Structuring catalyst and reactor – an inviting avenue to process intensification

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Abstract

Multiphase catalytic processes involve the combination of scale-dependent and scale-independent phenomena, often resulting in a compromised, sub-optimal performance.

Multiphase catalytic processes involve the combination of scale-dependent and scale-independent phenomena, often resulting in a compromised, sub-optimal performance. The classical approach of randomly packed catalyst beds using unstructured catalyst particles may be outperformed by the careful design of the catalyst at the nano-scale and by the judicious choice and design of reactor. Application of structured catalysts and reactor internals and the combination of advanced reactor and catalyst systems with in situ separation allow decoupling the various phenomena involved, opening the way to intensified processes on a large scale. The integral approach of Catalysis and Reaction Engineering discussed here will play a pivotal role in the development of novel, future-proof processes.

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Stable single-unit-cell nanosheets of zeolite MFI as active and long-lived catalysts.

Minkee Choi, Kyungsu Na, Jeongnam Kim … (2009)

Zeolites-microporous crystalline aluminosilicates-are widely used in petrochemistry and fine-chemical synthesis because strong acid sites within their uniform micropores enable size- and shape-selective catalysis. But the very presence of the micropores, with aperture diameters below 1 nm, often goes hand-in-hand with diffusion limitations that adversely affect catalytic activity. The problem can be overcome by reducing the thickness of the zeolite crystals, which reduces diffusion path lengths and thus improves molecular diffusion. This has been realized by synthesizing zeolite nanocrystals, by exfoliating layered zeolites, and by introducing mesopores in the microporous material through templating strategies or demetallation processes. But except for the exfoliation, none of these strategies has produced 'ultrathin' zeolites with thicknesses below 5 nm. Here we show that appropriately designed bifunctional surfactants can direct the formation of zeolite structures on the mesoporous and microporous length scales simultaneously and thus yield MFI (ZSM-5, one of the most important catalysts in the petrochemical industry) zeolite nanosheets that are only 2 nm thick, which corresponds to the b-axis dimension of a single MFI unit cell. The large number of acid sites on the external surface of these zeolites renders them highly active for the catalytic conversion of large organic molecules, and the reduced crystal thickness facilitates diffusion and thereby dramatically suppresses catalyst deactivation through coke deposition during methanol-to-gasoline conversion. We expect that our synthesis approach could be applied to other zeolites to improve their performance in a range of important catalytic applications.

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Hierarchical zeolites: enhanced utilisation of microporous crystals in catalysis by advances in materials design.

Javier Pérez-Ramírez, Claus H Christensen, Kresten Egeblad … (2008)

The introduction of synthetic zeolites has led to a paradigm shift in catalysis, separations, and adsorption processes, due to their unique properties such as crystallinity, high-surface area, acidity, ion-exchange capacity, and shape-selective character. However, the sole presence of micropores in these materials often imposes intracrystalline diffusion limitations, rendering low utilisation of the zeolite active volume in catalysed reactions. This critical review examines recent advances in the rapidly evolving area of zeolites with improved accessibility and molecular transport. Strategies to enhance catalyst effectiveness essentially comprise the synthesis of zeolites with wide pores and/or with short diffusion length. Available approaches are reviewed according to the principle, versatility, effectiveness, and degree of reality for practical implementation, establishing a firm link between the properties of the resulting materials and the catalytic function. We particularly dwell on the exciting field of hierarchical zeolites, which couple in a single material the catalytic power of micropores and the facilitated access and improved transport consequence of a complementary mesopore network. The carbon templating and desilication routes as examples of bottom-up and top-down methods, respectively, are reviewed in more detail to illustrate the benefits of hierarchical zeolites. Despite encircling the zeolite field, this review stimulates intuition into the design of related porous solids (116 references).