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Structured Glass-Fiber
Catalysts
Structured Glass-Fiber
Catalysts
Authored by
Andrey Zagoruiko and Sergey Lopatin
CRC Press
Taylor & Francis Group
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Boca Raton, FL 33487–2742
© 2020 by Taylor & Francis Group, LLC
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vii
viii Contents
xi
Acknowledgments
The authors consider it their honor to express their gratitude to all their colleagues
and friends, without whom working on this paper would be impossible:
Dr. Pavel Mikenin, Danil Pisarev, Dmitry Baranov, Sergey Zazhigalov, Dr. Sergey
Vanag, Prof. Eugene Paukshtis, Dr. Tatyana Larina, Dr. Svetlana Cherepanova,
Dr. Svetlana Yashnik, Ilya Pakharukov, Dr. Oleg Klenov, Dr. Sergey Veniaminov,
Dr. Arkadii Ischenko, Nina Rudina, Dr. Nikolay Yazykov, Ksenia Golyashova,
Prof. Vadim Yakovlev (Boreskov Institute of Catalysis), Prof. Pavel Tsyrulnikov,
Dr. (Institute for Hydrocarbon Processing), Dr. Andrey Elyshev (Tyumen State
University), Yulia Kotolevich, Dr. Maxim Popov, Dr. Alexander Bannov, Ulyana
Ovchinnikova (Novosibirsk State Technical University), Dr. Alexander Zykov and
Sergey Anichkov (All-Russian Thermal Engineering Institute), who directly took
part in the described research.
Prof. Valentin Parmon, Prof. Valerii Kirillov, Dr. Alexander Kulikov, Prof. Gilbert
Froment, Ilya Zolotarskii, Prof. Yurii Matros, Dr Liudmila Bobrova, Dr. Nadezhda
Vernikovskaya, Dr. Grigorii Bunimovich, Prof. Gianpiero Groppi, Prof. Dan
luss, Prof. Anton Maximov, Vera Fadeeva, Igor Kim, Irina Kharina, Dr. Vassily
Kruglyakov, Tamara Yudina, Liubov Poleschuk, Dr. Alexey Suknev, Dr. Viktor
Chumachenko, Dr. Alyona Ovchinnikova, Prof. Alexander Noskov, Dr. Olga Chub,
Sergey Kildyashev, Prof. Sergey Reshetnikov, Valentina Shport—for useful discus-
sions, advice, inspiration, and support.
Vladimir Serbinenko and all team at Sibtransservice Co.; Dr. Yurii Zhukov, Viktor
Glotov, Vassily Yankilevich, Nikolay Proskokov (Byisk Oleum Plant); Alexander
Pateev (Moscow Metro); Dr. Alexander Beskopylnii and Andrey Kovalenko (Volgograd
department of Boreskov Institute of Catalysis); Nayil Gilmutdinov and Ilziya
Nazmieva (Nizhnekamskneftehim Co.)—for active support in the arrangement and
performance of the pilot and semi-industrial tests of GFCs.
Eugenia Bobatkova, who made a cover design and many excellent photographs for
this book; Olga Lopatina for the great editorial work of this book.
xiii
About the Authors
xv
1 Current State of Research
and Development in the
Field of Catalysts With
Various Shapes and Their
Practical Application
1.1. INTRODUCTION
Today, catalysts and catalytic technologies are at the root of the modern chemical
industry, oil and gas processing, and the petrochemical industry that produce criti-
cally important products such as basic chemicals, fuel, polymers, fertilizers, etc.
A variety of technologies for environmental protection and utilization of wastes are
also based on catalysts. Catalytic technologies play an increasing role in a new green
energy, as well as in the field of renewable feedstocks and fuel. Nowadays more than
90% of industrial products are manufactured with the use of catalysts; moreover,
they are involved in the production of the most advanced products with the high level
and depth of feedstock processing. The further development of energy production
and energy storage sectors, as well as novel industry in the direction of substantial
increase of feedstock, energy, and environmental efficiency is impossible without
advanced growth of catalytic processes.
