Periodic open cellular structures (POCS) as enhanced catalyst supports: Optimization of the coating procedure and analysis of mass transport

Balzarotti, Riccardo; Ambrosetti, Matteo; Arnesano, Mauro; Anglani, A.; Groppi, Gianpiero; Tronconi, Enrico

doi:10.1016/j.apcatb.2020.119651

Cited by 17 publications

(7 citation statements)

References 36 publications

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“…POCS can be manufactured by advanced 3D printing techniques, which offer the opportunity to optimize the support geometry to tailor the design to the specific application and produce exact replicas of the optimized shapes. ,− In this view, several unit cell shapes are available in the literature and already reproducible by 3D printing . A few of these have been considered for chemical reaction engineering applications, namely, the Cubic, the Diamond, the Octet, and the Tetrakaidekahedral (TKKD) unit cells. − ,− ,, Klumpp et al proposed a fully theoretical derivation of the ideal Cubic unit cell geometrical features, providing the expressions for the evaluation of the porosity, the specific surface area, and the window length as a function of the cell tilting. Horneber additionally provided the geometrical models of the Diamond and the TKKD ideal unit cells.…”

Section: Introductionmentioning

confidence: 99%

“…Few studies in the literature report the investigation of the fluid–solid transport properties of POCS. From the experimental standpoint, gas–solid heat and mass transfer in POCS has been investigated for a reduced number of cell shapes and geometries. , Balzarotti et al investigated external mass transfer in Cubic cell POCS manufactured by investment casting and catalytically activated with Pd/CeO 2 by spin coating for CO oxidation. They derived a Sh-Re correlation to model gas–solid mass transfer rates in cubic cell POCS as a function of the support morphological parameters and the flow condition.…”

Section: Introductionmentioning

confidence: 99%

“…21 A few of these have been considered for chemical reaction engineering applications, namely, the Cubic, the Diamond, the Octet, and the Tetrakaidekahedral (TKKD) unit cells. [12][13][14][16][17][18][19]22,23 Klumpp et al 16 proposed a fully theoretical derivation of the ideal Cubic unit cell geometrical features, providing the expressions for the evaluation of the porosity, the specific surface area, and the window length as a function of the cell tilting. Horneber 24 additionally provided the geometrical models of the Diamond and the TKKD ideal unit cells.…”

Section: Introductionmentioning

confidence: 99%

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A Fundamental Investigation of Gas/Solid Heat and Mass Transfer in Structured Catalysts Based on Periodic Open Cellular Structures (POCS)

Ferroni

Bracconi

Ambrosetti

et al. 2021

Ind. Eng. Chem. Res.

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In this work, we investigate the gas–solid heat and mass transfer in catalytically activated periodic open cellular structures, which are considered a promising solution for intensification of catalytic processes limited by external transport, aiming at the derivation of suitable correlations. Computational fluid dynamics is employed to investigate the Tetrakaidekahedral and Diamond lattice structures. The influence of the morphological features and flow conditions on the external transport properties is assessed. The strut diameter is an adequate characteristic length for the formulation of heat and mass transfer correlations; accordingly, a power-law dependence of the Sherwood number to the Reynolds number between 0.33 and 0.67 was found according to the flow regimes in the range 1–128 of the Reynolds number. An additional −1.5-order dependence on the porosity is found. The formulated correlations are in good agreement with the simulation results and allow for the accurate evaluation of the external transfer coefficients for POCS.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

A Fundamental Investigation of Gas/Solid Heat and Mass Transfer in Structured Catalysts Based on Periodic Open Cellular Structures (POCS)

Ferroni

Bracconi

Ambrosetti

et al. 2021

Ind. Eng. Chem. Res.

