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The first half of this dissertation reports the development of supported Fe FT catalysts including the effects of various, carefully chosen preparation methods on the performance of alumina-supported iron/copper/potassium (FeCuK/Al2O3); it was determined that non-aqueous slurry impregnation and co-impregnation yielded catalysts with activities as high as any reported in the literature. Furthermore, the effects of support properties including pore size, hydroxyl group concentration, and support stabilizer were investigated for FeCuK/Al2O3 catalysts containing 20 or 40% Fe. For the first time, we report the performance of a supported Fe FT catalyst that is not only more active and stable than any supported Fe catalyst previously reported, but also has activity equivalent to that of the most active, unsupported catalysts. More importantly, the catalyst is extremely stable as evidenced by the fact that after 700 h on stream, its activity and productivity are still increasing. These catalyst properties result from the use of a novel γ-alumina support material doped with silica and pretreated at 1100°C. This unique support has a high pore volume, large pore diameter, and unusually high thermal stability. The ability to pretreat this support at 1100°C enables preparation of a material having a low number of acid sites and weak metal oxide-support interactions, all desirable properties for an FT catalyst. The second half of this dissertation investigates the effects of operating conditions including the partial pressures of CO and H2 and temperature on the deactivation by carbon of 25 wt% Co/ 0.25 wt% Pt/Al2O3 catalyst. It also reports the kinetics of the main FT reaction on this catalyst. As temperature increases, the H2 and CO orders for the main reaction (in the absence of deactivation) become more positive and more negative, respectively. A new mechanism was proposed to account for the inhibition effect of CO at high reaction temperatures, which includes H-assisted dissociation of CO to C* and OH*. Further, twelve samples of the CoPt/Al2O3 catalyst were tested over a period of 800 hours and XCO < 24%, each at a different set of CO and H2 partial pressures and temperature (220-250°C). At reaction temperature of 230°C, increasing PCO or PH2 increases the deactivation rate; possibly due to formation of polymeric carbons. The H2 and CO partial pressure orders for the deactivation rate at 230°C were found to be 1.12 and 1.43, respectively using a generalized-power-law-expression (GPLE) with limiting activity of 0.7 and 1st order deactivation. For a H2/CO of 2 (PH2 = 10 bar and PCO = 5 bar) the deactivation rate increases as process temperature increases from 220 to 250°C with an activation energy of 81 kJ/mol. However, at higher CO partial pressure (PCO = 10 bar) the deactivation rate for the Co catalyst of this study decreases with increasing temperature; this can possibly be attributed to the formation of more active cobalt sites at higher temperatures due to surface reconstruction.

<p>Thermal, non-catalytic conversion of light olefins (C2= - C4=) was originally utilized in the production of motor fuels at several U.S. refineries in the 1920-30’s. However, the resulting fuels had relatively low-octane number and required harsh operating conditions (T > 450 oC, P > 50 bar), ultimately leading to its succession by solid acid catalytic processes. Despite the early utilization of the thermal reaction, relatively little is known about the reaction products, kinetics, and initiation pathway under liquid-producing conditions. </p> <p>In this thesis, thermal ethylene conversion was investigated near the industrial operating conditions, i.e, at temperatures between 320 and 500 oC and ethylene pressures from 1.5 to 43.5 bar. Non-oligomer products such as propylene and/or higher odd carbon products were observed at all reaction temperatures, pressures, and reaction extents. Methane and ethane were minor products (< 1 % each), even at ethylene conversions as high as 74 %. The isomer distributions revealed a preference for linear, terminal C4 and C5. The reaction order was found to be 2nd order with a temperature dependent activation energy ranging from 165 to 244 kJ/mol. The importance of diradical species in generating free radicals during a two-phase initiation process was proposed. The reaction chemistry for ethylene, which has only strong, vinyl C-H bonds starkly contrasted propylene, which possesses weaker allylic C-H bonds and showed preference for dimeric C6 products over C2-C8 non-oligomers. </p> <p>Extending this work further, the thermal oligomerization of ethylene was enhanced using high surface area supports such as silica and alumina. Both supports resulted in order of magnitude rate increases compared to the gas phase reaction, however the ethylene conversion rate with alumina was superior to silica by a factor of between 100 and 1,000. Additionally, the alumina evidently confers a catalytic function, resulting in altered product distributions, notably an increase in branched products such as isobutene and isopentenes. The oligomerization chemistry with alumina appears to reflect the involvement of Lewis acid sites rather than traditional Brønsted acid or transition metal catalysis, which operate via carbenium ion and metal-alkyl intermediates, respectively. </p>

