Process intensification using multifunctional reactors

A Brief Introduction to Chemical Reaction Optimization

From the start of a synthetic chemist's training, experiments are conducted based on recipes from textbooks and manuscripts that achieve clean reaction outcomes, allowing the scientist to develop practical skills and some chemical intuition. This procedure is often kept long into a researcher's career, as new recipes are developed based on similar reaction protocols, and intuition-guided deviations are conducted through learning from failed experiments. However, when attempting to understand chemical systems of interest, it has been shown that model-based, algorithm-based, and miniaturized high-throughput techniques outperform human chemical intuition and achieve reaction optimization in a much more time- and material-efficient manner; this is covered in detail in this paper. As many synthetic chemists are not exposed to these techniques in undergraduate teaching, this leads to a disproportionate number of scientists that wish to optimize their reactions but are unable to use these methodologies or are simply unaware of their existence. This review highlights the basics, and the cutting-edge, of modern chemical reaction optimization as well as its relation to process scale-up and can thereby serve as a reference for inspired scientists for each of these techniques, detailing several of their respective applications.

The Steady State Characteristics of Multicomponent Diffusion in Micro- and Mesoporous Media for Adsorbable and Nonadsorbable Species

The study addresses one of the fundamental issues in the mathematical modeling and quantitative process analysis of complex multicomponent diffusion in meso- and microporous materials. The model presented here incorporates combined molecular diffusion, Knudsen diffusion, viscous flow, and surface diffusion. A methodology and algorithm for the determination of steady states of such complex diffusive processes are proposed. The adopted form of the surface diffusion model does not require the calculation of the thermodynamic factor matrix. The method was verified by comparing the profiles of the state variables with those obtained from the dynamic model for sufficiently long diffusion times. The application of the method is illustrated for two diffusion processes involving three components. In the first one, all components are subject to adsorption. In the other, one gaseous component is an inert and is therefore not adsorbed and does not participate in surface diffusion. It is shown that the presence of inerts as well as their number does not impede the application of the proposed algorithm for the determination of steady states.

Process Intensification in Chemical Reaction Engineering

In the present review article, the definitions and the most advanced findings within Process Intensification are collected and discussed. The intention is to give the readers the basic concepts, fixing the syllabus, as well as some relevant application examples of a discipline that is well-established and considered a hot topic in the chemical reaction engineering field at present.

Effect of Asymmetric Membrane Structure on Hydrogen Transport Resistance and Performance of a Catalytic Membrane Reactor for Ethanol Steam Reforming

The performance of catalytic membrane reactors (CMRs) depends on the specific details of interactions at different levels between catalytic and separation parts. A clear understanding of decisive factors affecting their operational parameters can be provided via mathematical simulations. In the present paper, main results of numerical studies of ethanol steam reforming, followed by downstream hydrogen permeation through an asymmetric supported membrane, are reported. The membrane module consists of a thin selective layer supported on a substrate with graded porous structure. One-dimensional isothermal reaction–transport model for the CMR has been developed, and its validation has been carried out by using performance data from a lab-scale reactor with a disk-shaped membrane. Simulations demonstrate the model’s capabilities to analyze local concentrations gradients, as required to provide accurate estimates of the relationship between structure–property–performance. It was shown that transport properties of multilayer asymmetric membranes are highly related to the structural properties of each single layer.

Immobilising Microalgae and Cyanobacteria as Biocomposites: New Opportunities to Intensify Algae Biotechnology and Bioprocessing

There is a groundswell of interest in applying phototrophic microorganisms, specifically microalgae and cyanobacteria, for biotechnology and ecosystem service applications. However, there are inherent challenges associated with conventional routes to their deployment (using ponds, raceways and photobioreactors) which are synonymous with suspension cultivation techniques. Cultivation as biofilms partly ameliorates these issues; however, based on the principles of process intensification, by taking a step beyond biofilms and exploiting nature inspired artificial cell immobilisation, new opportunities become available, particularly for applications requiring extensive deployment periods (e.g., carbon capture and wastewater bioremediation). We explore the rationale for, and approaches to immobilised cultivation, in particular the application of latex-based polymer immobilisation as living biocomposites. We discuss how biocomposites can be optimised at the design stage based on mass transfer limitations. Finally, we predict that biocomposites will have a defining role in realising the deployment of metabolically engineered organisms for real world applications that may tip the balance of risk towards their environmental deployment.

Process intensification

Process intensification (PI) is a rapidly growing field of research and industrial development that has already created many innovations in chemical process industry. PI is directed toward substantially smaller, cleaner, more energy-efficient technology. Furthermore, PI aims at safer and sustainable technological developments. Its tools are reduction of the number of devices (integration of several functionalities in one apparatus), improving heat and mass transfer by advanced mixing technologies and shorter diffusion pathways, miniaturization, novel energy techniques, new separation approaches, integrated optimization and control strategies. This review discusses many of the recent developments in PI. Starting from fundamental definitions, microfluidic technology, mixing, modern distillation techniques, membrane separation, continuous chromatography, and application of gravitational, electric, and magnetic fields will be described.

