Diffusion, catalyst deactivation

Reaction, diffusion, and catalyst deactivation in a porous catalyst layer are considered. A general model for mass transfer and reaction in a porous particle with an arbitrary geometry can be written as follows ... 

The selectivity in a system of parallel reactions does not depend much on the catalyst size if effective diffusivities of reactants, intermediates, and products are similar. The same applies to consecutive reactions with the product desired being the final product in the series. In contrast with this, for consecutive reactions in which the intermediate is the desired product, the selectivity much depends on the catalyst size. This was proven by Edvinsson and Cybulski (1994, 1995) for. selective hydrogenations and also by Colen et al. (1988) for the hydrogenation of unsaturated fats. Diffusion limitations can also affect catalyst deactivation. Poisoning by deposition of impurities in the feed is usually slower for larger particles. However, if carbonaceous depositions are formed on the catalyst internal surface, ageing might not depend very much on the catalyst size. 

J. Wood, L. F. Gladden 2003, (Effect of coke deposition upon pore structure and self-diffusion in deactivated industrial hydroprocessing catalysts), Appl.Cat. A General, 249, 241. 

The hydrogenation of para-substituted anilines over rhodium catalysts has been investigated. An antipathetic metal crystallite size effect was observed for the hydrogenation of /Moluidinc suggesting that terrace sites favour the reaction. Limited evidence was found for catalyst deactivation by the product amines. Catalysts with pore diameters less than 13.2 nm showed evidence of diffusion control on the rate of reaction but not the cis trans ratio of the product. 

In a fixed-bed catalytic reactor for a fluid-solid reaction, the solid catalyst is present as a bed of relatively small individual particles, randomly oriented and fixed in position. The fluid moves by convective flow through the spaces between the particles. There may also be diffusive flow or transport within the particles, as described in Chapter 8. The relevant kinetics of such reactions are treated in Section 8.5. The fluid may be either a gas or liquid, but we concentrate primarily on catalyzed gas-phase reactions, more common in this situation. We also focus on steady-state operation, thus ignoring any implications of catalyst deactivation with time (Section 8.6). The importance of fixed-bed catalytic reactors can be appreciated from their use in the manufacture of such large-tonnage products as sulfuric acid, ammonia, and methanol (see Figures 1.4,11.5, and 11.6, respectively). 

Note In the strong pore diffusion regime the rate is lower but the catalyst deactivates more slowly. Actually, for the catalyst used here if we could have been free of diffusional resistances reaction rates would have been 360 times as fast as those measured. 

From the following data, reported by Krishnaswamy and Kitterell, AIChE 28, 273 (1982), develop rate expressions to represent this decomposition, both in the diffusion free regime and in the strong pore diffusion regime, for the catalyst at hand. Note that the conversion decreases with time in all runs showing that the catalyst deactivates with use. 

Industrially relevant consecutive-competitive reaction schemes on metal catalysts were considered hydrogenation of citral, xylose and lactose. The first case study is relevant for perfumery industry, while the latter ones are used for the production of sweeteners. The catalysts deactivate during the process. The yields of the desired products are steered by mass transfer conditions and the concentration fronts move inside the particles due to catalyst deactivation. The reaction-deactivation-diffusion model was solved and the model was used to predict the behaviours of semi-batch reactors. Depending on the hydrogen concentration level on the catalyst surface, the product distribution can be steered towards isomerization or hydrogenation products. The tool developed in this work can be used for simulation and optimization of stirred tanks in laboratory and industrial scale. 

Some simulation results for trilobic particles (citral hydrogenation) are provided by Fig. 2. As the figure reveals, the process is heavily diffusion-limited, not only by hydrogen diffusion but also that of the organic educts and products. The effectiviness factor is typically within the range 0.03-1. In case of lower stirrer rates, the role of external diffusion limitation becomes more profound. Furthermore, the quasi-stationary concentration fronts move inside the catalyst pellet, as the catalyst deactivation proceeds. 

Various reports can be found in the literature in connection with catalyst deactivation kinetics (Wojchiechowsky, 1968), some of them also taking into account the effects of diffusion resistance (Beeckman and Froment, 1980). 

Vapor-phase alkylation of benzene by ethene and propene over HY, LaY, and REHY has been studied in a tubular flow reactor. Transient data were obtained. The observed rate of reaction passes through a maximum with time, which results from build-up of product concentration in the zeolite pores coupled with catalyst deactivation. The rate decay is related to aromatic olefin ratio temperature, and olefin type. The observed rate fits a model involving desorption of product from the zeolite crystallites into the gas phase as a rate-limiting step. The activation energy for the desorption term is 16.5 heal/mole, approximately equivalent to the heat of adsorption of ethylbenzene. For low molecular weight alkylates intracrystalline diffusion limitations do not exist. 

In several experiments, in particular the study by Temkin and co-workers [224] of the kinetics in ethylene oxidation, slow relaxations, i.e. the extremely slow achievement of a steady-state reaction rate, were found. As a rule, the existence of such slow relaxations is ascribed to some "side reasons rather than to the purely kinetic ("proper ) factors. The terms "proper and "side were first introduced by Temkin [225], As usual, we classify as slow "side processes variations in the chemical or phase composition of the surface under the effect of reaction media, catalyst deactivation, substance diffusion into its bulk, etc. These processes are usually considered to require significantly longer times to achieve a steady state compared with those characterizing the performance of chemical reactions. The above numerical experiment, however, shows that, when the system parameters attain their bifurcation values, the time to achieve a steady state, tr, sharply increases. 

Instead, they proposed a time on stream theory to model the catalyst deactivation. However, in an earlier work by Voorhies (2), a linear correlation between conversion and coke on catalyst for fixed-bed catalytic cracking was derived. Rudershausen and Watson (3) also observed the similar behavior. Coke on catalyst can reduce the activity by covering the active sites and blocking the pores. The effects of pore size on catalyst performance during hydrotreating coal oils in trickle-bed reactors have been studied experimentally by Ahmed and Crynes (4) and by Sooter (5). The pore size effects in other studies are also reported 7, 8). Prasher et al. (9) observed that the effective diffusivities of oils in aged catalysts were severely reduced by coke deposition. 

There have been numerous studies on HDM catalyst deactivation. They differ in the mechanisn of deactivation, in the kinetics used for the HDM reaction, in the expression employed to describe diffusivity or pore structure. These different approaches can lead to quite different conclusions as to the catalyst properties that yield optimum overall activity (3-9). 

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