Finally, if two arrows are orthogonal to each other, it means that the two parameters are uncorrelated.
Looking at the biplot in Fig. 3, we see that the conversion of n-butane (χbutane) is very closely grouped with three reaction parameters: catalyst amount, O2:n-butane flow and reaction temperature. Indeed, this is what you would expect. Further, we see that the selectivity of total butene is inverse to χbutane (cf.Fig. 1). Sbutadiene is correlated with the RDF descriptors. It depends directly on the parameters Rapex and Skew, and inversely on rapex and FWHHion. Interestingly, the product selectivity does not depend directly on the reaction conditions. This does not mean that Sbutadiene and Sbutenes are independent of each other. Butenes produced by ODH could be used for making 1,3-butadiene. Fig. 4 shows the loading of each sample on the first two principal components (PC1 and PC2). PC1 is sensitive to the type of catalyst, yet insensitive to any changes in the reaction conditions. This is important, because PC1 explains the largest amount of variance in the data, and the largest change in the production of butadiene comes when you change the catalyst precursor. Conversely, PC2 is much more sensitive to changes in the reaction conditions.
Fig. 4 Bar chart showing the loading coefficients of each sample on the two first principal components. |
First, we created and modeled our training set of 15 bimetallic supported oxide catalysts (catalysts 1–15). We applied a partial least squares (PLS) regression model, using the descriptor values based on the metal ion STOs as input. These differ from the pure metal STOs that we used earlier for modelling hydrogenation catalysts.16 The reason is that the pristine catalysts are metal oxides, and in an oxidative environment, metal(0) species are unlikely. The correlation coefficients (see Fig. 6) using the metal ion STOs were good: R2 = 0.865 for χbutane and R2 = 0.610 for Sbutadiene. These numbers may seem low, but they are actually impressive, especially considering the simplicity of the descriptors, and the fact that no interaction parameters were included for these bimetallic oxides. Control experiments showed that the correlation with metal(0) STO descriptors was much lower, R2 = 0.5748 for χbutane and 0.2321 for Sbutadiene, respectively, confirming the hypothesis that oxide models are more suitable for modelling metal oxides than pure metal models. All of the models were validated using leave-one-out cross-validation.
Fig. 6 Predicted vs. experimental values for χbutane (%, graph a) and Sbutadiene (%, graph b) obtained using the bimetallic oxide catalysts 1–15. |
We then created a large set of virtual bimetallic oxides, comprised of 1711 bimetallic combinations of 59 elements in total (see Fig. 7). Calculating the descriptor values for these 1711 virtual catalysts is very fast (especially as there are no interaction parameters). It takes only seconds using a simple laptop. We then projected the results of the descriptor models for the 1711 virtual catalysts on the set of the 15 real catalysts, and selected six bimetallic supported oxides catalysts. These were then synthesized and tested in the lab. Fig. 8 shows the so-called parity plot of the predicted vs. the experimental results, both for the conversion of butane and the selectivity to 1,3-butadiene. The plot shows that there is a good fit between the model's predictions and the actual experimental data. Note that we selected not only catalysts with an expected high performance (high conversion and selectivity) but also ones for which we had low expectations. This is important, because it shows the wide operational range of the model. There is an understandable bias in published papers towards good results – publishing papers about badly performing catalysts is a tough sell, but if you want to predict the performance of catalysts, your model should cover a wide range. This means testing both good and bad candidates.
Fig. 7 Periodic table showing the 59 metals used for creating the 1711 bimetallic oxide catalyst combinations in silico. |
The good performance of the models in the case of mixed metal oxide raises the question of the importance (or in this case, lack of importance) of the interaction parameter. Basically, if no interaction parameter is included, it means that the model is limited to a linear combination of the effects of oxide A and oxide B. That is, for a catalyst containing two metals, M1 and M2, the figure of merit would be FOM = f(M1Ox) + f(M2Ox), giving some weighted average of the effects of the two oxides. This does not necessarily mean that there is no interaction effect at all. Rather, it may reflect the fact that these catalysts contain relatively little active material, 1 wt% of M1 and 1 wt% of M2. When these are impregnated on the alumina support and calcined, the actual sites where mixing occurs between the oxides are probably few and far between (see Fig. 9, left). In such a case, the weighted average would give (and indeed gives) a good description of the catalytic properties of the surface. Avoiding the interaction term in the model makes sense, because such a second-order term would increase the chances of over-fitting. In the case of a main metal and a promoter metal (see example in Fig. 9, right) there may be more justification for including interaction parameters (e.g. in the dehydrogenation of alkanes catalysed by Pt/Sn).
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