Monolith alumina structure

In this study, a novel Monolith alumina structure was of interest as a base (or a carrier) material for Co-Mo-Alumina catalysts. The specific interest centered around assessing the suitability of the catalyst prepared by impregnating the novel alumina support with Co and Mo for hydrodesulfurization (HDS) and hydrodenitrogenation (HDN) of a relatively high boiling stock. The Monolith catalyst was also tested on a low boiling coal-derived liquid. 

Figure 2. Monolith alumina structure top, Monolith alumina segments bottom, cross section of a monolith alumina segment...

Effective preparation methods of hexaaluminates for catalytic applications, such as the hydrolysis of alkoxides and the co-precipitation in aqueous medium, ensure high interspersion of the constituents in the precursor. This allows the formation of single phase materials with layered-alumina structure at reasonably low temperature (1100-1200 °C) and with high surface area. The hydrolysis of alkoxides was extensively studied and used for the industrial scale-up in the production of catalysts in the monolith shape. However, the co-precipitation in aqueous medium has much potential in view of the possible commercialization of these materials due to its simplicity and low cost. 

Figure 2 shows the shape and size of the Monolith alumina supports. These are in the form of cylindrical segments of about 2.54 cm in length and about 1.0 cm in diameter. These have longitudinal and parallel channels along their length. The size, shape and thickness of the walls of the channels are also shown in Figure 2. The Monolith structure has about 60 to 80 percent of its cross-sectional area open. Therefore, a bed of regularly stacked Monoliths would offer significantly less pressure drop than that encountered in conventional packed beds. This has been observed by Satterfield and Ozel (1) for a water-air system.

The physical form of the support has to be chosen with a view to the type of reactor in which its use is intended. Silica and alumina are available as coarse granules or fine powders, and may be formed into various shapes with the aid of a binder (stearic acid, graphite) they can then be used in fixed bed reactors. For fluidised beds, or for use in liquid media, fine powders are required. Ceramic monoliths having structures resembling a honeycomb are used where (as in vehicle exhaust treatment) very high space velocities have to be used, but they are made of a non-porous material (a-alumina, muUite) and have to have a thin wash-coat of high area alumina applied, so that the metal can be firmly affixed. 

Scientists from Politecnico di Milano and Ineos Vinyls UK developed a tubular fixed-bed reactor comprising a metallic monolith [30]. The walls were coated with catalytically active material and the monolith pieces were loaded lengthwise. Corning, the world leader in ceramic structured supports, developed metallic supports with straight channels, zig-zag channels, and wall-flow channels. They were produced by extrusion of metal powders, for example, copper, fin, zinc, aluminum, iron, silver, nickel, and mixtures and alloys [31]. An alternative method is extrusion of softened bulk metal feed, for example, aluminum, copper, and their alloys. The metal surface can be covered with carbon, carbides, and alumina, using a CVD technique [32]. For metal monoliths, it is to be expected that the main resistance lies at the interface between reactor wall and monolith. Corning... 

The foam monoliths were a-Al203 samples with an open cellular, spongelike structure. We used samples with nominally 30 to 80 pores per inch (ppi) which were cut into 17 mm diameter cylinders 2 to 20 mm long. A 12 to 20 wt.% coating of Pt or Rh was then applied directly to the alumina by an organometallic deposition. 

Metallic monoliths made of both rhodium ([HCR 1]) and FeCrAlloy (72.6% Fe, 22% Cr and 4.8% Al ([HCR 3]) carrying micro channels of 120 pm x 130 pm cross-section at various length (5 and 20 mm) were applied. The monoliths were prepared of micro structured foils by electron beam welding. After bonding, the FeCrAlloy was oxidized in air at 1 000 °C for 4 h to form an a-alumina layer, which was verified by XRD. Its thickness was determined as < 10 pm by SEM/EDX. The alumina layer was impregnated with rhodium chloride and alternatively with a nickel salt solution. The catalyst loading with nickel (30 mg) was much higher than that with rhodium (1 mg) (see Table 2.4). The amount of rhodium on the catalyst surface was determined as 3% by XPS. 