Carbon ber composites have become popular in aerospace structures and applications due to their light weight, high strength, and high performance. Recently, scientists have begun investigating hybrid composites that include fibers and particulate fillers, since they allow for advanced tailoring of mechanical properties, such as improved fatigue life. This project investigated a hybrid carbon ber reinforced polymer (HCFRP) that includes carbon fiber and additional alumina nanoparticle fillers, which act as embedded nano stress-sensors. Utilizing the piezospectroscopic e ect, the photo-luminescent spectral signal of the embedded nanoparticles has been monitored as it changes with stress, enabling non-contact stress detection of the material. The HCRFPs stress-sensitive properties have been investigated in-situ using a laser source and a tensile mechanical testing system. Hybrid composites with varying mass contents of alumina nanoparticles have been studied in order to determine the e ect of particle content on the overall stress sensing properties of the material. Additionally, high resolution photo-luminescent maps were conducted of the surfaces of each sample in order to determine the particulate dispersion of samples with varying alumina content. The dispersion maps also served as a method of quantifying particulate sedimentation, and can aid in the improvement of the manufacturing process. The results showed that the emitted photo-luminescent spectrum can indeed be captured from the embedded alumina nanoparticles, and exhibits a systematic trend in photo-luminescent peak shift with respect to stress. The stress maps showed a linear increase in peak shift up to a certain critical stress, and matched closely with the DIC strain results. Therefore, the non-contact stress sensing results shown in this work have strong implications for the future of structural health monitoring and nondestructive evaluation (NDE) of aerospace structures.

Plasma spray processing is a technique that is used extensively in thermal barrier coatings on gas and steam turbine components, biomedical implants and automotive components. Many processing parameters are involved to achieve a coating with certain functionality. The coating could be required to function as thermal barrier, wear resistant, corrosion resistant or a high temperature oxidation resistant coating. Various parameters, such as, nozzle and electrode design, powder feeding system, spray distances, substrate temperature and roughness, plasma gas flow rates and others can greatly alter the coating quality and resulting performance. Feedstock (powder or solution precursor) composition and morphology are some of the important variables, which can affect the high end coating applications. The amount of heat a plasma plume has to offer to the particles being processed as a coating depends primarily on the dissociation of the atoms of gaseous mixtures being used to create the plasma and the residence time required for the particle to stay in the flame. The parameters that are conducive for nanostructured retention could be found out if the residence time of the particles in the flame and the available heat in the plume for various gas combinations could be predicted. If the feedstock is a liquid precursor instead of a powder feedstock, the heat that has to be offered by the plasma could be increased by suitable gas combination to achieve a good quality coating. Very little information is available with regard to the selection of process parameters and processing of nano materials feedstock to develop nanostructured coatings using plasma spray. In this study, it has been demonstrated that nano ceramics or ceramic composites either in the form of coatings or bulk free form near net components could be processed using DC plasma spray. For powder feedstock, analytical heat transfer calculations could predict the particle states for a given set of parameters by way of heat input from the plasma to the particles. The parameter selection is rendered easier by means of such calculations. Alumina nano ceramic particles are processed as a coating. During Spray drying, a process of consolidation of nano alumina particles to spherical agglomerates, parameter optimization for complete removal of moisture has been achieved. The parameters are tested for alumina nanoparticles with a plasma torch for the veracity of calculations. The amount of heat transfer from the surface of the agglomerates to the core has been quantified as a function of velocity of particles. Since preparation of nanostructured feedstock for plasma spray is expensive and cumbersome, alternative solution precursor route for direct pyrolysis of precursor to coating has been studied in case of nanocrystalline rare earth oxides. Thus, it has also been shown by this research that nanostructured coatings could be either from a powder feedstock or a solution precursor feedstock. MoSi2-Si3N4, Ni-Al2O3, W-HfC nano ceramic composite systems have been processed as a bulk free form nanocomposite with 60-70% retained nanostructures. The importance of selection of substrates, roughness and the substrate temperature for development of free form bulk components has been highlighted. The improvement in mechanical and high temperature properties associated with having such nanostructured coatings or bulk nanocomposites are revealed. These nanostructured coatings are known for their low thermal conductivity, high wear resistance and can be potentially used as steam and gas turbines coatings for improved thermal efficiency. In summary, bulk nanocomposite through plasma spray processing is a viable alternative to conventional processes such as sintering, HIP for high fracture toughness and hardness applications.

