Catalytic Reactor Support Structure for Hydrogenation
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Solution Overview
Problem
Industrial-scale hydrogenation reactors face challenges in achieving a balance between maximizing catalyst contact area and minimizing flow resistance, leading to potential catalyst breakage and reduced reactor performance due to high pressure losses and mechanical instability.
Innovation Solution
A catalytic reactor with a support structure formed from material webs with a dense three-dimensional network and a crosslinking density of at least 3 mm−3, having a thickness of 5 to 25 μm, made from metals like cobalt, nickel, and copper, which provides a high catalyst contact area while maintaining mechanical stability and low flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the catalyst contact area is increased to improve reaction efficiency, then the productivity is improved, but the flow resistance increases leading to higher pressure losses
Solution Approach 1:
The support structure is designed as a three-dimensional network of crosslinked material webs with controlled porosity, creating a porous medium that provides extensive catalyst contact area while maintaining open flow paths. The interconnected pore structure allows reaction medium to flow through with reduced resistance despite the high surface area available for catalysis.
Solution Approach 2:
The invention transitions from traditional granular or pellet catalyst supports to a three-dimensional network structure. This dimensional change creates a spatially distributed architecture where material webs form a continuous framework throughout the reactor volume, simultaneously providing catalyst support surface area and maintaining fluid flow channels in three dimensions.
2Productivity
If fine-grained bulk material is used to increase catalyst contact area, then the productivity is improved, but the mechanical stability decreases leading to catalyst breakage
Solution Approach 1:
The support structure combines material webs crosslinked to form a composite three-dimensional network. This composite architecture integrates the benefits of fine-grained materials (high surface area) with the mechanical robustness of a continuous network framework, preventing catalyst breakage while maintaining high catalyst contact area.
Solution Approach 2:
The support structure is segmented into interconnected material webs rather than using solid granules. This segmentation creates a flexible network that can distribute mechanical stresses throughout the structure, preventing localized failure and catalyst breakage while maintaining the fine-grained characteristics needed for high catalyst contact area.
3Productivity
If fine-grained bulk material is used to maximize catalyst contact area, then the productivity is improved, but the flow resistance increases
Solution Approach 1:
The three-dimensional network of crosslinked material webs creates a porous structure with controlled pore size and distribution. This porous architecture provides extensive catalyst contact area through the material web surfaces while the interconnected pore spaces maintain low flow resistance by allowing smooth fluid passage through the support structure.
4Productivity
If the reaction medium fills the fixed bed to high volume to improve contact, then the productivity is improved, but the pressure losses increase
Solution Approach 1:
The three-dimensional network structure allows the reaction medium to access catalyst surfaces throughout the entire reactor volume more efficiently. The spatially distributed material webs create multiple flow paths and reduce flow velocity at any given point, maintaining high contact efficiency while reducing pressure losses compared to traditional packed beds.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The reactor achieves high catalyst contact area with reduced flow resistance, preventing catalyst breakage and enhancing reactor performance by allowing efficient reaction medium flow, reducing pressure losses, and extending maintenance intervals, thus improving yield and operational safety.
Implementation Method 1
a support structure formed from material webs that has a dense three-dimensional network of crosslinks
Implementation Method 2
catalytic hydrogenation processes... with the use of catalytic contacts
Implementation Method 3
The reaction itself takes place on the catalyst (contact)
Implementation Method 4
the gases... and/or liquids (fluids) to be reacted flow through the reactor
Implementation Method 5
Hydrogenation reactions are exothermic. The enthalpy of reaction is normally within a range of 105-125 kJ per mol Hz
Data Source
AI summary
A catalytic reactor for industrial-scale hydrogenation processes is described. The catalytic reactor contains a catalytic fixed bed that comprises a support structure and a catalyst. During operation of the reaction in the catalytic reactor, the fixed bed is filled with reaction medium to at least 85% by volume. A very high contact area of the catalyst with the reaction medium is at the same time provided. The support structure is formed from material webs having a thickness of 5 to 25 μm, with a crosslinking density of at least 3 mm−3 present. The support structure consists of metals selected from elements of groups 8, 6 and 11 of the periodic table of the elements and mixtures thereof.