Performance enhancement by unsteady-state reactor operation: Theoretical analysis for two-sites kinetic model

Theor. anal. of the reactor performance under unsteady-state conditions was carried out. The reactions are described by two kinetic models, which involve the participation in catalytic reaction of two types of active sites. The kinetic model I assumes the blocking of one of the active sites by a reactant, and the kinetic model II suggests a transformation of active sites of one type into another under the effect of the reaction temp. The unsteady-state conditions on the catalyst surface are supposed to be created (i) by forced oscillations of temp. and concn. in the reactor inlet (periodic operation of reactor) and (ii) by catalyst circulation between two reactors in a dual-reactor system (spatial regulation). The effect of various parameters like concn. of reactant, cycle split, length of period of forced oscillations, temps. and the ratio of catalyst vols. in the dual-reactor was investigated with respect to the yield of the desired product. It is shown that for both cases of unsteady-state conditions (periodic reactor operation as well as in a dual-reactor system), a mean reaction rate predicted by the kinetic model I was up to two times higher than the steady-state value. The kinetic model II shows a 20% increase of the selectivity towards the desired product. [on SciFinder (R)]

Fast temperature cycling of the catalytic CO oxidation using microstructure reactors

Martin Luther

The possibility to increase the performance (productivity or selectivity) of a chemical reactor by using periodic variations of reaction parameters (e.g. reactant concentration or temperature) has been theoretically envisaged since the beginning of the 70th. The experimental validation of the predicted positive effects was successful in the case of concentration variation but failed for temperature variation. This was mainly due to the high thermal inertia of the conventional chemical reactors used for the measurements which prevented to create variations having a sufficiently high frequency. Microstructure reactors own, at the contrary to conventional reactors, a very low thermal inertia and allow to generate temperature oscillations with an amplitude of about ten to hundred Kelvin at a frequency in the order of magnitude of 10-1 to 4 Hz. These properties, coupled with the possibility to introduce a catalytic active material within the devices, seem to make them well suited for the study of the effects of fast periodic temperature variations of a catalytic reaction. The objective of this work was to demonstrate that non-stationary temperature conditions may increase the reaction rate of a heterogeneously catalyzed reaction up to values not predicted by the classical Arrhenius dependency towards the temperature. Two different types of microstructure reactors have been used. The reaction was taking place in the first one (FTC-type 2) in microstructured channels on whose walls a catalytic layer was deposed. In the second one (FTC-type 3), the reaction was taking place on a piece of sintered metal fibres (SMF) plate placed in a reaction chamber. The catalytic active material was deposed on the SMF plate filaments. Both devices where permanently heated by electrical resistors and periodically cooled down with water flowing through cooling channels incorporated in the devices. The test reaction chosen for the experimental measurements was the CO oxidation reaction, heterogeneously catalyzed by platinum supported on alumina (Pt/Al2O3). The reaction behaviour under stationary thermal conditions was consistent with the one predicted by the Arrhenius law. The dependency of the reaction rate with the temperature was exponential with an apparent activation energy of 104 kJ·mol-1, a negative partial reaction order for CO and a positive one for O2. The measurements effectuated under quasi-stationary thermal conditions (slow temperature ramps) have shown that a temperature change rate between 7 and 14 K·min-1 was not sufficient to observe any non-trivial effect of the temperature. The reaction behaviour was always predicted by the Arrhenius law. The surface coverage of the reactive species is, in this case, always able to follow the slow temperature changes and the reaction behaves as being always under steady-state conditions. The experiments realized under non-stationary thermal conditions using the FTC-type 2 reactor have also failed to demonstrate any non-trivial effects of the temperature oscillations. This device allows indeed to generate temperature oscillations with an amplitude of up to 120 K with a frequency of 0.1 Hz but unfortunately correlated with a very high thermal inhomogeneity. A temperature difference of up to 80 K was measured between a cold spot and a hot spot inside the device. Due to their very low local reaction rate the colder areas of the reactor have attenuated the product concentration (CO2) oscillations which should have been created by the temperature variations. This attenuation prevented the temperature oscillations to have any positive effect compared to the stationary thermal conditions. The FTC-type 3 reactor allowed temperature changes of lower amplitude but the thermal homogeneity was much better. The maximal temperature difference measured between two points within the reactor was only 15 K. Under temperature oscillation conditions, the measured instantaneous CO2 concentration was higher for any temperature within the oscillation range compared to the one recorded under stationary thermal conditions. The increase obtained in the mean CO2 concentration was ranging from 34% for a frequency of the oscillations of 0.035 Hz to 85% for a frequency of 0.052 Hz. The amplitude of the oscillations was kept constant at approximately 40 K and the mean temperature value at 437 K. The simulations effectuated using a theoretical model for the catalytic CO oxidation including a feed-back step in the form of the oxidation-reduction of the catalyst have shown that the experimentally observed increase may be qualitatively explained. Above a certain frequency, the temperature oscillations are fast enough compared to the characteristic time of the feedback step and are able to perturb the stationary established reactive species surface coverage. The formation of a transient surface coverage more favourable for the reaction than the surface coverage at high temperature allows during the transient period to reach an instantaneous surface reaction rate values higher than the one at high temperature. This reaction rate peak is then responsible for the increase of the mean reaction rate under non-stationary thermal conditions and, thus, for an increased yield.

