Catalytic Carrier Process

The catalyst transfers back and forth between the two reactors, as in Fig. 15.5, and effectively carries the chlorine value from the chlorinator to the oxidizer, where it can be released as chlorine gas. For this reason, the process was dubbed the Catalytic Carrier Process. Separation of the two stages allows each to operate at its own optimum conditions, and higher conversion of HCI to CI2 is the result. This process has operated on a pilot scale in Spain, but no commercial operation has been reported. A study of projected economics [19] based on the optimistic assumptions of quantitative conversion of HCI vapor to chlorine and the recovery of chlorine by absorption in the prohibited solvent CCI4 indicated that this process had advantages over certain other oxidation processes... 

The regenerative processes, conceptually, could be made continuous by supplying multiple columns or by operating two coupled fluidized beds, as in the Catalytic Carrier Process. The distinction between catalyzed reactions and regenerative processes then becomes blurred. 

Pan, H. Y., Benson, S., Minet, R. G., and Tsotsis, T. T., A Catalytic Carrier Process for HCl Oxidation , presented at 13th North American Meeting of the Catalysis Society, Pittsburgh, 1993. 

Catalytic oxidation of olefins Production of epoxides such as ethylene 97, 108 oxide and higher olefin oxides by the oxidation of olefins in the presence of silver oxide on silica-gel carrier process applicable to other organic oxidation processes... 

In many conventional reactors, the reactants arc typically premixed and the products are brought in contact with the reactants until equilibrium is approached. Thus the reaction conversion is limited by the reaction equilibrium. Furthermore, uncontrolled contact between the reaction components may lead to certain reaction paths for some undesirable intermediate or side products. Finally, the valuable catalysts need to be immobilized or encapsulated in some carriers and their loss should be minimized to make the catalytic reaction processes economically viable. 

The predominant process for manufacture of aniline is the catalytic reduction of nitroben2ene [98-95-3] ixh. hydrogen. The reduction is carried out in the vapor phase (50—55) or Hquid phase (56—60). A fixed-bed reactor is commonly used for the vapor-phase process and the reactor is operated under pressure. A number of catalysts have been cited and include copper, copper on siHca, copper oxide, sulfides of nickel, molybdenum, tungsten, and palladium—vanadium on alumina or Htbium—aluminum spinels. Catalysts cited for the Hquid-phase processes include nickel, copper or cobalt supported on a suitable inert carrier, and palladium or platinum or their mixtures supported on carbon. 

Succinic anhydride is manufactured by catalytic hydrogenation of maleic anhydride [108-31-6]. In the most widely used commercial process this reaction is performed in the Hquid phase, at temperatures of 120—180°C and at moderate pressures, in the range of 500—4000 kPa (72—580 psi). Catalysts mentioned in the patent Hterature include nickel (124), Raney nickel (125,126), palladium on different carriers (127,128), and palladium complexes (129). The hydrogenation of the double bond is exothermic Ai/ = —133.89 kJ/mol (—32 kcal/mol) (130). 

Selective Catalytic Reduction (SCR) SCE is a process to reduce NO, to nitrogen and water with ammonia in the presence of a catalyst between 540-840 F (282-449 C). Ammonia is usually injected at a 1 1 molar ratio with the NOx contaminants. Ammonia is used due to its tendency to react only with the contaminants and not with the oxygen in the gas stream. Ammonia is injected by means of compressed gas or steam carriers. Efficiencies near 90% have been reported with SCR. See Exxon Thermal DeNO. ... 

An improved design undertaken by Sacony used high-velocity gases to replace the mechanical elevator systems as catalyst carriers. These so-called air-lift units improved upon the Thermofor process both in terms of economies and octane numbers. It was, however, only with the fluid cracking process that catalytic technology realized fully continuous production. 

Epoxides such as ethylene oxide and higher olefin oxides may be produced by the catalytic oxidation of olefins in gas-liquid-particle operations of the slurry type (S7). The finely divided catalyst (for example, silver oxide on silica gel carrier) is suspended in a chemically inactive liquid, such as dibutyl-phthalate. The liquid functions as a heat sink and a heat-transfer medium, as in the three-phase Fischer-Tropsch processes. It is claimed that the process, because of the superior heat-transfer properties of the slurry reactor, may be operated at high olefin concentrations in the gaseous process stream without loss with respect to yield and selectivity, and that propylene oxide and higher... 

In the sixties of past century, a few patents issued to Bergbau Chemie [5,48,49] and to Mobil Oil [50-52], respectively described the use of CFPs as supports for catalytically active metal nanoclusters and as carriers for heterogenized metal complexes of catalytic relevance. For the latter catalysts the term hybrid phase catalysts later came into use [53,54], At that time coordination chemistry and organo-transition metal chemistry were in full development. Homogeneous transition metal catalysis was expected to grow in industrial relevance [54], but catalyst separation was generally a major problem for continuous processing. That is why the concept of hybrid catalysis became very popular in a short time [55]. 

In many cases there is an interaction between the carrier and the active component of the catalyst so that the character of the active surface will change. For example, the electronic character of the supported catalyst may be influenced by the transfer of electrons across the catalyst-carrier interface. In some cases the carrier itself has a catalytic activity for the primary reaction, an intermediate reaction, or a subsequent reaction, and a dual-function catalyst is thereby obtained. Materials of this type are widely employed in reforming processes. There are other cases where the interaction of the catalyst and support are much more subtle and difficult to label. For example, the crystal size and structure of supported metal catalysts as well as the manner in which the metal is dispersed can be influenced by the nature of the support material. 

The hypothesis that the cobalt carbonyl radicals are the carriers of catalytic activity was disproved by a high pressure photochemistry experiment /32/, in which the Co(CO), radical was prepared under hydroformylation conditions by photolysis of dicobalt octacarbonyl in hydrocarbon solvents. The catalytic reaction was not enhanced by the irradiation, as would be expected if the radicals were the active catalyst. On the contrary, the Co(C0)4 radicals were found to inhibit the hydroformylation. They initiate the decomposition of the real active catalyst, HCo(C0)4, in a radical chain process /32, 33/. 

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