Diffusion catalyst particles

Pore Diffusion Catalyst Particle Crush catalyst and compare rate with Size that obtained with uncrushed catalysts. (Batch System) CatalystiSubstrate Decrease flow rate until the degree of Contact Time conversion becomes constant. Flow System) Catalyst Particle Crush catalyst and compare rate with Size that obtained with uncrushed catalysts. ... 

Reactants must diffuse through the network of pores of a catalyst particle to reach the internal area, and the products must diffuse back. The optimum porosity of a catalyst particle is deterrnined by tradeoffs making the pores smaller increases the surface area and thereby increases the activity of the catalyst, but this gain is offset by the increased resistance to transport in the smaller pores increasing the pore volume to create larger pores for faster transport is compensated by a loss of physical strength. A simple quantitative development (46—48) follows for a first-order, isothermal, irreversible catalytic reaction in a spherical, porous catalyst particle. 

Concentration gradient inside the catalyst particle. The continuity statement, at the catalyst surface, is similar to Pick s first law for diffiasion. The reaction rate is equal to the diffusion rate at the outside layer of the catalyst... 

The dehydrogenation reaction is an extremely rapid endothermic reaction which converts alkylcyclohexanes to aromatics almost quantitatively. It is promoted by the catalyst platinum function and is so rapid that it is normally limited by diffusion into the catalyst particle. 

It was shown in laboratory studies that methanation activity increases with increasing nickel content of the catalyst but decreases with increasing catalyst particle size. Increasing the steam-to-gas ratio of the feed gas results in increased carbon monoxide shift conversion but does not affect the rate of methanation. Trace impurities in the process gas such as H2S and HCl poison the catalyst. The poisoning mechanism differs because the sulfur remains on the catalyst while the chloride does not. Hydrocarbons at low concentrations do not affect methanation activity significantly, and they reform into methane at higher levels, hydrocarbons inhibit methanation and can result in carbon deposition. A pore diffusion kinetic system was adopted which correlates the laboratory data and defines the rate of reaction. 

Equation 1 has as its basis the concept that diffusion, either through pores or to the gross surface of the catalyst particle, controls the reaction rate. When the control is strictly by the gas film surrounding the catalyst, one would have to convert Equation 1 to... 

Finally, one must know the effect of catalyst particle size on Kw. For a pore diffusion-controlled reaction, activity should be inversely proportional to catalyst particle diameter, that is directly proportional to external catalyst surface area. 

In the discussion so far, the fluid has been considered to be a continuum, and distances on the molecular scale have, in effect, been regarded as small compared with the dimensions of the containing vessel, and thus only a small proportion of the molecules collides directly with the walls. As the pressure of a gas is reduced, however, the mean free path may increase to such an extent that it becomes comparable with the dimensions of the vessel, and a significant proportion of the molecules may then collide direcdy with the walls rather than with other molecules. Similarly, if the linear dimensions of the system are reduced, as for instance when diffusion is occurring in the small pores of a catalyst particle (Section 10.7), the effects of collision with the walls of the pores may be important even at moderate pressures. Where the main resistance to diffusion arises from collisions of molecules with the walls, the process is referred to Knudsen diffusion, with a Knudsen diffusivily which is proportional to the product where I is a linear dimension of the containing vessel. 

The internal structure of the catalyst particle is often of a complex labyrinth-like nature, with interconnected pores of a multiplicity of shapes and sizes, In some cases, the pore size may be less than the mean free path of the molecules, and both molecular and Knudsen diffusion may occur simultaneously. Furthermore, the average length of the diffusion path will be extended as a result of the tortuousity of the channels. In view of the difficulty of precisely defining the pore structure, the particle is assumed to be pseudo-homogeneous in composition, and the diffusion process is characterised by an effective diffusivity D, (equation 10.8). 

A first-order chemical reaction takes place in a reactor in which the catalyst pellets are platelets of thickness 5 mm. The effective diffusivity De for the reactants in the catalyst particle is I0"5 m2/s and the first-order rate constant k is 14.4 s . 

Explain why, when applying the equation to reaction in a porous catalyst particle, it is necessary to replace the molecular diffusivity D by an effective diffusivity De. 

Transport of the reactants into the catalyst particle by diffusion through the pores. 

Step 3. Transport within a catalyst pore is usually modeled as a one-dimensional diffusion process. The pore is assumed to be straight and to have length The concentration inside the pore is ai =ai(l,r,z) where I is the position inside the pore measured from the external surface of the catalyst particle. See Figure 10.2. There is no convection inside the pore, and the diameter of the pore is assumed to be so small that there are no concentration gradients in the radial direction. The governing equation is an ODE. 

Example 10.6 A commercial process for the dehydrogenation of ethylbenzene uses 3-mm spherical catalyst particles. The rate constant is 15s , and the diffusivity of ethylbenzene in steam is 4x 10 m /s under reaction conditions. Assume that the pore diameter is large enough that this bulk diffusivity applies. Determine a likely lower bound for the isothermal effectiveness factor. 

The void fraction should be the total void fraction including the pore volume. We now distinguish Stotai from the superficial void fraction used in the Ergun equation and in the packed-bed correlations of Chapter 9. The pore volume is accessible to gas molecules and can constitute a substantial fraction of the gas-phase volume. It is included in reaction rate calculations through the use of the total void fraction. The superficial void fraction ignores the pore volume. It is the appropriate parameter for the hydrodynamic calculations because fluid velocities go to zero at the external surface of the catalyst particles. The pore volume is accessible by diffusion, not bulk flow. 

