Title: Catalysis Engineering, a Multi-level Approach

Abstract:

Catalysis plays an important role in Chemical Process technology. It is the enabling technology for good chemical manufacturing processes. Catalysis as a discipline is not just a part of chemistry or physics but it also is an engineering discipline. Chemical and physical aspects are often scale-independent but in the engineering disciplines usually, the scale of the operation plays a role. In catalysis, both scale- independent and scale-dependent phenomena play a role. The reaction mechanism and structure of the active sites are usually scale-independent. Reactor design studies belong to the realm of chemical reaction engineering and are clearly dependent on the scale. In catalysis good contact between reactants and active sites is essential and the contact is, in general, scale-dependent. An integrated approach of catalysis research and development covering aspects of (bio) chemistry and physics and chemical reaction engineering, referred to as ‘Catalysis Engineering ‘, is rewarding. It is appropriate to distinguish three levels, the microlevel, focusing on molecules and catalytic sites, the mesolevel focusing on the catalyst particle and the reactor, and the macro level, considering the total process. This lecture focuses mainly on multiphase (G/L) systems.

On the microlevel, the scale-independent information is collected. Thermodynamics defines the possible window of operation and heats of reaction. Information on kinetics is crucial. On the mesolevel, fascinating developments are visible in the field of structuring the space. On the one hand, at the scale of the particle, optimal porosity (optimal hierarchal pore networks consisting of micro-, meso- and macropores) is important. On the other hand, structured reactors often outperform conventional reactors such as packed bed reactors. Pros of fixed bed reactors are high catalyst loading, convenience, low cost and often the possibility to use commercially available catalysts; cons are maldistribution, leading to non-uniform concentration profiles and even hot spots, internal diffusion limitations that might lead to reduced activity and selectivity. In a packed bed reactor hydrodynamics and mass transfer rates are coupled to particle shape and size. In a structured reactor, more degrees of freedom exist. For instance, dependent on the design, particle sizes can be chosen to be much smaller than those in packed beds. Structured reactors allow a high efficiency, based on a high mass transfer rate at relatively low energy dissipation. The low energy dissipation is related with the hydrodynamics regime: laminar rather than turbulent. In addition, in multiphase flow under most practical conditions, the flow pattern is that of segmented flow (called Taylor flow), resulting in large gas-liquid mass transport rates. Structured reactors have a large potential in Process Intensification. From a chemical engineering point of view, the intrinsic scalability of these reactors is intriguing.

It is not wise to carry out the research aimed at developing a good catalyst separately from the reactor design. It does not make sense to develop the best possible catalyst and to use it in an unsatisfactory reactor. Both the catalyst and the reactor should be optimal. In addition, it does not make sense to develop a catalyst and reactors without attention to the macro- level. In all stages of process development or improvement, the (conceptual) process design should play a role.

The benefits of a multi-level approach will be illustrated with practical examples.

Biography:

Jacob A. Moulijn is emeritus Professor of Chemical Engineering at the Delft University of Technology (19902007) and at the University of Amsterdam (1986-1990), visiting professor at several universities, including University of Delaware, USA, University of Gent, Belgium, National University of Singapore the University of Mumbai, India and Cardiff University, UK. During the nineties he was active in China for the UN-World Bank. He is active as consultant for several companies. He is the recipient of an Honorary Doctorate of the Åbo University, Finland and received several awards, including the BP Energy Price, and the NWO-STW ‘Simon Stevin Meesterschap’ award (2000). His research interests include: catalysis engineering, catalytic reactors, zeolitic membranes, kinetics, mass transfer, multiphase monolithic reactors, catalyst testing, petroleum conversion (Hydrotreatment, FCC, FischerTropsch), exhaust gas catalysis (soot from diesel engines, N2O removal, NO abatement, H2S removal, CFC conversion), selective hydrogenation, selective oxidation, photo- and electrocatalysis, catalyst synthesis by Atomic Layer Deposition (ALD), coal conversion (gasification, pyrolysis, combustion), and biomass conversion. He is (co-) author of over 750 technical papers, co-author of two books, editor of seven books, holder of several patents (reactor design, zeolitic membranes, catalyst development, biomass conversion).

