Heterogeneous catalysis reactors

FIGURE 8.3 Heterogeneous catalysis reactor types (a) fixed bed, (b) batch fluid bed, (c) slurry, (d) catalytic gauze, (e) trickle bed, (f) moving bed, (g) continuous fluid bed, and (h) transport line. 

The microscopic understanding of tire chemical reactivity of surfaces is of fundamental interest in chemical physics and important for heterogeneous catalysis. Cluster science provides a new approach for tire study of tire microscopic mechanisms of surface chemical reactivity [48]. Surfaces of small clusters possess a very rich variation of chemisoriDtion sites and are ideal models for bulk surfaces. Chemical reactivity of many transition-metal clusters has been investigated [49]. Transition-metal clusters are produced using laser vaporization, and tire chemical reactivity studies are carried out typically in a flow tube reactor in which tire clusters interact witli a reactant gas at a given temperature and pressure for a fixed period of time. Reaction products are measured at various pressures or temperatures and reaction rates are derived. It has been found tliat tire reactivity of small transition-metal clusters witli simple molecules such as H2 and NH can vary dramatically witli cluster size and stmcture [48, 49, M and 52]. 

Catalysis in a single fluid phase (liquid, gas or supercritical fluid) is called homogeneous catalysis because the phase in which it occurs is relatively unifonn or homogeneous. The catalyst may be molecular or ionic. Catalysis at an interface (usually a solid surface) is called heterogeneous catalysis, an implication of this tenn is that more than one phase is present in the reactor, and the reactants are usually concentrated in a fluid phase in contact with the catalyst, e.g., a gas in contact with a solid. Most catalysts used in the largest teclmological processes are solids. The tenn catalytic site (or active site) describes the groups on the surface to which reactants bond for catalysis to occur the identities of the catalytic sites are often unknown because most solid surfaces are nonunifonn in stmcture and composition and difficult to characterize well, and the active sites often constitute a small minority of the surface sites. 

These reactors were, and unfortunately still are, used in a few laboratories for process studies on heterogeneous catalysis, frequently with the... 

A good review of the transient response method in heterogeneous catalysis was published by Kobayashi and Kobayashi (1974). These authors credit Bermett (1967) for applying this previously microcatalytic research technique to recycle reactors and thereby, in view of this author, to engineering problems. 

Because diacetylene is unstable, a stable diacetylene derivative, 1-methoxybut-l-en-3-yne (65CB98), is often employed in the synthesis of pyrroles. The reaction with ammonia proceeds under conditions of heterogeneous catalysis (a mixture of reagent vapors is passed through a catalyst-containing reactor heated to 150°C), approaching a yield of 50-70% but with primary aromatic amines, the yield drops to 20%. 

All these steps can influence the overall reaction rate. The reactor models of Chapter 9 are used to predict the bulk, gas-phase concentrations of reactants and products at point (r, z) in the reactor. They directly model only Steps 1 and 9, and the effects of Steps 2 through 8 are lumped into the pseudohomoge-neous rate expression, a, b,. ..), where a,b,. .. are the bulk, gas-phase concentrations. The overall reaction mechanism is complex, and the rate expression is necessarily empirical. Heterogeneous catalysis remains an experimental science. The techniques of this chapter are useful to interpret experimental results. Their predictive value is limited. 

Steps 1 through 9 constitute a model for heterogeneous catalysis in a fixed-bed reactor. There are many variations, particularly for Steps 4 through 6. For example, the Eley-Rideal mechanism described in Problem 10.4 envisions an adsorbed molecule reacting directly with a molecule in the gas phase. Other models contemplate a mixture of surface sites that can have different catalytic activity. For example, the platinum and the alumina used for hydrocarbon reforming may catalyze different reactions. Alternative models lead to rate expressions that differ in the details, but the functional forms for the rate expressions are usually similar. 

Control of emissions of CO, VOC, and NOj, is high on the agenda. Heterogeneous catalysis plays a key role and in most cases structured reactors, in particular monoliths, outperform packed beds because of (i) low pressure drop, (ii) flexibility in design for fast reactions, that is, thin catalytic layers with large geometric surface area are optimal, and (iii) attrition resistance [17]. For power plants the large flow... 

Support materials are commonly u.sed in heterogeneous catalysis. Their major function is to maximize the dispersion of the active phase by providing a large surface area over which the active phase can be distributed. In this way the cataly.st material is shaped into a form suitable for use in technical reactors. Supports are not always chemically inert they can also show certain catalytic activity and often they act as a stabilizer for the actual active phase. A number of materials are u.sed as catalyst supports. Table 3.2 gives an overview. 

In any catalyst selection procedure the first step will be the search for an active phase, be it a. solid or complexes in a. solution. For heterogeneous catalysis the. second step is also deeisive for the success of process development the choice of the optimal particle morphology. The choice of catalyst morphology (size, shape, porous texture, activity distribution, etc.) depends on intrinsic reaction kinetics as well as on diffusion rates of reactants and products. The catalyst cannot be cho.sen independently of the reactor type, because different reactor types place different demands on the catalyst. For instance, fixed-bed reactors require relatively large particles to minimize the pressure drop, while in fluidized-bed reactors relatively small particles must be used. However, an optimal choice is possible within the limits set by the reactor type. 

Advantageously, SAPC as a technique with immobilized catalysts does not need devices for catalyst separation and recycling, since the reactions can in principle be carried out using standard flow reactors commonly used in heterogeneous catalysis. On the other hand, the presumed processes for the work-up of the constituents of the catalyst, the ligand (and - may be - the support) will be demanding and expensive, too. 

The single particle acts as a batch reactor in which conditions change with respect to time, This unsteady-state behavior for a reacting particle differs from the steady-state behavior of a catalyst particle in heterogeneous catalysis (Chapter 8). The treatment of it leads to the development of an integrated rate law in which, say, the fraction of B converted, /B, is a function oft, or the inverse. 

Chapter 4 concerns differential processes, which take place with respect to both time and position and which are normally formulated as partial differential equations. Applications include heterogeneous catalysis, tubular chemical reactors, differential mass transfer, heat exchangers and chromatography. It is shown that such problems can be solved with relative ease, by utilising a finite-differencing solution technique in the simulation approach. 

---