Reactions porous catalyst structures

Reaction and Mass Transfer in Porous Catalyst Structures... 

Legal limits for the emissions of the main pollutants in the automobile exhaust gases are becoming more and more strict The development of new and advanced catalytic converters demands not only experimental work, but also extensive and detailed modelling and simulation studies. The models become more complex, when all the important physical and chemical phenomena arc considered. Particularly the use of non-stationary kinetic models (microkinetics) with surface deposition of reaction components (Jirtit et al., 1999, e.g.) and the incorporation of diffusion effects in porous catalyst structure lead to a large system of partial differential equations. 

To be able to model the processes of diffusion and reaction, one needs to know some parameters describing the porous catalyst structure. One characteristic parameter is the internal surface area, that can be determined with adsorption experiments. This is frequently expressed as units of area per gram of catalyst. In this text the specific internal surface area a. is used, with dimension m/tti or m ... 

Many theoretical embellishments have been made to the basic model of pore diffusion as presented here. Effectiveness factors have been derived for reaction orders other than first and for Hougen and Watson kinetics. These require a numerical solution of Equation (10.3). Shape and tortuosity factors have been introduced to treat pores that have geometries other than the idealized cylinders considered here. The Knudsen diffusivity or a combination of Knudsen and bulk diffusivities has been used for very small pores. While these studies have theoretical importance and may help explain some observations, they are not yet developed well enough for predictive use. Our knowledge of the internal structure of a porous catalyst is still rather rudimentary and imposes a basic limitation on theoretical predictions. We will give a brief account of Knudsen diffusion. 

Quantitative analytical treatments of the effects of mass transfer and reaction within a porous structure were apparently first carried out by Thiele (20) in the United States, Dam-kohler (21) in Germany, and Zeldovitch (22) in Russia, all working independently and reporting their results between 1937 and 1939. Since these early publications, a number of different research groups have extended and further developed the analysis. Of particular note are the efforts of Wheeler (23-24), Weisz (25-28), Wicke (29-32), and Aris (33-36). In recent years, several individuals have also extended the treatment to include enzymes immobilized in porous media or within permselective membranes. The important consequence of these analyses is the development of a technique that can be used to analyze quantitatively the factors that determine the effectiveness with which the surface area of a porous catalyst is used. For this purpose we define an effectiveness factor rj for a catalyst particle as... 

This section is concerned with analyses of simultaneous reaction and mass transfer within porous catalysts under isothermal conditions. Several factors that influence the final equation for the catalyst effectiveness factor are discussed in the various subsections. The factors considered include different mathematical models of the catalyst pore structure, the gross catalyst geometry (i.e., its apparent shape), and the rate expression for the surface reaction. 

When consecutive reactions take place within a porous catalyst, the concentrations of A and V within the pellet will be significantly different from those prevailing at the external surface. The intermediate V molecules formed within the pore structure have a high probability of reacting further before they can diffuse out of the pore. 

Skeletal (Raney ) catalysts are made by a very simple technique. An alloy of two metals in roughly equal proportions, where one metal is the desired catalytic material, and the other is dissolvable in hydroxide, is first made. This alloy is crashed and leached in concentrated hydroxide solution. The soluble metal selectively dissolves, leaving behind a highly porous spongelike structure of the desired catalytic metal. Catalysts formed by this technique show high activity and selectivity, and have found wide use in industry, particularly for hydrogenation and dehydrogenation reactions. 

Membranes can also be used as a reactor where catalysts are used frequently. The membrane may physically segregate the catalyst in the reactor, or have the catalyst immobilized in the porous/microporous structure or on the membrane surface. The membrane having the catalyst immobilized in/on it acts almost in the same way as a catalyst particle in a reactor does, except that separation of the product(s) takes place, in addition, through the membrane to the permeate side. All such configurations involve the bulk flow of the reaction mixture along the reactor length while diffusion of the reactants/products takes place generally in a perpendicular direction to/from the porous/microporous catalyst. 

As mentioned earlier, if the rate of a catalytic reaction is proportional to the surface area, then a catalyst with the highest possible area is most desirable and that is generally achieved by its porous structure. However, the reactants have to diffuse into the pores within the catalyst particle, and as a result a concentration gradient appears between the pore mouth and the interior of the catalyst. Consequently, the concentration at the exterior surface of the catalyst particle does not apply to die whole surface area and the pore diffusion limits the overall rate of reaction. The effectiveness factor tjs is used to account for diffusion and reaction in porous catalysts and is defined as... 