Title: Catalysis Engineering, a Multi-level Approach

Abstract:

Catalysis plays an important role in Chemical Process technology. It is the enabling technology for good chemical manufacturing processes. Catalysis as a discipline is not just a part of chemistry or physics but it also is an engineering discipline. Chemical and physical aspects are often scale-independent but in the engineering disciplines usually, the scale of the operation plays a role. In catalysis, both scale- independent and scale-dependent phenomena play a role. The reaction mechanism and structure of the active sites are usually scale-independent. Reactor design studies belong to the realm of chemical reaction engineering and are clearly dependent on the scale. In catalysis good contact between reactants and active sites is essential and the contact is, in general, scale-dependent. An integrated approach of catalysis research and development covering aspects of (bio) chemistry and physics and chemical reaction engineering, referred to as ‘Catalysis Engineering ‘, is rewarding. It is appropriate to distinguish three levels, the microlevel, focusing on molecules and catalytic sites, the mesolevel focusing on the catalyst particle and the reactor, and the macro level, considering the total process. This lecture focuses mainly on multiphase (G/L) systems.

On the microlevel, the scale-independent information is collected. Thermodynamics defines the possible window of operation and heats of reaction. Information on kinetics is crucial. On the mesolevel, fascinating developments are visible in the field of structuring the space. On the one hand, at the scale of the particle, optimal porosity (optimal hierarchal pore networks consisting of micro-, meso- and macropores) is important. On the other hand, structured reactors often outperform conventional reactors such as packed bed reactors. Pros of fixed bed reactors are high catalyst loading, convenience, low cost and often the possibility to use commercially available catalysts; cons are maldistribution, leading to non-uniform concentration profiles and even hot spots, internal diffusion limitations that might lead to reduced activity and selectivity. In a packed bed reactor hydrodynamics and mass transfer rates are coupled to particle shape and size. In a structured reactor, more degrees of freedom exist. For instance, dependent on the design, particle sizes can be chosen to be much smaller than those in packed beds. Structured reactors allow a high efficiency, based on a high mass transfer rate at relatively low energy dissipation. The low energy dissipation is related with the hydrodynamics regime: laminar rather than turbulent. In addition, in multiphase flow under most practical conditions, the flow pattern is that of segmented flow (called Taylor flow), resulting in large gas-liquid mass transport rates. Structured reactors have a large potential in Process Intensification. From a chemical engineering point of view, the intrinsic scalability of these reactors is intriguing.

It is not wise to carry out the research aimed at developing a good catalyst separately from the reactor design. It does not make sense to develop the best possible catalyst and to use it in an unsatisfactory reactor. Both the catalyst and the reactor should be optimal. In addition, it does not make sense to develop a catalyst and reactors without attention to the macro- level. In all stages of process development or improvement, the (conceptual) process design should play a role.

The benefits of a multi-level approach will be illustrated with practical examples.

Biography:

Jacob A. Moulijn is emeritus Professor of Chemical Engineering at the Delft University of Technology (19902007) and at the University of Amsterdam (1986-1990), visiting professor at several universities, including University of Delaware, USA, University of Gent, Belgium, National University of Singapore the University of Mumbai, India and Cardiff University, UK. During the nineties he was active in China for the UN-World Bank. He is active as consultant for several companies. He is the recipient of an Honorary Doctorate of the Åbo University, Finland and received several awards, including the BP Energy Price, and the NWO-STW ‘Simon Stevin Meesterschap’ award (2000). His research interests include: catalysis engineering, catalytic reactors, zeolitic membranes, kinetics, mass transfer, multiphase monolithic reactors, catalyst testing, petroleum conversion (Hydrotreatment, FCC, FischerTropsch), exhaust gas catalysis (soot from diesel engines, N2O removal, NO abatement, H2S removal, CFC conversion), selective hydrogenation, selective oxidation, photo- and electrocatalysis, catalyst synthesis by Atomic Layer Deposition (ALD), coal conversion (gasification, pyrolysis, combustion), and biomass conversion. He is (co-) author of over 750 technical papers, co-author of two books, editor of seven books, holder of several patents (reactor design, zeolitic membranes, catalyst development, biomass conversion).

