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The shift towards biomass and lower quality fossil fuel feedstocks will require new conversion approaches. Catalysis will be critical in the processing of these new feedstocks. By studying catalysis at industrially relevant conditions, it may be possible to reduce the time and cost of developing new catalyst systems. Microreactors enable the study of multiphase catalyst systems at pressures that were previously difficult to attain on the laboratory scale. The reduced length scales, characteristic of microchemical systems, provide additional benefits such as enhanced heat and mass transfer and a reduction of hazardous waste. The improved heat and mass transfer allow for kinetics to be probed at isothermal conditions in the absence of complicating mass transfer effects. A high-pressure microreactor system for catalyst study was designed, fabricated, and tested. The system allows for the multiphase study of homogenously and heterogeneously catalyzed systems, with a unique reactor designed for each application. A multicomponent gas phase is delivered simultaneously with a liquid stream, resulting in regular segmented (slug) flow. The isobaric system is operated at pressures of up to 100 bar. Gas and liquid flow rates, and therefore residence time, are specified independently of pressure. The system is capable of being operated at temperatures of up to 350°C and residence times of up to 15 minutes. Inline analysis, using an attenuated total reflection FTIR flow cell, and sample collection for offline analysis can be performed simultaneously. Both homogeneous and heterogeneous catalysis were demonstrated in the high-pressure system. A kinetic expression was derived for the homogeneous hydroformylation of terminal alkenes, catalyzed by Wilkinson's catalyst. The empirical reaction orders for the dependence on catalyst, hydrogen, and carbon monoxide were determined, along with the activation energy and pre-exponential factor. These results were then reconciled with a mechanistic model. The hydrogenation of cyclohexene over platinum catalysts was chosen to demonstrate the performance of the heterogeneous reactor. This reaction proceeded rapidly allowing mass transfer to be characterized in the microreactor. Observed mass transfer rates were two orders of magnitude higher than in traditional systems.
Provides a holistic approach to multiphase catalytic reactors from their modeling and design to their applications in industrial manufacturing of chemicals Covers theoretical aspects and examples of fixed-bed, fluidized-bed, trickle-bed, slurry, monolith and microchannel reactors Includes chapters covering experimental techniques and practical guidelines for lab-scale testing of multiphase reactors Includes mathematical content focused on design equations and empirical relationships characterizing different multiphase reactor types together with an assortment of computational tools Involves detailed coverage of multiphase reactor applications such as Fischer-Tropsch synthesis, fuel processing for fuel cells, hydrotreating of oil fractions and biofuels processing
This book is a printed edition of the Special Issue "Design and Engineering of Microreactor and Smart-Scaled Flow Processes" that was published in Processes
Microreactors have been demonstrated to provide many advantages over conventional process technologies for the synthesis of chemical compounds and kinetic studies at the laboratory scale. High heat and mass transfer rates, rapid mixing, and higher selectivities and conversions can be achieved in these microdevices thanks to the small characteristic dimensions, enabling the synthesis of compounds that cannot be synthesized in conventional reactors. In the past years, efforts have been directed towards the application of microreactor technology for production purposes, especially in the pharmaceutical and fine chemicals industry. The challenge is how to get benefit of the transport rates inherent to microreactors while increasing the throughput for production applications. Two approaches to increase production rate are possible: a) scale-out by parallelization of units; b) scale-up by increase in channel size and flow rates. Scale-out would require thousands of units to achieve kg/min of production rates and development of very expensive and complex control systems to ensure identical operating conditions in each unit for a perfect and predictable overall reactor performance. On the other hand, scale-up by increase in channel size risks losing mass and heat transfer performance. The Advanced-Flow Reactor (AFR) manufactured by Corning Inc. combines both approaches being able to yield production rates of 10 - 300 g/min per module. If the AFR is demonstrated to perform efficiently and to be easily scalable, it may become an alternative for process intensification and transition from batch to continuous in the pharmaceutical and fine chemicals industry. Additional advantages include shorter process development times thanks to the scalability of the reactor modules, higher selectivities and yields, greener production processes, and possibility of introducing new chemistries. In this context, fundamental understanding of the hydrodynamics for multiphase systems is essential and critical for process development and scale-up purposes. The objective of this thesis is to study both experimentally and through computational fluid dynamic simulations the hydrodynamic characteristics of the AFR to demonstrate the capabilities of this technology using non-reactive (hexane/water) and reactive systems (carbon dioxide/water, ozone/alkene) at ambient conditions.