The main progress drivers in catalysis can be identified as follows:
Engineering approaches to create a new catalytic technology are based on the fol-
lowing problems solutions:
The first and second problems noted are of special interest within the context of the
given work.
value of equivalent hydrodynamic diameter (with the same external size of the pel-
lets), and this allows a significant decrease of diffusion resistance. The drawbacks
of such pellets are the high technical complexity of their production and their lower
thermal stability, especially in cases of complex shapes (rings with internal bridges,
multilobes) and thermal shocks.
From the hydrodynamic properties point of view, the fixed beds of granular cata-
lysts have a good ability to turbulize the reaction fluids, even at low fluid velocities,
thereby providing a high intensity of heat and mass transfer.4 These beds are charac-
terized with full hydrodynamic isotropy, that is, the equality of hydraulic resistance
coefficients for fluid movement in any direction inside the bed. The last property,
along with the relatively high bed pressure drop, provides an excellent leveling abil-
ity of fixed granular beds, making it possible to minimize the non-uniformities of the
flow distribution across the bed volume.
On the other hand, the high pressure drop of the fixed granular beds may become
a significant disadvantage in catalytic reactors with high reaction fluid velocities.
1.3. MONOLITH CATALYSTS
A significant decrease of the catalyst pressure drop can be achieved by the appli-
cation of the structured catalysts, also known as monolith catalysts or honeycomb
blocks.5–8 Such catalysts represent themselves as blocks with a regular system of
straight parallel internal channels (see Figure 1.2).
The size of the channels usually varies in the range of a few tenths of a millimeter
up to a few millimeters; the cross-section of a channel can be square, rectangle, tri-
angle, polygon, or round. Minimum channel size is defined by pressure drop require-
ments and manufacturing complexity; the maximum size is limited by diffusion
resistance requirements. Externally the monolith may have a shape of a cylinder or
prism with a square, rectangle, or polygon cross-section. The external shape and size
of catalytic blocks are usually determined by the technological simplicity of their
production and application.
The base of monolith catalyst is typically made of thermo-stable ceramics, though
metal and carbon supports are also known.
The main advantage of monolith honeycomb catalysts is their extremely low pres-
sure drop, which is important for the performance of the catalytic reactions under
high velocities of fluid movements, for example, during purification of exhaust gases
in combustion engines or flue gases at thermal electric power plants.
From the internal fluid dynamics point of view, monolith blocks with parallel
channels have an absolute spatial anisotropy—the fluid can move inside them only
along the channels; it is impossible to move in any other direction. It makes any
redistribution of the flows between the channels impossible; therefore, the ability to
level the non-uniformities of the initial flow distribution across the inlet section is
zero. This drawback can be reduced by the application of the monoliths with inter-
channel fluid passages.9 However, such monoliths are hard to produce and are expen-
sive; hence, their practical application is very limited.
Another fluid dynamic problem is the laminar nature of the fluid flows inside the
channels even at high fluid velocities.10 This results in a low efficiency of heat and
mass transfer processes inside the blocks.
Ceramic catalytic monoliths are manufactured by extrusion of the support or
catalytic material with a further possible application of a secondary support and/or
an active component, in all cases followed by thermal treatment. Not every catalytic
material can be successfully extruded, and not every support with the applied active
component can successfully withstand the thermal treatment. This significantly lim-
its the range of the supports and catalytic materials that can be used in the production
of monolith catalysts and the variety of external shapes of the producing monoliths.
Moreover, the ceramic monoliths may have a low mechanical strength and a low
resistance to thermal shocks, which is even more important.
deactivation down to complete loss of activity. To some extent, this problem can be
solved by the use of aluminum-containing alloys as a primary support; for example,
in case of fechral alloy it is possible to create a firm film of alumina on the surface,
which can be used as a secondary support or as a substrate for the secondary sup-
port.24 However, the use of such supports is limited by their relatively low mechani-
cal strength and low ability to bear the mechanical processing, such as corrugation.
