Thiele modulus, monolithic catalysts

Diffusion effects can be expected in reactions that are very rapid. A great deal of effort has been made to shorten the diffusion path, which increases the efficiency of the catalysts. Pellets are made with all the active ingredients concentrated on a thin peripheral shell and monoliths are made with very thin washcoats containing the noble metals. In order to convert 90% of the CO from the inlet stream at a residence time of no more than 0.01 sec, one needs a first-order kinetic rate constant of about 230 sec-1. When the catalytic activity is distributed uniformly through a porous pellet of 0.15 cm radius with a diffusion coefficient of 0.01 cm2/sec, one obtains a Thiele modulus y> = 22.7. This would yield an effectiveness factor of 0.132 for a spherical geometry, and an apparent kinetic rate constant of 30.3 sec-1 (106). 

To have a quantitative idea of the problem of intraparticle diffusion, effectiveness factors for the two catalysts were calculated from the observed second order rate constants (based on surface area) using the "triangle method" suggested by Saterfield (4). The effectiveness factors for Monolith and Nalcomo 474 catalysts on Synthoil liquid at 371°C (700 F) were calculated to be 0.94 and 0.216, respectively. In applying the relationship between the "Thiele Modulus," 4>> and the "effectiveness factor," n> the following simplifying assumptions were made ... 

Both studies show that at relatively low temperatures, i.e., during ignition of the catalyst, the rate-limiting step shifts from chemical kinetics to diffusion in the washcoat. This is clear from Fig. 7, computed using a one-dimensional model by Nakhjavan et al. [54]. Figure 7A shows the Thiele modulus and Fig. 7B an external diffusion limiting factor F versus dimensionless axial position in the reactor at various times on-stream for the catalytic combustion of propene in monolith reactors. The time is defined as the time after injection of the fuel in a preheated air flow. 

The conditions used for pellet forming can have a major influence on several important catalyst properties, including pore size distribution, pellet strength, and abrasion resistance. Both the size and shape of catalyst pellets affect the pressure drop across a packed bed reactor and also, as indicated earlier, affect the Thiele modulus and thus the effectiveness factor. Recently, monolith catalysts have begun to be used in circumstances where low-pressure drop and/or... 

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