New method of determination of intrinsic kinetic and mass transport parameters from typical catalyst activity tests: Problem of mass transfer resistance and diffusional limitation of reaction rate

Analysis of Entropy Production in Structured Chemical Reactors: Optimization for Catalytic Combustion of Air Pollutants

Optimization of structured reactors is not without some difficulties due to highly random economic issues. In this study, an entropic approach to optimization is proposed. The model of entropy production in a structured catalytic reactor is introduced and discussed. Entropy production due to flow friction, heat and mass transfer and chemical reaction is derived and referred to the process yield. The entropic optimization criterion is applied for the case of catalytic combustion of methane. Several variants of catalytic supports are considered including wire gauzes, classic (long-channel) and short-channel monoliths, packed bed and solid foam. The proposed entropic criterion may indicate technically rational solutions of a reactor process that is as close as possible to the equilibrium, taking into account all the process phenomena such as heat and mass transfer, flow friction and chemical reaction.

Simulative Minimization of Mass Transfer Limitations Within Hydrogel-Based 3D-Printed Enzyme Carriers

In biotechnology, immobilization of functional reactants is often done as a surface immobilization on small particles. Examples are chromatography columns and fixed-bed reactors. However, the available surface for immobilization is directly linked to particle diameter and bed porosity for these systems, leading to high backpressure for small particle sizes. When larger molecules, such as enzymes are immobilized, physical entrapment within porous materials like hydrogels is an alternative. An emerging technique for the production of geometrically structured, three-dimensional and scalable hollow bodies is 3D-printing. Different bioprinting methods are available to produce structures of the desired size, resolution and solids content. However, in case of entrapped enzymes mass transfer limitations often determine the achievable reactivities. With increasing complexity of the system, for example a fixed-bed reactor, 3D-simulation is indispensable to understand the local reaction conditions to be able to highlight the optimization potential. Based on experimental data, this manuscript shows the application of the dimensionless numbers effectiveness factor and Thiele modulus for the design of a 3D-printed flow-through reactor. Within the reactor, enzymes are physically entrapped in 3D-printed hydrogel lattices. The local reaction rate of the enzymes is directly dependent on the provided substrate amount at the site of reaction which is limited by the diffusion properties of the hydrogel matrix and the diffusion distance. All three parameters can be summed up by one key figure, the Thiele modulus, which, in short, quantifies mass transfer limitations of a catalytic system. Depending on the rate of the enzymatic reaction in correlation to the diffusional transport, mass transfer limitations will shift the optimum of the system, favoring slow enzyme kinetics and small diffusion distances. Comparison with the enzymatic reaction rate in solution yields the effectiveness factor of the system. As a result, the optimization potential of varying the 3D-printed geometries or the reaction rate within the experimentally available design space can be estimated.

Metal Foams as Novel Catalyst Support in Environmental Processes

Metal foams are considered as promising catalyst carriers due to their high porosity, large specific surface area, and satisfactory thermal and mechanical stability. The study presents heat transfer and pressure drop experiments performed for seven foams of different pore densities made from diverse metals. Mass transfer characteristics are derived using the Chilton–Colburn analogy. It was found that the foams display much more intense heat/mass transfer than a monolith, comparable to packed bed. Next, the foams’ efficiencies have been compared, using 1D reactor modeling, in catalytic reactions displaying either slower (selective catalytic reduction of NOx) or faster kinetics (catalytic methane combustion). For the slow kinetics, the influence of carrier specific surface area at which catalyst can be deposited (i.e., catalyst amount) was decisive to achieve high process conversion and short reactor. For this case, monolith appears as the best choice assuming it’s the lowest pressure drop. For the fast reaction, the mass transfer becomes the limiting parameter, thus solid foams are the best solution.

Catalytic Ozonation in Arrayed Zinc Oxide Nanotubes as Highly Efficient Mini-Column Catalyst Reactors (MCRs): Augmentation of Hydroxyl Radical Exposure

Reactor design is significant to catalytic ozonation for an efficient mass transfer and exposure of the powerful but short-lived hydroxyl radicals (HO•). Herein, five groups of zinc oxide nanotube arrays with pore sizes from 168 to 10 nm were produced as mini-column catalyst reactors (MCRs) for internal catalytic ozonation, whose performance was comparatively studied on the kinetics of ozone transfer, consumption, and radical probe interaction. Using an R_CT value describing HO• exposure, all the MCRs with sufficient ozone transfer featured an R_CT level of at least 3.2 × 10^-6, which is substantially higher than most values in referenced works (10^-9∼10^-6) and that for microscale reactors in our work (∼10^-8). Furthermore, the HO• exposure dramatically increased with diminishing pore size, causing an elevated R_CT up to 8.0 × 10^-5 for the smallest MCR with 10 nm pore. The interphase formed in this flow-through system might have enriched HO• radicals produced via surface, and for a smaller MCR, the effect would be greater with a more confined microfluidic region. Investigations on electron paramagnetic resonance and the treatment of ozone-recalcitrant organics corroborated the nanoscale effect of MCR on augmentation of HO• exposure. This study offers a new way to design nanotube reactors for internal HO•-based heterogeneous catalysis.