The use of massive flat ribbons as a support, as with monolith catalysts, will result
in the formation of laminar fluid with a relatively low efficiency of external mass
transfer. Moreover, the flow redistribution between channels will be also missing,
negatively influencing the uniformity of flow distribution in the block volume. These
problems can be overcome by application of the supports in the form of permeable
metal meshes, both flat and corrugated, as well as various structures made of a metal
wire.25–28 These structures, shown in Figure 1.5, have come to be known as wire-
mesh monoliths.
8 Structured Glass-Fiber Catalysts
In general, the catalysts on the base of fibrous supports are promising for the
development of novel catalytic structures, provided that the problems with making a
mechanically strong and thermally stable active component coverage at the surface
will be successfully solved.
REFERENCES
1. Boreskov G.K. 1986. Heterogeneous catalysis. Novosibirsk: Nauka.
2. Afandizadeh S., Foumeny E.A. 2001. Design of packed bed reactors: Guides to catalyst
shape, size, and loading selection. Appl Therm Eng. 21: 669–82.
3. Mariani N.J., Mocciaro C., Keegan S.D. et al. 2009. Evaluating the effectiveness factor
from a 1D approximation fitted at high Thiele modulus: Spanning commercial pellet
shapes with linear kinetics. Chem Eng Sci. 64: 2762–6.
4. Aerov M.E., Todes O.M., Narinskii D.A. 1979. Apparatuses with stationary granular
bed: Hydraulic and heat basis of operation. Leningrad: Chemistry.
5. Birtigh G., Parbel H., Sauer H. 1975. US Patent No.3926565. Apparatus for cleaning
exhaust gases.
6. Ridgway S.L. 1965. US Patent No.3211534. Exhaust control.
7. Boger T., Heibel A.K., Sorensen C.M. 2004. Monolithic catalysts for the chemical
industry. Ind Eng Chem Res. 43: 4602–11.
8. Mochida Shigeru, Kojima Masaru, Hijikata Toshihiko. 1983. US Patent No.4396664.
Ceramic honeycomb structural body.
9. Gulati S.T. 1977. US Patent No.4042738. Honeycomb structure with high thermal shock
resistance.
Current State of Research and Development 9
10. Klenov O.P., Pokrovskaya S.A., Chumakova N.A. et al. 2009. Effect of mass transfer on
the reaction rate in a monolithic catalyst with porous walls. Catal Today. 144: 258–64.
11. Pestryakov A.N., Fyodorov A.A., Shurov V.A. 1994. Foam metal catalysts with inter-
mediate support for deep oxidation of hydrocarbons. React Kinet Catal L. 53: 347–52.
12. Richardson J.T., Remue D., Hung J-K. 2003. Properties of ceramic foam catalyst sup-
ports: Mass and heat transfer. Appl Catal A-Gen. 250: 319–29.
13. Giani L., Groppi G., Tronconi E. 2005. Mass-transfer characterization of metallic
foams as supports for structured catalysts. Ind Eng Chem Res. 44: 4993–2.
14. Twigg M.V., Richardson J.T. 2007. Fundamentals and applications of structured ceramic
foam catalysts. Ind Eng Chem Res. 46: 4166–77.
15. Incera Garrido G., Patcas F.C., Lang S. et al. 2008. Mass transfer and pressure drop in
ceramic foams: A description for different pore sizes and porosities. Chem Eng Sci. 63:
5202–17.
16. Fischer F.C. 1933. US Patent No.1932927. Device for converting carbon monoxide.
17. Kirillov V.A., Bobrin A.S., Kuzin N.A. et al. 2004. Compact radial reactor with a
structured porous metal catalyst for the conversion of natural gas to synthesis gas:
Experiment and modeling. Ind Eng Chem Res. 43(16): 4721–31.