Microfibrous-Structured Pd/AlOOH/Al-Fiber for CO Coupling to Dimethyl Oxalate: Effect of Morphology of AlOOH Nanosheet Endogenously Grown on Al-Fiber

We report a green, template-free, and general one-pot method of endogenous growth of free-standing boehmite (AlOOH) nanosheets on a 3D-network 60 μm-Al-fiber felt through water-only hydrothermal oxidation reaction between Al metal and H₂O (2Al + 4H₂O → 2AlOOH + 3H₂). Content and morphology of AlOOH nanosheets can be finely tuned by adjusting the hydrothermal oxidation time length and temperature. Palladium is highly dispersed on such AlOOH endogenously formed on Al-fiber felt via incipient wetness impregnation method and as-obtained Pd/AlOOH/Al-fiber catalysts are checked in the CO coupling to dimethyl oxalate (DMO) reaction. Interestingly, Pd dispersion is very sensitive to the thickness (26-68 nm) of AlOOH nanosheet, and therefore the conversion shows strong AlOOH-nanosheet-thickness dependence whereas the intrinsic activity (TOF) is AlOOH-nanosheet-thickness independence. The most promising structured catalyst is the one using a microfibrous-structured composite with the thinnest AlOOH nanosheet (26 nm) to support a small amount of Pd of only 0.26 wt %. This catalyst, with high thermal-conductivity and satisfying structural robustness, delivers 67% CO conversion and 96% DMO selectivity at 150 °C using a feed of CH₃ONO/CO/N₂ (1/1.4/7.6, vol) and a gas hourly space velocity of 3000 L kg^-1 h^-1, and particularly, is very stable for at least 150 h without deactivation sign.

Effect of bed characters on the direct synthesis of dimethyldichlorosilane in fluidized bed reactor

This paper presents the numerical investigation of the effects of the general bed characteristics such as superficial gas velocities, bed temperature, bed heights and particle size, on the direct synthesis in a 3D fluidized bed reactor. A 3D model for the gas flow, heat transfer, and mass transfer was coupled to the direct synthesis reaction mechanism verified in the literature. The model was verified by comparing the simulated reaction rate and dimethyldichlorosilane (M2) selectivity with the experimental data in the open literature and real production data. Computed results indicate that superficial gas velocities, bed temperature, bed heights, and particle size have vital effect on the reaction rates and/or M2 selectivity.

Cascade reactions catalyzed by metal organic frameworks

Cascade or tandem reactions where two or more individual reactions are carried out in one pot constitute a clear example of process intensification, targeting the maximization of spatial and temporal productivity with mobilization of minimum resources. In the case of catalytic reactions, cascade processes require bi-/multifunctional catalysts that contain different classes of active sites. Herein, we show that the features and properties of metal-organic frameworks (MOFs) make these solids very appropriate materials for the development of catalysts for cascade reactions. Due to composition and structure, MOFs can incorporate different types of sites at the metal nodes, organic linkers, or at the empty internal pores, allowing the flexible design and synthesis of multifunctional catalysts. After some introductory sections on the relevance of cascade reactions from the point of view of competitiveness, sustainability, and environmental friendliness, the main part of the text provides a comprehensive review of the literature reporting the use of MOFs as heterogeneous catalysts for cascade reactions including those that combine in different ways acid/base, oxidation/reduction, and metal-organic centers. The final section summarizes the current state of the art, indicating that the development of a first commercial synthesis of a high-added-value fine chemical will be a crucial milestone in this area.

Composite nonwovens in filters: applications

This chapter discusses the role of composite nonwoven filters in different structural forms such as combining mechanical support and durability with filtration, providing two or more layers of different filtration efficiency and combining different separation technologies/functionality into one filter medium. In many situations, composite nonwovens might fulfill multiple objectives. Applications of composite nonwovens are quite diverse and increasing in the area of air, liquid and engine filtration. The developmental objectives of composite filtering media are lower energy consumption, longer filter life, high filtration capacity, greater dust holding (in depth filtration) and easy cleanability (of surface filter), satisfying more than one functional requirement and easier maintenance.

Single and Multi-Channel Reactor for Oxidative Coupling of Methane

Management of the produced heat has been one of the challenges encountered in the oxidative coupling of methane (OCM) process. In this study, the influence of the thermal conductive tubular reactor on the total productivity and selectivity of OCM was investigated. The reactors were made from three different metal compounds: two stainless steel tubes and one gold-coated copper tube, and their impact on the operating conditions was compared. 5% Li/MgO was prepared as a catalyst for OCM and characterized by XRD, CO2-TPD, FTIR, and BET. In addition, the effect of reactor geometry on the oxidative coupling process was investigated experimentally in the single channel and multi-channel reactors with different hydraulic diameters.