"Catalytic Microreactors for Portable Power Generation” addresses a problem of high relevance and increased complexity in energy technology. This thesis outlines an investigation into catalytic and gas-phase combustion characteristics in channel-flow, platinum-coated microreactors. The emphasis of the study is on microreactor/microturbine concepts for portable power generation and the fuels of interest are methane and propane. The author carefully describes numerical and experimental techniques, providing a new insight into the complex interactions between chemical kinetics and molecular transport processes, as well as giving the first detailed report of hetero-/homogeneous chemical reaction mechanisms for catalytic propane combustion. The outcome of this work will be widely applied to the industrial design of micro- and mesoscale combustors.
Numerical simulation of multiphase reactors with continuous liquid phase provides current research and findings in multiphase problems, which will assist researchers and engineers to advance this field. This is an ideal reference book for readers who are interested in design and scale-up of multiphase reactors and crystallizers, and using mathematical model and numerical simulation as tools. Yang and Mao’s book focuses on modeling and numerical applications directly in the chemical, petrochemical, and hydrometallurgical industries, rather than theories of multiphase flow. The content will help you to solve reacting flow problems and/or system design/optimization problems. The fundamentals and principles of flow and mass transfer in multiphase reactors with continuous liquid phase are covered, which will aid the reader’s understanding of multiphase reaction engineering. Provides practical applications for using multiphase stirred tanks, reactors, and microreactors, with detailed explanation of investigation methods Presents the most recent research efforts in this highly active field on multiphase reactors and crystallizers Covers mathematical models, numerical methods and experimental techniques for multiphase flow and mass transfer in reactors and crystallizers
The chemical industry is essential in the daily humn life of modern society; despite the misconception about the real need for chemical production, everyone enjoys the benefit of the chemical progress. However, the chemical industry generates a large variety of products, including (i) basic chemicals, e.g., polymers, petrochemicals, and basic inorganics; (ii) specialty chemicals for crop protection, paints, inks, colorants, textiles, paper, and engineering; and (iii) consumer chemicals, including detergents, soaps, etc. For these reasons, chemists in both acdemia and industry are challenged with developing green and sustainable chemical production towrad the full-recycling of feedstocks and waste. Aiming to improve the intensification of the process, chemists have established chemical reactions based on catalysis, as well as alternative technologies, such as continuous flow. The aim of this book is to cover promising recent research and novel trends in the field of novel catalytic reactions (homogeneous, heterogeneous, and enzymatic, as well as their combinations) in continuous flow conditions. A collection of recent contribution for conversion of starting material originated from petroleum resources or biomass into highly-added value chemicals are reported.
Process Intensification: Engineering for Efficiency, Sustainability and Flexibility is the first book to provide a practical working guide to understanding process intensification (PI) and developing successful PI solutions and applications in chemical process, civil, environmental, energy, pharmaceutical, biological, and biochemical systems. Process intensification is a chemical and process design approach that leads to substantially smaller, cleaner, safer, and more energy efficient process technology. It improves process flexibility, product quality, speed to market and inherent safety, with a reduced environmental footprint. This book represents a valuable resource for engineers working with leading-edge process technologies, and those involved research and development of chemical, process, environmental, pharmaceutical, and bioscience systems. No other reference covers both the technology and application of PI, addressing fundamentals, industry applications, and including a development and implementation guide Covers hot and high growth topics, including emission prevention, sustainable design, and pinch analysis World-class authors: Colin Ramshaw pioneered PI at ICI and is widely credited as the father of the technology