Industrial catalysis provides concise summaries in 3 sentences or less that provide the high level and essential information from the document. Catalysts are vital to the global economy and impact many industries by enabling chemical reactions to occur more efficiently. They work by lowering the activation energy of reactions and increasing reaction rates. The field of industrial catalysis is multidisciplinary, involving chemistry, physics, engineering and other areas to develop catalyst formulations for diverse applications and reaction conditions.
Industrial catalysis provides concise summaries in 3 sentences or less that provide the high level and essential information from the document. Catalysts are vital to the global economy and impact many industries by enabling chemical reactions to occur more efficiently. They work by lowering the activation energy of reactions and increasing reaction rates. The field of industrial catalysis is multidisciplinary, involving chemistry, physics, engineering and other areas to develop catalyst formulations for diverse applications and reaction conditions.
Industrial catalysis provides concise summaries in 3 sentences or less that provide the high level and essential information from the document. Catalysts are vital to the global economy and impact many industries by enabling chemical reactions to occur more efficiently. They work by lowering the activation energy of reactions and increasing reaction rates. The field of industrial catalysis is multidisciplinary, involving chemistry, physics, engineering and other areas to develop catalyst formulations for diverse applications and reaction conditions.
Industrial catalysis provides concise summaries in 3 sentences or less that provide the high level and essential information from the document. Catalysts are vital to the global economy and impact many industries by enabling chemical reactions to occur more efficiently. They work by lowering the activation energy of reactions and increasing reaction rates. The field of industrial catalysis is multidisciplinary, involving chemistry, physics, engineering and other areas to develop catalyst formulations for diverse applications and reaction conditions.
Arun Basrur Süd-Chemie India Pvt. Ltd. (Clariant JV) 1st State Level Seminar Parul University 22 SEP 2017 This talk Target audience • Graduate and Post Grad Students
Objective • Provide a flavor of catalysts & catalysis • Impact on Society • Touch upon inter-disciplinary nature of the subject • Cover current trends in this field Some aspects about catalysts • Catalysts are materials which alter {increase} the rate of chemical reactions
• Vital to Global economy
– Worldwide demand 20.6 Bio US$ [2018] {1.3 x 10 5 Cr. INR} • Touch almost every walk of life yet little known to the layman: Behind the scenes player
• “Heart” of the process
Aspects about catalysts… • Preparation of HETEROGENEOUS catalysts described as an ‘ART’
• Catalysts – multicomponent – multifunctional:
‘OPTIMIZATION’ between multiple properties
• Catalysis multi-disciplinary
• Current Global R&D focus >> Sustainability, GHG
abatement, Green Processes; Water splitting, artificial photosynthesis > Significant Global funding
– 15 fold increase in yield of transportation fuels
derived from crude oil between 1920 to 2015
– Catalysts played an important role along with
engineering
– Reference: Six-Revolutions – Chapter 4 - The drive for
yield: www.uop.com How catalysts work
• Chemical Reactions are transformations
• Existing chemical bonds break and new ones are formed: Optimal bond strength of TS Reactant + Catalyst TS* Product + Catalyst SURFACE PHENOMENON Diffusion Adsorption R Surface Reaction Desorption TS Diffusion P What catalysts cannot do • Violate thermodynamics – BUT can cheat thermodynamics: Molecular sieving
• Magical Solutions>> Catalyst development is OPTIMAL COMPROMISE
Broad Types Homogeneous Heterogeneous • Same physical state as reactants and • Different physical state than products reactants and products PROS PROS • High rates of reaction • Ease of separation • Good control over selectivity • Harsh reaction conditions • Long life • Defined structure • Ease of disposal of spent catalyst
CONS CONS • Mild reaction conditions • Diffusion limited – lower rates of • Separation from product difficult reaction • Expensive • Relatively lower selectivity • Short life • Difficult to produce with consistent quality & characterize • Disposal of spent catalyst difficult HAZARDOUS Diversity of catalysts • Materials ranging from single component system – Ex: Sponge Nickel or Pt; -Al2O3 – Metal complexes TO Multiple requirements to service Diverse reaction environments • Highly Complex FORMULATIONS – Supported metals – Mixed oxides [6-10 elements] – Metal ‘alloys’ Reactants – Blends
• Adsorbents & Traps
– To remove impurities from feed streams Flow is important Microstructure / Morphology • Catalysis = Surface Phenomenon WHICH • Active phase and Carrier / Substrate for dispersion, ONE? mechanical & thermal stability • High surface area >> ‘Porosity’ Internal surface / ‘Nano’ Power of POROSITY = Power of SIZE
Porous or Nano??? Sp. Surface area = f{1/Pore size} Nanomaterials - Au active only in nanosize
Win-Win situation ‘COMPROMISE’ • Carrier: Sacrifice nanosize, get moderate porosity & surface area • Get high Pd ‘active’ surface area ‘Nano’
• HR-TEM of Pd / -Alumina: Ref: Applied Catalysis B:
Environmental 97 (2010) 57–71 Selection of actives • Reactivity for main reaction and side reactions – Match properties with classical organic reaction mechanism • Properties of elements/compounds – Electronegativity – % d character – Acid-base character – Redox character – {Semi}conductor – Melting Point
• Mild to moderate heat • Highly exothermic reactions
changes; slow deactivation • Multi-tubular fixed bed – gradient catalysts • Fixed Bed reactors • Fluid bed reactors • Catalyst particle Dimension • Catalyst particle dimension 20-70m 1.2+ mm • High abrasion resistance • Type of reactor • Loss of selectivity – back-mixing • Heat and Mass transfer • Managing heat of reaction • Reaction Kinetics and Sizing reactor Engineering Solutions Fast deactivation: hours V. Fast deactivation: seconds scale scale Moving bed or Circulating catalyst Parallel fixed bed reactors reactors
Reaction Regeneration Example – H2 production
ZnO Trap Thermally stable Fe-Cr Cu-Zn Ni Catalyst PSA
Co-Mo HDS Ni based catalysts Catalyst Catalyst catalyst
Complexity - Train of catalysts and adsorbents working in tandem
Reference: nptel.ac.in/module2 Example - Naphtha Reforming Multi-functionality: Pt-Sn/Cl-Alumina
Reference: What-when-how.com State of the art Catalyst preparation “An ART” – Hitherto Limitations in determining structure-property correlations
ENABLERS: ART >>> SCIENCE
• ALD [Atomic Layer Deposition] – Enables structuring the surface of the catalyst
• OPERANDO Spectroscopy – Understanding of structure-activity relations under reaction conditions
• High Throughput Screening
– Robotic Parallel synthesis and performance evaluation
• Models for catalyst design: Predictive modeling / DEM / DFT
