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474 Part 5 Applications

active substances can be fabricated by a tailored coating (for coating methods of honeycombs and ceramic foams, see Section 5.4.2). These coatings have the advantage of a large specific surface area without the disadvantage of outer diffusion through shaped catalyst parts.

The following section deals with catalytic applications of ceramic foams, mostly in laboratory-scale experiments. The processes described herein are of very heterogeneous nature with respect to the reaction mechanisms and process parameters such as temperature, pressure, and space velocity. However, a more practical classification is given on the basis of (potential) applications of ceramic foam catalysts.

5.4.4.1

Improvement of Technical Processes for Base Chemicals Production

The promising properties of ceramic foam catalysts were investigated in several types of catalytic processes, whereby a marked improvement in terms of higher selectivity and/ or yield could be expected in fast reactions or reactions with a pronounced heat development such as 1) oxidative dehydrogenation of alkanes, 2) partial oxidation of ethylene, and 3) steam and dry reforming of methane. The important requirements in such chemical processes are short contact times and good temperature control.

The investigation of the substitution of the commonly used catalyst (e.g., V2O5/ SiO2) in the oxidative dehydrogenation of ethane or other alkanes by ceramic monoliths exemplifies the potential of these materials. The oxidative dehydrogenation of ethane was carried out on a 45–80 ppi alumina foam coated with 1–5 wt % Pt, Rh, or Pd. With the Pt-loaded monolith a conversion of about 80 % with a C2H4 selectivity of greater than 70 % can be achieved, comparable to those of currently used catalysts. A remarkable improvement is that the contact time in the ceramic foam catalyst is reduced to 5–10 ms, which would allow the construction of a reactor 100 to 1000 times smaller in size than currently used for the same olefin yield [123].

Table 1 list more results from investigations regarding the application of ceramic monoliths in industrially important reactions, whereby the desired improvement can be in selectivity, yield, energy requirements, special product composition, or reducing working temperature or reactor size.

In a special and effective construction the combination of catalytic combustion and reforming is realized. To increase heat conduction, NiCr metal foam is used as cellular structure and alumina-coated by plasma spraying prior to impregnation with the catalyst component [137]. The reactor consists of alumina-cladded nickel catalyst foam metal core inserted into a metal tube, which itself is inserted into an LaCo-impregnated core-cladding foam. The inner foam operates as reformer, while the outer foam is used for heating the inner foam by methane combustion in air. With a methane conversion in the range 50–63 % the feasibility of this combined catalytic combustion/reforming apparatus was demonstrated, but no relations of the data to technical processes are given. A detailed description of ceramic coating by plasma spraying with alumina is given in Ref. [138]. Due to their higher ductility as compared to ceramic foams, the ceramic-coated metal foams could have several advantages in mobile applications.

5.4 Heterogeneously Catalyzed Processes with Porous Cellular Ceramic Monoliths 475

Table 1 Investigations on the application of ceramic monoliths in industrially important reactions.

Chemical process

Experimental setup

Aims/results

Refs.

 

 

 

 

Dehydrogenation of ethane

45–80 ppi alumina foam,

Pt on ceramic foams

123, 124

and other alkanes

1–5 % Pt, Rh, or Pd

improves olefin yield and

 

 

 

selectivity, shorter contact

 

 

 

times

 

Ethane dehydrogenation

Cr2O3 on ZrO2 foam,

prevention of deactivation

125

 

Pt-modified

 

 

Methane dehydrogenation

Al2O3 foam,

higher product selectivity

126

 

1–20 % Pt or Rh

 

 

Oxidative dehydrogenation

Pt/ZrO2 foam monolith

good activity, higher

11, 127

of propane and butane

 

selectivity

 

Dehydrogenation of C5

alumina foam with Pt

mechanistic studies

128

and C6 alkanes

 

 

 

Ethane dehydrogenation

20, 45, and 80 ppi alumina

influence of the cell size

129

 

foam

 

 

Partial oxidation of liquid

alumina foam with 5 % Rh

use of higher alkanes for

130–132

fuels

 

H2 production

 

Methane reforming

a-Al2O3-foam pellets with

lower working tempera-

122, 133

(CH4 + H2O ! 3 H2 + CO)