Title: Catalysis Engineering, a Multi-level Approach

Abstract:

Catalysis plays an important role in Chemical Process technology. It is the enabling technology for good chemical manufacturing processes. Catalysis as a discipline is not just a part of chemistry or physics but it also is an engineering discipline. Chemical and physical aspects are often scale-independent but in the engineering disciplines usually, the scale of the operation plays a role. In catalysis, both scale- independent and scale-dependent phenomena play a role. The reaction mechanism and structure of the active sites are usually scale-independent. Reactor design studies belong to the realm of chemical reaction engineering and are clearly dependent on the scale. In catalysis good contact between reactants and active sites is essential and the contact is, in general, scale-dependent. An integrated approach of catalysis research and development covering aspects of (bio) chemistry and physics and chemical reaction engineering, referred to as ‘Catalysis Engineering ‘, is rewarding. It is appropriate to distinguish three levels, the microlevel, focusing on molecules and catalytic sites, the mesolevel focusing on the catalyst particle and the reactor, and the macro level, considering the total process. This lecture focuses mainly on multiphase (G/L) systems.

On the microlevel, the scale-independent information is collected. Thermodynamics defines the possible window of operation and heats of reaction. Information on kinetics is crucial. On the mesolevel, fascinating developments are visible in the field of structuring the space. On the one hand, at the scale of the particle, optimal porosity (optimal hierarchal pore networks consisting of micro-, meso- and macropores) is important. On the other hand, structured reactors often outperform conventional reactors such as packed bed reactors. Pros of fixed bed reactors are high catalyst loading, convenience, low cost and often the possibility to use commercially available catalysts; cons are maldistribution, leading to non-uniform concentration profiles and even hot spots, internal diffusion limitations that might lead to reduced activity and selectivity. In a packed bed reactor hydrodynamics and mass transfer rates are coupled to particle shape and size. In a structured reactor, more degrees of freedom exist. For instance, dependent on the design, particle sizes can be chosen to be much smaller than those in packed beds. Structured reactors allow a high efficiency, based on a high mass transfer rate at relatively low energy dissipation. The low energy dissipation is related with the hydrodynamics regime: laminar rather than turbulent. In addition, in multiphase flow under most practical conditions, the flow pattern is that of segmented flow (called Taylor flow), resulting in large gas-liquid mass transport rates. Structured reactors have a large potential in Process Intensification. From a chemical engineering point of view, the intrinsic scalability of these reactors is intriguing.

It is not wise to carry out the research aimed at developing a good catalyst separately from the reactor design. It does not make sense to develop the best possible catalyst and to use it in an unsatisfactory reactor. Both the catalyst and the reactor should be optimal. In addition, it does not make sense to develop a catalyst and reactors without attention to the macro- level. In all stages of process development or improvement, the (conceptual) process design should play a role.

The benefits of a multi-level approach will be illustrated with practical examples.

Biography:

Jacob A. Moulijn is emeritus Professor of Chemical Engineering at the Delft University of Technology (19902007) and at the University of Amsterdam (1986-1990), visiting professor at several universities, including University of Delaware, USA, University of Gent, Belgium, National University of Singapore the University of Mumbai, India and Cardiff University, UK. During the nineties he was active in China for the UN-World Bank. He is active as consultant for several companies. He is the recipient of an Honorary Doctorate of the Åbo University, Finland and received several awards, including the BP Energy Price, and the NWO-STW ‘Simon Stevin Meesterschap’ award (2000). His research interests include: catalysis engineering, catalytic reactors, zeolitic membranes, kinetics, mass transfer, multiphase monolithic reactors, catalyst testing, petroleum conversion (Hydrotreatment, FCC, FischerTropsch), exhaust gas catalysis (soot from diesel engines, N2O removal, NO abatement, H2S removal, CFC conversion), selective hydrogenation, selective oxidation, photo- and electrocatalysis, catalyst synthesis by Atomic Layer Deposition (ALD), coal conversion (gasification, pyrolysis, combustion), and biomass conversion. He is (co-) author of over 750 technical papers, co-author of two books, editor of seven books, holder of several patents (reactor design, zeolitic membranes, catalyst development, biomass conversion).