EPFL2008

Compact reactor for continuous multi-phase reactions

Martin Grasemann

The objective of this thesis is the development of a compact reactor for continuous three-phase reactions in single-pass configurations. The design is based on a bubble column reactor staged with layers of catalytic material. To make the reactor suitable for reactions with high adiabatic temperature rise such as highly exothermic hydrogenation reactions under solvent free conditions, work focuses on two different aspects of integrated reactor and catalyst design: Preparation and characterization of structured catalyst stages optimized for high intrinsic activity as well as for intense gas-liquid redistribution and mass transfer on each reactor stage Development of heat transfer equipment integrated in the staged bubble column for efficient, quasi continuous in-line removal of process heat. Chapter 3 is dedicated to the preparation and characterization of a structured catalyst for the use in a staged bubble column reactor. Sintered Metal Filters (SMF), a material consisting of metal fibers with a diameter of ~ 20 µm forming thin and highly porous sheets is chosen as support material. The fibers are coated with a 5wt% layer of ZnO grains, leaving the open structure of the SMF material intact. Monodispersed Pd nanoparticles as active phase are deposited on the ZnO surface layer with a total metal loading of 0.2wt%. The resulting Pd/ZnO/SMF catalyst shows high activity in the model hydrogenation reaction of 2-methyl-3-butyn-2-ol (MBY) to 2-methyl-3-butene-2-ol (MBE). Semi-batch autoclave hydrogenations show rates of up to 30 mol/molPds with target product (MBE) yields of up to 96.5%. Activity and selectivity of the Pd/ZnO/SMF catalyst are strongly influenced by Strong Metal Support Interaction (SMSI) between the ZnO support and the deposited Pd nanoparticles. XPS and XRD analysis show the formation of a PdZn alloy already under ambient conditions, decreasing the catalyst activity but, on the other hand, preventing strong catalyst deactivation. The formation of this alloy phase was observed under ambient conditions as well as low temperature reaction conditions, but can also be achieved by high temperature treatment of the catalyst in hydrogen atmosphere. The intrinsic kinetics of the MBY hydrogenation was studied in semi-batch experiments. First order towards hydrogen was found and a Langmuir-Hinshelwood kinetic model was developed, describing the experimental data reasonably well. Chapter 4 describes a compact heat exchange (HEX) element integrated in the SBCR. The cross flow heat exchanger design is based on vertical micro-slits of 0.3mm width, a breadth between 12mm and 40mm and 6mm length as reaction side channel geometry, ensuring a minimum of added reaction volume and small heat transfer distances. The single and two-phase heat transfer performance of the HEX element is studied considering the influence of gas and liquid superficial velocities as well as liquid properties. With one SMF layer placed at the HEX element entrance redispersing gas and liquid phase, heat transfer performance was observed to increase linearly with gas and liquid throughput. The maximum heat transfer performance per reaction volume was determined as ~ 0.5 MW/m3K, obtained for moderate gas and liquid superficial velocities. The hydrodynamics of a bubble column staged only with ZnO/SMF sheets show an narrow residence time distribution (RTD) and negligible backmixing through the catalyst layers. The RTD can be described accurately by a "tanks-in-series" model. The gas-liquid pressure drop through the SMF material is mainly governed by capillary effects and the gas velocity. A semi-empirical model is developed, combining both friction and surface tension effects and predicting the pressure drop through the SMF material with an accuracy of ±10%. In Chapter 5, the novel SBCR based on Pd/ZnO/SMF catalytic stages and the integrated micro-HEX elements are tested in the hydrogenation model reaction of MBY to MBE. The reaction in a loop setup comprising 5 HEX/catalyst stages is shown to be strongly influenced by external mass transfer, resulting in an observed catalyst effectiveness below 65%. Intense gas-liquid mass transfer in the SMF structure leads to high volumetric mass transfer coefficient in the staged bubble column of 1s-1 - 4s-1 and an observed reactor productivity of up to ~ 12000 kg/m3h. This signifies an increase of around two orders of magnitude compared to standard industrial semi-batch equipment. High catalyst densities in the reactor lead to high reactor productivity, but have a detrimental effect on product selectivity. The drop in product yield amounts up to 6% for high catalyst density, but can be decreased to only 0.5% if a 5mm distance ring is inserted between HEX stages to decrease the catalyst loading in the reactor.