NiO, TiO2

ture, higher effectiveness

 

 

 

factor

 

Dry methane reforming

c-Al2O3 foam with

14 times higher turnover

134

(CH4 + CO2 ! 2 H2

alumina wash coat, Rh

numbers

 

+ 2 CO)

and PtRe impregnation

 

 

Methane conversion

Al2O3 and SiC foams, Ru

using solar energy for

135 and

 

 

process heating

Chapter 5.7

HCN production and

honeycombs, extruded

catalytic performance:

136

Ostwald process

metallic monoliths, and

ceramic foams > honey-

 

 

ceramic foams

combs > metallic monoliths

 

5.4.4.2

Hydrogen Liberation from Liquid Precursors/Hydrogen Cleaning for Fuel Cell Applications

In mobile fuel-cell systems in situ hydrogen generation from liquid sources at ambient pressure and temperature is preferred, and methanol and ethanol have been suggested for catalytic on-board hydrogen production. For long-term operation of the catalyst, however, high-purity hydrogen with a CO content of less than 50 ppm is required [139], and high-quality hydrogen for solid-polymer fuel cells (SPFCs) can be produced by steam reforming of methanol [140]. This endothermic process (Eq. (3)) can be operated at 150–280 C over wash coat catalyst (e.g., alumina-sup- ported platinum). The thermal energy to operate the process is provided by combustion of part of the methanol feed (Eq. (4)).

476

Part 5 Applications

 

 

CH3OH + H2O fi 3 H2 + CO2

(3)

 

 

2 CH3OH + 3 O2 fi 2 CO2 + 4 H2O

(4)

It was demonstrated that 20–25 ppi aluminum foam and a heat-exchanger structure, both with a catalytic wash coat, provided about 100 % CH3OH conversion at 260 C. In comparison to a packed-bed reformer (3 mm pellet diameter) the amount of catalyst could be reduced by factor of four in both structures, and the optimal temperature control led to greater than 90 % methanol conversion over a period of 450 h. Better performance, attributed to the significantly higher heat transport and faster thermal response at startup, was found, and the structural advantage of the foam was clearly demonstrated.

Steam reforming of ethanol (Eq. (5)) for the same application was investigated on catalyst pellets, ceramic foams, and honeycombs with Ru as catalytically active component [141]. The active-metal loading on the cordierite monolith (400 channels per square inch) and the alumina–zirconia foam (1/16-inch c-alumina extrudate, 50 ppi) was carried out by wash coating with a Ru(NO)(NO3)3/c-alumina slurry followed by in situ reduction, typically at 750 C under hydrogen. The catalysis experiments were carried out in the temperature range from 400 to 1000 C. The temperature

was controlled by combustion of part of the ethanol (Eq. (6)).

 

C2H5OH + 3 H2O fi 2 CO2 + 6 H2

(5)

C2H5OH + 0.61 O2 + 1.78 H2O fi 2CO2 + 4.78 H2

(6)

With ethanol conversion greater than 95 % and H2 selectivity of 90–97 % the impregnated foams showed the best results at medium space velocities, (lowest yield of CH4 and CH3OH, which are undesired byproducts; high CO2 selectivity, less CO).

Reticulated SiC foams (18 mm diameter, 45 mm in length), which were washcoated with c-Al2O3 to increase the specific surface area and impregnated by different procedures using several Ru salts, showed excellent performance in CO removal by oxidation in the temperature range from 100 to 160 C. A CO content in the feed gas (75 % H2, 18 % CO, 4 % H2O, 4000 ppm CO, 6000 ppm CO2, 2 % N2) of less than 30 ppm was achieved after conversion [139].

