Catalyst Engineering Technology

This book gives a comprehensive explanation of what governs the breakage of extruded materials, and what techniques are used to measure it. The breakage during impact aka collision is explained using basic laws of nature allowing readers to determine the handling severity of catalyst manufacturing equipment and the severity of entire plants. This information can then be used to improve on the architecture of existing plants and how to design grass-roots plants. The book begins with a summary of particle forming techniques in the particle technology industry. It covers extrusion technology in more detail since extrusion is one of the workhorses for particle manufacture. A section is also dedicated on how to describe transport and chemical reaction in such particulates for of course their final use. It presents the fundamentals of the study of breakage by relating basic laws in different fields (mechanics and physics) and this leads to two novel dimensionless groups that govern breakage. These topics are then apply these topics to R&D scale-up and manufacturing and shows how this approach is directly applicable.

Autorentext

JEAN W. L. BEECKMAN obtained his chemical engineering degree in 1975 and later his doctorate in 1979 at the Rijksuniversiteit Gent, Belgium. Since 2001, the author has been with ExxonMobil in Annandale, NJ. His entire career has been in the area of catalyst development, catalyst manufacturing and mathematical modeling. Jean has over 35 patents and over 25 peer reviewed technical publications.

Klappentext
PROVIDES THE READER FUNDAMENTAL KNOWLEDGE TO QUANTIFY THE LENGTH TO DIAMETER RATIO OF CATALYSTS DURING SCALE-UP AND MANUFACTURE AND FURTHER INTRODUCES VERY DEEP NETWORK PERTURBATION TO MODEL REACTION AND DIFFUSION WITH WHITE NOISE VARIABILITY IN CATALYST PROPERTIES Catalyst Engineering Technology: Fundamentals and Applications gives a comprehensive explanation of what governs the breakage of extruded materials, and what techniques are used to measure it. The breakage during impact aka collision is explained using basic laws of nature allowing readers to determine the handling severity of catalyst manufacturing equipment and the severity of entire plants. In addition, the author introduces Very Deep Network Perturbation (VDNP) for handling white noise variability in catalyst modeling. This information can then be used in R&D scale-up, to improve on the architecture of existing plants and how to design grass-roots plants. The book begins with a summary of the diverse particle forming techniques used in laboratories and commercial plants. It also covers the typical equipment and process variables used for impregnation and rotary calcination. Catalyst Engineering Technology further expands into the mathematical modeling of extrusion technology as extrusion is one of the workhorses for particle manufacture covering particle shear, particle friction and extrusion paste rheology. The book further goes into a comprehensive explanation of what governs the breakage and length to diameter ratio of extruded catalysts and is modeled using Newton's second law and the modulus of rupture. This approach introduces two dimensionless groups that play a key role in catalyst extrudate breakage and this methodology allows to determine the catalyst handling severity of individual equipment as well as the severity of entire plants. The final chapter is dedicated to the description of steady state diffusion and first order reaction in catalyst particles through the use of Very Deep Network Perturbation allowing one to obtain specific solutions in the presence of white noise variability for mass transfer, surface area and the kinetic rate coefficient.

Inhalt
About the Author ix

Acknowledgments xi

Foreword xiii

1 Catalyst Preparation Techniques and Equipment 1

1.1 Introduction 1

1.2 Forming of Catalysts 4

1.3 Impregnation and Drying 12

1.4 Rotary Calcination 13

1.5 From the Laboratory to a Commercial Plant 29

Nomenclature 29

References 30

2 Extrusion Technology 35

2.1 Background 35

2.2 Rheology 36

2.3 Extrusion 47

Nomenclature 57

References 59

3 The Aspect Ratio of an Extruded Catalyst: An In-depth Study 61

3.1 General 61

3.2 Introduction to Catalyst Strength and Catalyst Breakage 63

3.3 Mechanical Strength of Catalysts 67

3.4 Experimental Measurement of Mechanical Strength 76

3.5 Breakage by Collision 88

3.6 Breakage by Stress in a Fixed Bed 129

3.7 Breakage in Contiguous Equipment 145

3.8 Statistical Methods Applied to Manufacturing Materials 158

Nomenclature 159

Greek Symbols 161

Subscripts 162

References 162

4 Steady-state Diffusion and First-order Reaction in Catalyst Networks 165

4.1 Introduction 165

4.2 Classic Continuum Approach 169

4.3 The Network Approach 171

Nomenclature 270

Greek Symbols 270

References 271

Appendix 4.1 Diffusion in a simple network 272

Appendix 4.2 Property of the semi-inverse 272

Appendix 4.3 Diffusion and reaction in a simple network 273

Appendix 4.4 Matrix properties for diffusion and reaction in a simple network 274

Appendix 4.5 Perturbation in a simple network 274

Appendix 4.6 A random variable 275

Appendix 4.7 Diffusion along a string of nodes 275

Appendix 4.8 Diffusion in a rectangular strip with an equal number of nodes 276

Appendix 4.9 Diffusion in a rectangular strip with an unequal number of nodes 277

Appendix 4.10 Diffusion and first-order reaction in a very deep network of 500 layers deep and five nodes per layer 279

Appendix 4.11 Diffusion and first-order reaction 280

Index 281