Ceramics membranes are made in a wide variety of different techniques using a wide variety of different materials. However, many of the common techniques utilize a slurry of ceramic particles, additives, and either organic solvent or water that is shaped into a membrane, left to dry, and then sintered together. Drying is a time consuming process, often requiring several hours for the liquid medium to evaporate. Defect formation caused by development of partial pressures across the drying membrane, including cracks and warpage, also typically occurs during the drying process. To address this, slurries of ceramic particles made with a low viscosity UV-curable resin, which can cure in the span of a few seconds, eliminating the need for drying and any defects associated with drying. Slurries were made with different particle sizes and volume fractions and made into thin membranes using an Autodesk Ember 3D printer. Curing of UV resin and slurries were examined with FTIR. Pyrolytic behavior of resin was examined using isothermal TGA. Cure depth profiles were determined using the modified Beer-Lambert Law and compared against models in literature. Results showed contrasting curing behavior based on volume fraction and particle size due to differences in UV light exposure methods.

Yes / Alumina-cubic boron nitride (cBN) composites were prepared using the spark plasma sintering (SPS) technique. Alpha-alumina powders with particle sizes of ∼15 µm and ∼150 nm were used as the matrix while cBN particles with and without nickel coating were used as reinforcement agents. The amount of both coated and uncoated cBN reinforcements for each type of matrix was varied between 10 to 30 wt%. The powder materials were sintered at a temperature of 1400 °C under a constant uniaxial pressure of 50 MPa. We studied the effect of the size of the starting alumina powder particles, as well as the effect of the nickel coating, on the phase transformation from cBN to hBN (hexagonal boron nitride) and on the thermo-mechanical properties of the composites. In contrast to micro-sized alumina, utilization of nano-sized alumina as the starting powder was observed to have played a pivotal role in preventing the cBN-to-hBN transformation. The composites prepared using nano-sized alumina reinforced with nickel-coated 30 wt% cBN showed the highest relative density of 99% along with the highest Vickers hardness (Hv2) value of 29 GPa. Because the compositions made with micro-sized alumina underwent the phase transformation from cBN to hBN, their relative densification as well as hardness values were relatively low (20.9–22.8 GPa). However, the nickel coating on the cBN reinforcement particles hindered the cBN-to-hBN transformation in the micro-sized alumina matrix, resulting in improved hardness values of up to 24.64 GPa.

The Investigation of Nickel-Based Catalysts for the Oxidative Dehydrogenation of Ethane Justin Lane ParkDepartment of Chemistry & Biochemistry, BYU Doctor of Philosophy Chemistry The advancement of creating ethylene from ethane via oxidative dehydrogenation (ODH) rather than the traditional direct dehydrogenation is right on the cusp of commercialization. The oxidative pathway provides a novel route that reduces the operating temperature of this reaction by 400-500°C. A variety of metals including Mo, V, and Ni that have redox properties suitable for the partial oxidation of small chain alkanes have been investigated. Currently, a MoVNbTe oxide is the most promising catalyst but it suffers from a long and difficult preparation method and the combination of four expensive metals. Nickel based catalysts have also shown great promise but are limited by the reactivity of the oxygen species on the surface of the catalyst. In this manuscript, the details for improving the activity of the nickel and altering the activation mechanism are outlined.Bulk CeNiNb oxide catalysts were shown to almost double the rate of ethylene yields at temperatures as low as 300°C. This is partially related to the improved rate of oxygen adsorption and transfer to the active oxygens on the nickel oxide via the ceria additive. However, with further characterization of these materials, it was shown that there is likely an interaction between the Ce and Nb, forming a Ce-O- Nb linkage that is also selective towards ethylene. This facilitates a higher activity of the catalyst by creating two redox active sites. The improved rates of ethylene formation observed with these catalysts led to the initial development of a commercially viable nickel based catalyst. The support interactions of NiO with a novel silica doped alumina support show higher yields than previously reported studies of NiO on alumina for ODH. These initial metal support interactions show that the addition of the niobium and ceria to this catalyst should give ethylene yields that are satisfactory for the commercialization of this catalyst.

<p> A kinetic and mechanistic study on catalytic decomposition of n- and sec-butyl acetate was carried out. The catalysts were silica-alumina and synthetic zeolites including type A, X, Y and mordenite. The reactions were performed in the temperature region of 140° to 290°C at atmospheric pressure using a fixed-bed flow reactor.</p> <p> The esters decomposed to acetic acid and n-butenes. The isomerization of butenes occurred consecutively. The mechanism of ester decomposition was different from that of pyrolysis. The catalytic activity was effected by acidity, cations and pore size. The Langmuir-Hinshelwood rate equation corresponding to the surface reaction on dual-sites correlated data satisfactorily. Strong adsorption of acetic acid, crystal collapse and the blocking of pores with organic deposit caused aging of catalysts.</p> / Thesis / Doctor of Philosophy (PhD)