Novel catalysts concepts

Although the discussion reported here will be mainly in reference to titania nanostructured films, the opportunities and problems analyzed are of more general interest and regard how to use the concept of bidimensional nanostructured oxide films to prepare novel catalysts with tailored nano-architectures. 

Special catalysts have also been studied and developed for low-temperature and clean-gas applications They comprehend both metal-oxide-based and noble-metal-based catalysts and apply novel design concepts, as presented in a subsequent paragraph... 

An alternative to filling or coating with a catalyst layer the microcharmels, with the related problems of avoiding maldistribution, which leads to a broad residence time distribution (RTD), is to create the microchannels between the void space left from a close packing of parallel filaments or wires. This novel MSR concept has been applied for the oxidative steam reforming of methanol [173]. Thin linear metallic wires, with diameters in the millimeter range, were close packed and introduced into a macro tubular reactor. The catalyst layer was grown on the external surface of these wires by thermal treatment. 

Novel Catalysts. - One other promising option exists that might, in the long run, lead to a viable alternative to the above process concepts. Recent advances in biomimetic catalysis have resulted in the development of molecular catalysts that are selective in liquid-phase oxidation of C,-Cj aliphatic hydrocarbons under mild conditions. The catalysts have now been placed on suitable support materials for vapor-phase oxidation of methane to methanol. Significant laboratory research is still required on the properties and synthesis of these special molecular catalysts before process conditions, products, and yields can be defined, even on a laboratory scale. 

Reaction engineers are expected to transform laboratory discoveries of new synthesis routes or design concepts into economic, safe, and environmentally compatible processes. The highly competitive industrial environment has added the need to shorten the time interval in which this task has to be completed and to decrease the production price. This motivated several innovations. The first was development of novel catalysts, which increased the yield in existing processes, such as the novel Kellogg ammonia-synthesis process, which uses the much more active BP catalyst. Other catalysts were designed to provide either new synthesis routes, such as the production of synthesis gas by direct oxidation, or new products, such as production of novel polymers by metallocene catalysts. 

Clusters are intennediates bridging the properties of the atoms and the bulk. They can be viewed as novel molecules, but different from ordinary molecules, in that they can have various compositions and multiple shapes. Bare clusters are usually quite reactive and unstable against aggregation and have to be studied in vacuum or inert matrices. Interest in clusters comes from a wide range of fields. Clusters are used as models to investigate surface and bulk properties [2]. Since most catalysts are dispersed metal particles [3], isolated clusters provide ideal systems to understand catalytic mechanisms. The versatility of their shapes and compositions make clusters novel molecular systems to extend our concept of chemical bonding, stmcture and dynamics. Stable clusters or passivated clusters can be used as building blocks for new materials or new electronic devices [4] and this aspect has now led to a whole new direction of research into nanoparticles and quantum dots (see chapter C2.17). As the size of electronic devices approaches ever smaller dimensions [5], the new chemical and physical properties of clusters will be relevant to the future of the electronics industry. 

P. Oser, Catalyst Systems with and Emphasis on Three-Way Conversion and Novel Concepts, SAE 790306, Society of Automotive Engineers, Warrendale, Pa., 1979. 

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