18. Sanz O., Echave F.J., Romero-Sarria F. et al. 2013. Advances in structured and micro-
structured catalytic reactors for hydrogen production. Renewable hydrogen tech-
nologies/ed. by L.M. Gandía, G. Arzamendi, P.M. Diéguez. Amsterdam: Elsevier.
Chapter 9: 201–24.
19. Retallick W.B. 1988. US Patent No.4762567. Washcoat for a catalyst support.
20. Fukuhara C., Hyodo R., Yamamoto K. et al. 2013. A novel nickel-based catalyst for
methane dry reforming: A metal honeycomb-type catalyst prepared by sol—gel method
and electroless plating. Appl Catal A-Gen. 468: 18–25.
21. Meille V. 2006. Review on methods to deposit catalysts on structured surfaces. Appl
Catal A- Gen. 315: 1–17.
22. Pacheco Benito S., Lefferts L. 2010. The production of a homogeneous and well-
attached layer of carbon nanofibers on metal foils. Carbon. 48(10): 2862–72.
23. Seijger G.B.F., Palmaro S.G., Krishna K. et al. 2002. In situ preparation of ferrierite
coatings on structured metal supports. Micropor Mesopor Mat. 56(1): 33–45.
24. Sigaeva S., Temerev V.L., Borisov V.A. et al. 2015. Pyrolysis of methane on fechral
resistive catalyst with additions of hydrogen or oxygen to the reaction mixture. Catalysis
in Industry. 7(3): 171–4.
25. Jiang Z., Chung K-S., Kim G-R. et al. 2003. Mass transfer characteristics of wire-mesh
honeycomb reactors. Chem Eng Sci. 58: 1103–11.
26. Sun H., Shu Y., Quan X. et al. 2010. Experimental and modeling study of selective
catalytic reduction of NOx with NH3 over wire mesh honeycomb catalysts. Chem Eng
J. 165: 769–75.
27. Banús E.D., Sanz O., Milt V.G. et al. 2014. Development of a stacked wire-mesh struc-
ture for diesel soot combustion. Chem Eng J. 246: 353–65.
28. Porsin A.V., Kulikov A.V., Rogozhnikov V.N. et al. 2015. Catalytic reactor with metal
gauze catalysts for combustion of liquid fuel. Chem Eng J. 282: 233–40.
2 Glass-Fiber Catalysts
2.1. GENERAL DESCRIPTION
Glass-fiber catalysts (GFCs) are a revolutionary type of catalytic system that uti-
lize glass microfibers as structured supports (see Figure 2.1). Active components for
these systems are usually selected from a wide range of various metals (Pt, Pd, Rh,
Ir, Ag, Au, Fe, Cr, Co, N, Mn, Pb, Cu, etc.) and/or their oxides, depending on the
specifics of the target application.
These catalysts have been known about for a rather long time,1–9 but active devel-
opment and research on GFCs started only in 1990s in the Institute of Chemical
Physics of the Russian Academy of Sciences under the guidance of Professor V.
V. Barelko.10–13 Since the late 1990s, systematic studies of GFCs, mostly based on
the use of the noble metals (Pt, Pd), have been started at the Boreskov Institute of
Catalysis.14–30
It has been shown that GFCs demonstrate high activity and selectivity toward
the target products in a number of reactions; moreover, they also show high resis-
tance to deactivation in various aggressive media.20,27–34 Their major advantage is
an extra-low (below 0.1% mass) content of the noble metals, ensuring relatively
low cost.
Later, investigations of GFCs were also started at Saint Petersburg University of
Technology and Design in Russia,35,36 the Technion Institute of Technology in Haifa,
Israel,37 the Institute for Hydrocarbon Processing in Omsk, Russia,38 the Technische
Universität, Dresden, Germany,39 the North University of China, Taiyuan, China,40
and many other universities and R&D companies worldwide.
Currently, GFCs are considered to be promising catalysts for the numerous reac-
tions, including the following, as well as many others:
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