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“…220 Some other techniques include metal encapsulation techniques (mainly Fe, Co, and Rh) on sol−gel support (i.e., titanium, silica) with fixation by calcination 221−223 or using centrifugal force for a more uniform coating. 224,225 The microstructured packed bed uses a different form of active phase arrangement. It stands out for having a wide variety of parallel channels with properties of transferring mass and energy intensively, making it attractive in the application of highly exothermic reactions.…”

Section: ■ Reactors In Ft Processmentioning

confidence: 99%

An Overview of Low-Temperature Fischer–Tropsch Synthesis: Market Conditions, Raw Materials, Reactors, Scale-Up, Process Intensification, Mechanisms, and Outlook

Apolinar-Hernández,

Bertoli,

Riella

et al. 2023

Energy Fuels

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The Fischer−Tropsch technology has allowed, since its emergence a century ago, the production of stable liquid fuels from different raw materials in different geographic scenarios that do not necessarily have oil reserves. Some of these raw materials can generate high-quality fuels with a lower content of sulfur, aromatic, and heterocyclic compounds. The scaling and intensification of the reactors are essential factors in this context, and important challenges such as energy transfer due to the highly exothermic reaction, hydrodynamics due to limited information on pilot-scale in a reasonable range of conditions, or reducing CH 4 selectivity while maintaining high conversion through catalyst design, must be considered. This perspective provides an overview of recent developments in industrial-scale low-temperature Fischer−Tropsch reactors, with a focus on the significance of microchannel reactors in the scale-up process. The advancement in the Fischer−Tropsch synthesis is discussed, with an emphasis on the carbide and CO insertion mechanisms, as well as the socio-political-economic factors that continue to impact the development of this technology.

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“…Spin coating represents a valid alternative to blowing. While this technique is well consolidated in the field of flat surfaces functionalization (Sahu et al, 2009), only in recent years has it been technologically transferred to complex geometry supports (Zhang et al, 2012), with promising results reported both for honeycomb monoliths (Balzarotti et al, 2019b), open cell foams (Ambrosetti et al, 2018) and POCS (Balzarotti et al, 2021). Finally, slurry-based processes require a series of thermal treatment stages after wet coating deposition, in order to complete the washcoating process and to obtain the morphological and mechanical resistance properties of the final catalytic washcoat (Meille, 2006;Montebelli et al, 2014).…”

Section: Strategies For the Catalytic Activation Of Structured Supportsmentioning

confidence: 99%

Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study

et al. 2022

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Structured catalysts are strong candidates for the intensification of non-adiabatic gas-solid catalytic processes thanks to their superior heat and mass transfer properties combined with low pressure drops. In the past two decades, different types of substrates have been proposed, including honeycomb monoliths, open-cell foams and, more recently, periodic open cellular structures produced by additive manufacturing methods. Among others, thermally conductive metallic cellular substrates have been extensively tested in heat-transfer limited exo- or endo-thermic processes in tubular reactors, demonstrating significant potential for process intensification. The catalytic activation of these geometries is critical: on one hand, these structures can be washcoated with a thin layer of catalytic active phase, but the resulting catalyst inventory is limited. More recently, an alternative approach has been proposed, which relies on packing the cavities of the metallic matrix with catalyst pellets. In this paper, an up-to-date overview of the aforementioned topics will be provided. After a brief introduction concerning the concept of structured catalysts based on highly conductive supports, specific attention will be devoted to the most recent advances in their manufacturing and in their catalytic activation. Finally, the application to the methane steam reforming process will be presented as a relevant case study of process intensification. The results from a comparison of three different reactor layouts (i.e. conventional packed bed, washcoated copper foams and packed copper foams) will highlight the benefits for the overall reformer performance resulting from the adoption of highly conductive structured internals.

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Periodic open cellular structures (POCS) as enhanced catalyst supports: Optimization of the coating procedure and analysis of mass transport

Cited by 17 publications

References 36 publications

A Fundamental Investigation of Gas/Solid Heat and Mass Transfer in Structured Catalysts Based on Periodic Open Cellular Structures (POCS)

A Fundamental Investigation of Gas/Solid Heat and Mass Transfer in Structured Catalysts Based on Periodic Open Cellular Structures (POCS)

An Overview of Low-Temperature Fischer–Tropsch Synthesis: Market Conditions, Raw Materials, Reactors, Scale-Up, Process Intensification, Mechanisms, and Outlook

Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study

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