For the detailed study of reaction-transport interactions in the porous catalytic layer, the spatially 3D model computer-reconstructed washcoat section can be employed (Koci et al., 2006, 2007a). The structure of porous catalyst support is controlled in the course of washcoat preparation on two levels (i) the level of macropores, influenced by mixing of wet supporting material particles with different sizes followed by specific thermal treatment and (ii) the level of meso-/ micropores, determined by the internal nanostructure of the used materials (e.g. alumina, zeolites) and sizes of noble metal crystallites. Information about the porous structure (pore size distribution, typical sizes of particles, etc.) on the micro- and nanoscale levels can be obtained from scanning electron microscopy (SEM), transmission electron microscopy ( ), or other high-resolution imaging techniques in combination with mercury porosimetry and BET adsorption isotherm data. This information can be used in computer reconstruction of porous catalytic medium. In the reconstructed catalyst, transport (diffusion, permeation, heat conduction) and combined reaction-transport processes can be simulated on detailed level (Kosek et al., 2005). 

The industrial catalyst consists of a mixture of V2Os and K2S207 supported on silica. Under technical reaction conditions (>440°C), this mixture forms a viscous molten phase on the surface of the porous silica structure. Apparently a redox model can also be applied to such a system [154],... 

Diffusion and Reaction in a Porous Structure (Porous Catalyst Pellet)... 

Figure 2 shows a schematic of a porous catalyst slab that is supplied by reactant from the outer surface and in which reaction takes place at the internal catalytic surface. It is known in such systems that, when diffusion of species internally in the structure is slow in comparison to the rate of reaction, a variation in reactant concentration will occur in the catalyst. This variation in concentration changes the rate locally in the electrode. 

When modeling phenomena within porous catalyst particles, one has to describe a number of simultaneous processes (i) multicomponent diffusion of reactants into and out of the pores of the catalyst support, (ii) adsorption of reactants on and desorption of products from catalytic/support surfaces, and (iii) catalytic reaction. A fundamental understanding of catalytic reactions, i.e., cleavage and formation of chemical bonds, can only be achieved with the aid of quantum mechanics and statistical physics. An important subproblem is the description of the porous structure of the support and its optimization with respect to minimum diffusion resistances leading to a higher catalyst performance. Another important subproblem is the nanoscale description of the nature of surfaces, surface phase transitions, and change of the bonds of adsorbed species. 

After the spatially 2D or 3D model of the porous catalyst support and the distribution of catalyst are generated, the multicomponent diffusion, adsorption, and chemical reaction within this porous structure can be modeled. 

In the following example, we use a simple microkinetic model of CO oxidation on Pt together with the reconstructed porous catalyst to follow the evolution of local concentration profiles within the porous structure. The reaction-diffusion problem of the CO oxidation on the Pt/y-Al203 porous catalyst... 

The MCFC membrane electrode assembly (MEA) comprises three layers a porous lithiated NiO cathode structure and a porous Ni/NiCr alloy anode structure, sandwiching an electrolyte matrix (see detail below). To a first approximation, the porous, p-type semiconductor, nickel oxide cathode structure is compatible with the air oxidant, and a good enough electrical conductor. The nickel anode structure, coated with a granular proprietary reform reaction catalyst, is compatible with natural gas fuel and reforming steam, and is an excellent electrical conductor. As usual, the oxygen is the actual cathode and the fuel the anode. Hence the phrase porous electrode structure . 

Nanostructured microporous catalysts or catalyst supports offer intensified catalysis as they provide enhanced surface area accessible to the reactants and products. In nonstructured catalysts, although the surface area may be large, they are often inaccessible as a result of surface fouling and diffusion resistance can slow down the rate of reaction. In a recent development, microporous materials were used as templates for the solution deposition of metals, which were subsequently heat treated to obtain porous metallic structures, where the size of the pores ranged from 10 pm to lOnm. " The relative phase volume of these two regions can be controlled and the overall porosity can be in excess of 50%. Fig. 7 illustrates the size scale of structures ranging from 10 pm to 10 nm. 

---