Weisz, P. B. and Hicks, J. S., The behaviour of porous catalyst particles in view of internal mass and heat diffusion effects, Chem. Eng. Sci., 17, 265-275 (1962). 

Figure 10.5 shows the basic concept of the particle-level MR that gives (i) selective addition of reactants to the reaction zone and (ii) selective removal of products from the reaction zone. In the first case, if the diffusivity of one reactant (A) is much higher than that of the other components (B), the reactant (A) selectively diffuses into a catalyst particle through a membrane. Undesired reactions or the adsorption of poisons on the catalysts can be prevented. In the second case, the reaction has a hmited yield or is selectivity controlled by thermodynamics. The selective removal of the desired product from the catalyst particle gives enhancement of selectivity when the diffusivity of one product (R) is much greater than that of the other products (S). 

Although hydrogenation of 4-CBA over Pd/C is very fast, there is strong diffusion resistance. Furthermore, apparent kinetic equations on different catalyst particle sizes have been obtained from experimental data. 

Membrane Diffusion layer Nafion ionomer Catalyst Particle... 

The characteristic times on which catalytic events occur vary more or less in parallel with the different length scales discussed above. The activation and breaking of a chemical bond inside a molecule occurs in the picosecond regime, completion of an entire reaction cycle from complexation between catalyst and reactants through separation from the product may take anywhere between microseconds for the fastest enzymatic reactions to minutes for complicated reactions on surfaces. On the mesoscopic level, diffusion in and outside pores, and through shaped catalyst particles may take between seconds and minutes, and the residence times of molecules inside entire reactors may be from seconds to, effectively, infinity if the reactants end up in unwanted byproducts such as coke, which stay on the catalyst. 

Minimize the effects of transport phenomena If we are interested in the intrinsic kinetic performance of the catalyst it is important to eliminate transport limitations, as these will lead to erroneous data. We will discuss later in this chapter how diffusion limitations in the pores of the catalyst influence the overall activation energy. Determining the turnover frequency for different gas flow velocities and several catalyst particle sizes is a way to establish whether transport limitations are present. A good starting point for testing catalysts is therefore ... 

The effect of transport limitations can conveniently be evaluated by considering the spherical catalyst particle shown in Fig. 5.32. We will introduce a dimensionless quantity called the Thiele diffusion modulus (Og) [W. Thiele Ind. Eng. Chem. 31... 

We start with an ideal, porous, spherical catalyst particle of radius R. The catalyst is isothermal and we consider a reaction involving a single reactant. Diffusion is described macroscopically by the first and second laws of Pick, stating that... 

Above we considered a porous catalyst particle, but we could similarly consider a single pore as shown in Fig. 5.36. This leads to rather similar results. The transport of reactant and product is now determined by diffusion in and out of the pores, since there is no net flow in this region. We consider the situation in which a reaction takes place on a particle inside a pore. The latter is modeled by a cylinder with diameter R and length L (Fig. 5.36). The gas concentration of the reactant is Cq at the entrance of the pore and the rate is given by... 

Thus, considering diffusion in pores leads to very similar results to those we obtained when describing diffusion in catalyst particles. 

In this exercise we shall estimate the influence of transport limitations when testing an ammonia catalyst such as that described in Exercise 5.1 by estimating the effectiveness factor e. We are aware that the radius of the catalyst particles is essential so the fused and reduced catalyst is crushed into small particles. A fraction with a narrow distribution of = 0.2 mm is used for the experiment. We shall assume that the particles are ideally spherical. The effective diffusion constant is not easily accessible but we assume that it is approximately a factor of 100 lower than the free diffusion, which is in the proximity of 0.4 cm s . A test is then made with a stoichiometric mixture of N2/H2 at 4 bar under the assumption that the process is far from equilibrium and first order in nitrogen. The reaction is planned to run at 600 K, and from fundamental studies on a single crystal the TOP is roughly 0.05 per iron atom in the surface. From Exercise 5.1 we utilize that 1 g of reduced catalyst has a volume of 0.2 cm g , that the pore volume constitutes 0.1 cm g and that the total surface area, which we will assume is the pore area, is 29 m g , and that of this is the 18 m g- is the pure iron Fe(lOO) surface. Note that there is some dispute as to which are the active sites on iron (a dispute that we disregard here). 

Figure 7. SEM and XRMA microphotographs of palladium catalysts supported on the amphiphilic resin made by DMAA, MTEA, MBAA (cross-linker) [30]. Microphotographs (a) and (b) show an image and the radial palladium distribution after uptake of [Pd(OAc)2] from water/acetone the precursor diffuses only into the outer layer of the relatively little swollen CFP after reduction the nanoclusters remain close to the edge of the catalyst beads. Microphotographs (c) and (d) show the radial distribution of sulfur and palladium, respectively, after uptake of [PdCU] from water after reduction palladium is homogenously distributed throughout the catalyst particles. This indicates that under these conditions the CFP was swollen enough to allow the metal precursor to readily penetrate the whole of polymeric mass. (Reprinted from Ref. [30], 2005, with permission from Elsevier.)...

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