Synthesis of ZSM-5 coatings on stainless steel grids and their catalytic performance for partial oxidation of benzene by N2O

The hydroxylation of benzene was carried out over a structured catalytic bed of ZSM-5-coated stainless steel grids. The catalysts demonstrated a 97% selectivity to PhOH at benzene conversion 11%. In addn. to achieving the same reactivity as traditional zeolitic fixed beds, the grid catalyst has several advantages gained by special arrangement of the catalytic bed, including: low pressure drop, improved heat and mass transfer and controlled hydrodynamics. [on SciFinder (R)]

Développement de réacteurs microstructurés pour la conversion du propane en produits valorisés

Olivier Wolfrath

Industry requires continuously new chemical processes to convert raw materials to valuable products limiting the formation of by-products. Since a few years, an increasing interest has been given to the intensification of chemical processes. This represents a new approach in chemical reaction engineering and calls for a new type of chemical reactors: the microstructured reactors. They are characterized by miniature structures whose components have a sub-millimeter size. The flow channels, for example, have a diameter from ten to several hundred microns. The distinctive feature of these structures is a very large surface/volume ratio, namely between 10'000 and 50'000 m2/m3. In these conditions, heat transfer coefficient is very high, up to 25 kW · m-2 · K-1. It is accepted that the residence time distribution in a reactor strongly influences the product selectivity and yield. In these thin channels, the RTD is particularly narrow due to a short radial diffusion time (ms), allowing a precise control of the residence time. Another advantage of these microstructures is an increase of the inherent safety due to a small amount of the compounds used. However, fabrication of microreactors, especially the introduction of active catalyst in microchannels remains a difficult operation. And integration of microsystems in conventional chemical processes is still a challenge. The aim of this work is first to develop a novel membrane reactor based on a new microstructured catalytic packing in the filamentous form and to apply it to the nonoxydative dehydrogenation of propane. A second objective is to develop a reactor with micro heat exchangers allowing an optimized control of homogeneous reactions. This reactor was tested with the partial oxidation of propene to propylene oxide. The microstructured catalyst above is made of thin and long catalytic filaments placed in parallel with a tubular reactor. This new kind of catalyst is based on silica fibres covered by a γ-alumina layer. The position in parallel of these filaments of 7 μm diameter forces the gases to flow in the fibres direction between the filaments. The hydraulic diameter is about 70 μm. Due to this laminar and regular flow, the pressure drop in the bed was divided by 5 compared to a conventional bed (100-160 μm spheres) and the residence time distribution was particularly narrower. Such novel packing brings new opportunities to the heterogeneous catalysis domain because it can be used for many other reactions improving highly the hydrodynamics and keeping an excellent contact with the reactants. The microstructured catalyst was installed in two concentric zones of a tubular reactor separated by a palladium-silver membrane permeable to hydrogen. This product was removed from the gas phase to shift the thermodynamic equilibrium, enhancing the propane conversion from 22% up to 30%. Another significant advantage in this reactor is the increase of propene selectivity up to 97% in comparison to conventional industrial processes reaching 80-90%. This difference is due to the diminution of hydrogenolysis and hydroisomerization reactions. The dehydrogenation is known to be endothermic. Oxidation of the hydrogen passing through the membrane produced heat for this reaction along the catalytic zone. Moreover, a periodic regeneration by air allowed recovering the activity of the catalyst deactivated by coke formed during dehydrogenation. Periodic reaction operations allowed producing continuously propene with a high selectivity, and regenerating simultaneously the catalyst. The second microstructured reactor was developed integrating two micro heat exchangers at the inlet and outlet of a macroscopic tube. The aim is to heat up very fast the gas and to cool it down as well. Without these exchangers, heating and cooling duration corresponded each to about 20% of the total residence time. The use of the microstructures allowed diminishing significantly these durations (4-5% each). Applied to partial oxidation of propene, this reactor reached a more precise control of reaction temperature and duration. The propylene oxide (PO) selectivity was not increased with this system but, due to the microstructures, it was possible to work at higher temperatures where the reaction becomes very fast, without reaching an oxygen conversion of 100%. Indeed, it is essential to avoid this situation where oligomers and coke form dividing by 2 the PO selectivity. So another new kind of reactor was developed suitable for any fast exothermic reaction whose progression has to be limited because of potential consecutive reactions reducing, for example, the selectivity of an intermediate desired compound.