5.4.4.3

Automotive and Indoor Exhaust Gas Cleaning

Significant reduction of exhaust emissions of internal combustion engines can be achieved inter alia by reducing emissions of hydrocarbons (HC), CO, and NOx during the cold start phase. A promising method is microwave-enhanced conversion of the pollutants. A microwave absorbing ceramic foam of the composition SiO2– NiO–SiC–Fe2O3 was developed and covered with a Pd-doped slurry of CeO2– ZrO2–Al2O3 [142]. This catalyst was heated by microwave radiation during operation

5.4 Heterogeneously Catalyzed Processes with Porous Cellular Ceramic Monoliths 477

and compared to a conventionally heated ceramic foam of the same type with a simulated exhaust gas mixture. The exhaust gas inlet temperature was varied. Prior to the measurements the catalyst was reduced under hydrogen and aged under working conditions. The microwave-heated catalyst achieved 50 % conversion at an exhaustgas inlet temperature of 60 C, while the conventionally heated catalyst reached the same conversion rate only at 320 C. At 110 C the conversion was 100 % HC, 95 % NOx, and 92 % CO for the microwave-heated catalyst. Conventional heating required a temperature of 450 C. Moreover, the catalyst showed an almost constant pollutant conversion over a broad range of space velocity from 20 000 to 60 000 h–1.

Diesel-soot converters operate on the basis of a supported molten-salt catalyst consisting of eutectic mixtures of Cs2O, V2O5, MoO3, and Cs2SO4 [143–145]. An alternative system consists of a Pt-loaded SiC foam, partly combined with a soot-loaded foam or a SiC membrane wall-flow reactor to assist diesel-soot combustion by NO2 reduction [146]. More details of these systems are given in Chapter 5.2.

In a photocatalytic oxidation reactor for air cleaning by catalytic combustion of volatile organic compounds (VOCs) the catalyst is activated by UV light. The most common, most powerful oxidizing agent is TiO2, and activation is carried out by excitation at a wavelength of 300–400 nm. The mechanism may be more complex, but a set of simplified equations for the activation of the semiconductor oxide, the formation of the reactive hydroxyl radicals (OH.) and the total oxidation of VOCs are

described according to Ref. [147] in Eqs. (7)–(10):

 

TiO2 + hm fi h+ + e

(activation)

(7)

OH+ h+ fi OH

(oxidation)

(8)

O2(ads) + e O2(ads)

(reduction)

(9)

OH. + pollutant + O2 ! products (CO2, H2O, etc.)

(10)

Requirements for this setup are a large-volume reactor, a low pressure drop, and an efficient contact among the photons, the catalyst, and the gaseous reactants. Several types of reactor design were developed, with membranes, honeycombs, or even the inner wall of a quartz glass tube as the catalyst support [147]. Novel developments make use of ceramic monoliths. The kind of monolith – honeycomb or foam

– affects the radiation field of the UV source, and model calculations must be performed for optimal reactor design. First simulations of the UV absorption process in cellular ceramics (foams and honeycombs) for a tailored reactor are described in Ref. [148], and two different reactor designs were realized in Ref. [149]. One type of reactor consists of an alternating arrangement of UV lamps and titania-coated foam monolith plates. The monoliths are arranged perpendicular to the flow direction, and lamps are mounted at the inlet and outlet and between the plates (Fig. 12).

In the annular-type reactor a UV lamp is inserted in a hollow cylinder of ceramic foam. First catalytic experiments demonstrated 80 % conversion of isopropanol as a model compound.

478 Part 5 Applications

Air/VOC inlet

Air/CO2, H2O outlet

 

3

 

2

1

Fig. 12 Schematic of a PCO reactor [149]. 1) Reactor cabinet, 2) UV lamps, 3) TiO2/ceramic foam.

Catalyst systems for ozone decomposition, which are necessary for deozonisation of, for example, airplane passenger cabins and photocopiers, work over a temperature range of 2–177 C, typically 20–50 C in most technical applications. The degree of decomposition is between 69 and 100 %, but greater than 90 % in most systems. A review on ozone decomposition including several catalyst systems, decomposition mechanism, reactivity of ozone-decomposition catalysts, and reactor designs/support materials is given in Ref. [150]. Ceramic cordierite and reticulated carbon foams (both 20 ppi) were used as monolithic catalyst supports [151]. The foams were coated with a slurry consisting of activated carbon (AC) and metal oxide or a system of AC and two metal oxides. The highest decomposition rate was achieved over AC/MnO2/Fe2O3 supported on activated carbon foam, which achieved a value of greater than 90 % when gum arabicum was used as disperser in the slurry.