EPFL2009

Nitrous Oxide Abatement over Fe-Zeolite

Bryan Bromley

The use of zeolites for catalytic reactions is a field in continuous development. Since it was demonstrated that metal-zeolites are efficient catalysts for NOx abatement, decomposition of nitrous oxide (N2O) over Fe-containing zeolites has attracted great interest by the scientific community mainly due: N2O is the third most important gas contributing to global warming, its concentration in atmosphere is still on the rise and direct N2O decomposition to N2 and O2 is a sustainable alternative. N2O interaction with Fe-zeolite leads to the formation of "special" adsorbed oxygen (often called α-oxygen) with great potential for selective oxidation. Although the focus of a number of studies, the nature of the actives sites for the formation of this adsorbed oxygen is still unclear. The main objectives of this work are: 1) study the decomposition mechanism of N2O over isomorpously substituted Fe-ZSM-5 zeolite aiming on catalyst optimization and 2) optimization and further use of structured Fe-zeolite in novel micro-structured reactor. A number of refined transient kinetics methods were intensively used such as transient response, Temperature Programmed Desorption (TPD) and Temporal Analysis of Product (TAP). Density Functional Theory (DFT) and in situ IR spectroscopy studies were conducted in collaboration and our results support the following: In chapter 3, quantitative measurements have been carrier out to analyze the effect of temperature on the activation (under helium flow) and the irreversible deactivations that can happen during the pretreatment. The results obtained indicate that high temperature treatment (1273 K) results in the formation of a high amount of α-sites. The addition of a very low fraction of oxygen (2%) in the feed demonstrates that the catalyst is sensitive to its presence. Certain sites can be irreversibly destroyed, a result ascribed to the oxidation of active Fe(II) to Fe2O3 clusters which contain inactive Fe(III). Catalyst treatment at high temperature (1273 K) in He for up to 3 hours, also reduced irreversibly the concentration of α-sites. TPD measurements have shown desorption of oxygen at 3 different temperatures. Desorption at the lowest temperature (650 K) was assign to the α-oxygen recombination. The oxygen which desorbs at 700 K was associated to the oxygen from the deactivated sites. Oxygen which desorbs at the highest temperature (730 K) is originated from the surface NOx that desorbed as NO and O2. After a comparison of the concentration of the molecules accumulated, we propose that NO2 is the adsorbed specie. The mechanism of N2O decomposition on the binuclear oxo-hydroxo bridged extraframework iron core site [FeII(μ-O)(μ-OH)FeII]+ inside the ZSM-5 zeolite has been studied by combining theoretical and experimental approaches (see chapter 4). Rate parameters computed using standard statistical mechanics and transition state theory reveal that elementary catalytic steps involved into N2O decomposition are strongly dependent on the temperature. This theoretical result was contrasted with the experimentally observed steady state kinetics of the N2O decomposition and TPD experiments. As predicted by the theoretical study, the switch of the reaction order with respect to N2O pressure (from zero to one) occurs at around 800 K which confirms a change of the rate determining step from the α-oxygen recombination to α-oxygen formation. The proposed mechanism was also confirmed by O2-TD which confirmed the viability of the binuclear complex. The α-oxygen recombination at low temperature (

EPFL2010