EPFL2001

Novel structured adsorber and oxidation catalysts for the removal of VOCs in low concentration

Kim Martin Nikolajsen

One possibility for the removal of volatile organic compounds (VOCs) is catalytic oxidation. For the removal of VOCs in low concentration (≲ 3000 ppmv for propane) it is not possible to sustain the required oxidation temperature over the catalyst without external heating. An approach to overcome this problem is to concentrate the VOC by adsorption, in a "two-step adsorption-incineration" process. This is an unsteady state process in which the VOC laden effluent gas is cleaned by passing it through an adsorber. Once the adsorber is saturated the VOC is desorbed by heating and purging. The concentrated VOC from the desorber can then be oxidized over the catalyst, producing enough heat to sustain the oxidation temperature. Conventional adsorbents have some drawbacks such as tailing during desorption due to the large particle size, high pressure drop and hot-spot formation. The objective of this work was to develop, characterize and test the adsorbent and catalyst, with low resistance to mass transfer resulting from thin films of active material, for the two-step adsorption-incineration process. Both the adsorbent and the oxidation catalysts were supported on sintered metal fibers (SMF). This is a novel, structured support offering several advantages over conventional randomly packed beds: Low pressure drop, due to the high porosity of the SMF, which is important where large flow rates and/or high quantities of gas must be treated. High thermal conductivity, due to the metallic nature, leading to smaller temperature gradients in the fixed-bed. A very high geometric surface area, due to the small fiber size. On the order of 200,000 m2/m3 with a fiber diameter of 20 µm. Furthermore, a mathematical model was developed to show the feasibility of the coupling of the two steps in the process. The adsorber was made from a thin, homogeneous film of MFI-type zeolite covering the fibers of the SMF. The film was grown by the seed-film method by hydrothermal treatment. A 3 µm film was obtained with 10 wt.% zeolite on the fiber after 24 h synthesis at 125 °C. This material had a specific surface area of 30 m2/g. The adsorption equilibrium of propane was described well by the Langmuir isotherm and the heat of adsorption was found to be ΔH0ads = - 43.1 kJ/mol. Isothermal breakthrough curves were measured as a function of temperature and film thickness. A mathematical model, comprised of a tanks-in-series model with a linear driving force (LDF) mass transfer description, successfully described the breakthrough behavior. The overall mass transfer was found to be solely due to diffusion in the zeolite film. However, the thin films show very low resistance to mass transfer leading to low internal concentration gradients and efficient utilization of the adsorbent. The pressure drop was measured and compared to that of a randomly packed fixed-bed of spheres. The equivalent diameter for a constant volumetric flow rate and superficial cross sectional area was dp = 180 µm, for a fiber diameter of df = 26 µm at 10 wt.% zeolite loading. The oxidation catalysts were all supported on SMF and cobalt oxide was used as the active phase. Three different groups of catalysts were developed. The support was modified by coating the fibers either with a thin film of fine powder (alumina or catalyst powder) or with a MFI-type zeolite film identical to the adsorbent. The third group was made from cobalt oxide impregnated directly on the oxidized fibers. The latter type of catalyst was found to be the most active during the screening experiments. The base support composition was varied (stainless steel (SS), FeCrAlloy and inconel) to investigate the support effect on the kinetics. The stainless steel and FeCrAlloy supports had similar activities, surpassing that of the inconel supported catalyst, which might be attributed to a Co3O4 surface enriched with iron from the support. Between the 1.1 wt.%Co3O4/SMFSS and 1.5 wt.%Co3O4/SMFFeCrAlloy catalyst the FeCrAlloy based had the highest normalized activity at low temperature (< 310 °C), low propane mole fraction (0.13 %) and high oxygen mole fraction (16.7 %). The chemical kinetics were determined from a novel and efficient experimental design. The apparent activation energy for this catalyst was found to be 87.5 ± 2.6 kJ/mol, with reaction orders in propane of 0.38 ± 0.04 and in oxygen of 0.30 ± 0.08. The catalysts were tested up to 350 °C. Mass transfer limitations were absent and the kinetics was described well with the power rate law as compared to the Mars-van Krevelen model. Catalysts based on Co3O4, supported directly on oxidized SMF, are very active catalysts, simple to prepare, withstand deactivation due to hot-spot formation and show great potential in comparison to the industrial reference catalyst (copper and manganese oxide supported on alumina). The adiabatic desorption process was investigated by mathematical modeling. Simply purging the adsorption bed with the hot exhaust gas from the reactor cannot result in the concentration of the VOC due to the high heat capacity of the fixed-bed. Hence, it will be necessary to use either a high heat carrier like steam, with the adverse effects of drying and separation of water and VOC, or an approach in which the desorber is heated prior to purging the bed, changing the adsorption equilibrium in favor of high gas concentrations. For the latter method, the minimum theoretical propane mole fraction for an autothermal process was found to be 350 ppmv to sustain a catalytic incinerator at 250 °C. Finally, it can be concluded that for the first time zeolite films on SMF were used as structured adsorbents, leading to very low internal mass transfer and increased process efficiency. Furthermore, the advantages of the SMF can be exploited in a catalytic oxidizer, which can be combined with the adsorber to annihilate VOCs in low concentrations. A novel method for the deposition of fine powder catalyst on SMF was also developed for the first time.

EPFL2007

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