Selective catalytic reduction of NOx was investigated on zeolite-coated structured catalyst packings [152]. An a-alumina foam (45 ppi) and a cordierite monolith honeycomb (300 csi with a square channel cross section of 1 0 1 mm) were used as supports. The zeolite coating was generated by in situ supported crystallization [23] followed by ion exchange. The catalyst-loaded alumina foams were arranged to form a parallel-passage reactor (PPR, Fig. 13). Catalytic NOx reduction as shown in Eq. (1) was carried out in the temperature range 200–350 C in the PPR and at 125–370 C

Gas inlet

Fig. 13 Schematic of the parallel passage reactor [152].

Gas outlet

5.4 Heterogeneously Catalyzed Processes with Porous Cellular Ceramic Monoliths 479

in the monolith reactor. An optimum operation temperature for the PPR was found to be 300 C, and an NO conversion of 80 % was found at a gas hourly space velocity (GHSV) of 3000 h–1 for the PPR and at 18 000 h–1 for the monolith reactor. However, the efficiency of the PPR was 17 % in this experiment, compared to the honeycomb monolith with about 95 %. The general workability of this novel reactor type employing a zeolite coating grown in situ was demonstrated. Due to the low efficiency factor it was concluded that the design of the PPR was not optimal and a lateral arrangement and optimized plate thickness was suggested for ongoing work. The low pressure drop in this system is of paramount importance.

5.4.4.4

Catalytic Combustion in Porous Burners

A further application of ceramic foams with a catalytically active surface was studied to improve the performance of porous burners. When a catalytically active coating is applied in porous burners, the combustion temperature of the burner fuels can be decreased, which results in reduced CO, HC, and NOx emissions. Coating a ceramic foam (60 ppi, mullite, 12 mm in thickness and 120 mm in diameter) with LaMnO3 lead to a significant decrease in burner temperature: complete methane combustion was found at about 800 C with no coating, while a LaMnO3 catalyst on the foam surface lead to a temperature of 700 C over a nonprecoated and to less than 650 C on an La2O3-pre- coated foam [153]. Further details on porous burners can be found in Chapter 5.5.

In Sections 5.4.3 and 5.4.4 the use of ceramic monoliths in several catalytic applications was demonstrated. Common ceramics such as cordierite, mullite, c- and a- alumina, and silicon carbide were applied, but also special developments with tailored specific properties, such as microwave-absorbing of metal oxides have been reported. Optimal radial and axial heat and mass flows allow the operational temperature range to be narrowed to the needs of a specific reaction. The range of service temperature is broad, from room temperature up to 1400 C, and the reaction conditions vary in a similarly broad range. This makes a careful selection of material, surface treatment and further modification of the ceramic monoliths (honeycombs and foams) necessary.

5.4.5

Summary

Ceramic honeycomb structures are a well-established class of catalyst supports. Uses range from mobile applications such as automotive and diesel exhaust gas catalysis, to indoor gas cleaning and production-site exhaust gas cleaning, and use in industrial chemical processes. A large number of applications are still the subject of research and development with major potential for application.

Open-cell ceramic foams have considerable potential for use as catalyst supports in heterogeneously catalyzed processes in the chemical industry and environment protection. In comparison to some of the well-established classical processes, ceram-

480 Part 5 Applications

ic foam catalysts showed superior catalytic performance, albeit so far on the laboratory scale. Due to the low pressure drop and the short contact times this class of supported catalysts has the potential for reduction of reactor size, which is associated with significant cost and energy savings in the chemical industry.

Development of novel materials, for example, the fabrication of electrically conductive monoliths with self-heating properties, and an improvement of their mechanical properties make both classes of ceramic support promising candidates for energy saving and for present and future applications in heterogeneous catalysis, where multifunctionality is a demand.

Acknowledgement

The authors gratefully acknowledge the Deutsche Forschungsgemeinschaft (DFG), the Bundesministerium f4r Bildung und Forschung (BMBF), the Fonds der Chemischen Industrie (FCI) and the Alexander-von-Humboldt Foundation (AvH), for financial support.

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