Different ways have been proposed to prepare zeolite membranes. A layer of a zeolite structure can be synthesized on a porous alumina or Vycor glass support [27, 28]. Another way is to allow zeolite crystals to grow on a support and then to plug the intercrystalline pores with a dense matrix [29], However, these two ways often lead to defects which strongly decrease the performance of the resulting membrane. A different approach consists in the direct synthesis of a thin (but fragile) unsupported monolithic zeolite membrane [30]. Recent papers have reported on the preparation of zeolite composite membranes by hydrothermal synthesis of a zeolite structure in (or on) a porous substrate [31-34]. These membranes can act as molecular sieve separators (Fig. 2), suggesting that dcfcct-frcc materials can be prepared in this way. The control of the thickness of the separative layer seems to be the key for the future of zeolite membranes. 

All the monolith composites were prepared at a 1 1 ratio between the magnesium silicate clay binder and the AC or alumina. After premixing of the dry powders by careful addition of water a dough was formed. This dough was extruded as honeycomb monolithic structures with parallel channels of square section at a cell density of 8 cells cm and a wall thickness of 0.9 mm using a Bonnot single screw extruder. 

Crynes et al. [41] continued the study of Kim et al. [40]. The novel monolithic froth reactor, with a monolithic section 0.42 m long and 5 cm in diameter, was used. Cordierite monoliths with a cell density of 62 cells/cm were stacked, one on top of another, to provide a structure 0.33 m long. The monoliths, washcoated with 7-alumina and impregnated with CuO, were tested at 383-423 K and 0.48-1.65 MPa. The liquid flow rate was varied from 0.4 to 3.5 cm sec", and the gas flow rate ranged from 15.8 to 50 cm sec". Phenol in a concentration of 5000 ppm was typically oxidized with air. The reaction rate versus the liquid flow rate showed a distinct maximum of approximately 2 mol g"t sec" at about 1.7 cm sec", while the dependence of the reaction rate on the gas flow rate was rather weak, with a tendency to decrease as the flow rate increased. 

Support - porous alumina - porous carbon - porous metal plate, disc, tube, monolith plate, tube, hollow fibre woven structures, disc, tube... 

The investigated structure (cf. fig. 1) consists of a pure nickel top layer (1.2mm thick), an FGM zone with a linear variation of the volume fraction (2.2mm thick), and a pure alumina bottom layer (0.45mm thick). Material data of the constituents are given in table 1, where Eh denotes the strain hardening modulus. The boundary conditions force all cross sections perpendicular to the monolithic/FGM interfaces to remain plane, i.e. the lefthand and the righthand side (as well as the viewing plane for three-dimensional considerations). The uniaxial load (which causes extension and bending for the present... 

The introduction of automobile exhaust catalysts in the United States and elsewhere has produced a major market for platinum-type oxidation and reduction systems. An innovative consequence of this industry has been the development of ceramic honeycombed monoliths as catalyst supports. These structures contain long, parallel channels of less than 0.1 mm in diameter, with about SO channels per square centimeter. The monolith is composed of cordierite (2MgO - 2AI2O) SSiOj) and is manufactured by extrusion. A wash coat of stabilized alumina is administered prior to deposition of the active metal, either by adsorption or impregnation methods. 

For the preparation of washcoated monoliths the suspensions of sol-aluminium hydroxide with pseudoboehmite structure have been used. This sol formed during the reaction between the hydroxide and nitric acid serves both as a binder and a source of y-A Oa in the final product after calcination. Salts of additives were introduced into sol. The influence of the following parameters on the formation of thermostable washcoated layer have been studied concentration of anhydrous alumina in the sol amount of added HNO3 dipping time number of dippings drying and calcination duration. 

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