Structured Catalyst with Resistance Heating for Compact Syngas Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Small-scale synthesis gas production is challenging due to energy-intensive reactions and the toxicity of carbon monoxide, making storage and handling difficult.
Innovation Solution
A structured catalyst with a three-dimensional network structure and ceramic coating supports a catalytically active material, optimized for electrical resistance and heat flux, allowing on-demand synthesis gas production in compact reactors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large-scale chemical plants are used for synthesis gas production, then energy-intensive reactions can proceed, but the plant size and complexity increase significantly
Solution Approach 1:
The catalyst is divided into modular macroscopic structures with standardized dimensions (e.g., 100mm length, specific cross-sections). These segmented modules can be arranged in different configurations within reactors, enabling scalable production capacity without proportionally increasing overall system complexity. The segmentation allows for easier manufacturing, handling, and replacement of catalyst components.
Solution Approach 2:
The invention uses composite macroscopic structures combining metal foam (providing mechanical strength and electrical conductivity) with ceramic coatings (providing catalytic activity and thermal stability). This composite approach enables small-scale reactors to achieve the thermal and mechanical properties previously only attainable in large-scale plants, while maintaining compact dimensions.
2Reliability
If synthesis gas is produced and stored, then energy supply can be maintained, but toxicity risks and storage difficulties increase
Solution Approach 1:
The macroscopic catalyst structures are electrically conductive and can be directly heated by passing electric current through them (Joule heating). This self-heating capability eliminates the need for external heating systems and allows rapid start-up and shutdown, enabling on-demand synthesis gas production without requiring large storage facilities. The system produces gas only when needed, reducing storage requirements and associated toxicity risks.
3Volume of moving object
If compact reactors are used for small-scale production, then plant size is reduced, but heat flux control and mass transfer performance may deteriorate
Solution Approach 1:
The macroscopic catalyst structures have non-uniform pore size distributions and wall thickness variations along their length, creating different local properties. The metal foam core provides high surface area for heat transfer, while the ceramic coating layers are optimized for catalytic activity. This local quality variation ensures efficient heat flux distribution and mass transfer throughout the compact reactor volume, maintaining high productivity despite reduced size.
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
Enables efficient, compact, and safe synthesis gas production in smaller plants with reduced gas storage and handling risks, using resistance heating to control heat flux and improve mass transfer performance.
Implementation Method 1
heat for the endothermic reaction is provided by resistance heating
Implementation Method 2
the ceramic coating supporting a catalytically active material
Data Source
AI summary
A structured catalyst for catalyzing an endothermic reaction of a feed gas to convert it to a product gas is provided.