Title: Catalysis Engineering, a Multi-level Approach

Abstract:

Catalysis plays an important role in Chemical Process technology. It is the enabling technology for good chemical manufacturing processes. Catalysis as a discipline is not just a part of chemistry or physics but it also is an engineering discipline. Chemical and physical aspects are often scale-independent but in the engineering disciplines usually, the scale of the operation plays a role. In catalysis, both scale- independent and scale-dependent phenomena play a role. The reaction mechanism and structure of the active sites are usually scale-independent. Reactor design studies belong to the realm of chemical reaction engineering and are clearly dependent on the scale. In catalysis good contact between reactants and active sites is essential and the contact is, in general, scale-dependent. An integrated approach of catalysis research and development covering aspects of (bio) chemistry and physics and chemical reaction engineering, referred to as ‘Catalysis Engineering ‘, is rewarding. It is appropriate to distinguish three levels, the microlevel, focusing on molecules and catalytic sites, the mesolevel focusing on the catalyst particle and the reactor, and the macro level, considering the total process. This lecture focuses mainly on multiphase (G/L) systems.

On the microlevel, the scale-independent information is collected. Thermodynamics defines the possible window of operation and heats of reaction. Information on kinetics is crucial. On the mesolevel, fascinating developments are visible in the field of structuring the space. On the one hand, at the scale of the particle, optimal porosity (optimal hierarchal pore networks consisting of micro-, meso- and macropores) is important. On the other hand, structured reactors often outperform conventional reactors such as packed bed reactors. Pros of fixed bed reactors are high catalyst loading, convenience, low cost and often the possibility to use commercially available catalysts; cons are maldistribution, leading to non-uniform concentration profiles and even hot spots, internal diffusion limitations that might lead to reduced activity and selectivity. In a packed bed reactor hydrodynamics and mass transfer rates are coupled to particle shape and size. In a structured reactor, more degrees of freedom exist. For instance, dependent on the design, particle sizes can be chosen to be much smaller than those in packed beds. Structured reactors allow a high efficiency, based on a high mass transfer rate at relatively low energy dissipation. The low energy dissipation is related with the hydrodynamics regime: laminar rather than turbulent. In addition, in multiphase flow under most practical conditions, the flow pattern is that of segmented flow (called Taylor flow), resulting in large gas-liquid mass transport rates. Structured reactors have a large potential in Process Intensification. From a chemical engineering point of view, the intrinsic scalability of these reactors is intriguing.

It is not wise to carry out the research aimed at developing a good catalyst separately from the reactor design. It does not make sense to develop the best possible catalyst and to use it in an unsatisfactory reactor. Both the catalyst and the reactor should be optimal. In addition, it does not make sense to develop a catalyst and reactors without attention to the macro- level. In all stages of process development or improvement, the (conceptual) process design should play a role.

The benefits of a multi-level approach will be illustrated with practical examples.

Biography:

Jacob A. Moulijn is emeritus Professor of Chemical Engineering at the Delft University of Technology (19902007) and at the University of Amsterdam (1986-1990), visiting professor at several universities, including University of Delaware, USA, University of Gent, Belgium, National University of Singapore the University of Mumbai, India and Cardiff University, UK. During the nineties he was active in China for the UN-World Bank. He is active as consultant for several companies. He is the recipient of an Honorary Doctorate of the Åbo University, Finland and received several awards, including the BP Energy Price, and the NWO-STW ‘Simon Stevin Meesterschap’ award (2000). His research interests include: catalysis engineering, catalytic reactors, zeolitic membranes, kinetics, mass transfer, multiphase monolithic reactors, catalyst testing, petroleum conversion (Hydrotreatment, FCC, FischerTropsch), exhaust gas catalysis (soot from diesel engines, N2O removal, NO abatement, H2S removal, CFC conversion), selective hydrogenation, selective oxidation, photo- and electrocatalysis, catalyst synthesis by Atomic Layer Deposition (ALD), coal conversion (gasification, pyrolysis, combustion), and biomass conversion. He is (co-) author of over 750 technical papers, co-author of two books, editor of seven books, holder of several patents (reactor design, zeolitic membranes, catalyst development, biomass conversion).