catalyst & catalysis
DESCRIPTION
It shows the basic facts of catalyst along with its importance in industry along with its long last milestone,its characteristics & application in industry its reaction process and preparation of a solid catalyst.TRANSCRIPT
CH4003 Lecture Notes 5 (Erzeng Xue)
CATALYST &CATALYSIS
Nofal Umair 2k11-Che-148
Catalysis & Catalysts2 Facts and Figures about Catalysts
Life cycle on the earth Catalysts (enzyme) participates most part of life cycle
e.g. forming, growing, decaying Catalysis contributes great part in the processes of converting sun energy to
various other forms of energies
e.g. photosynthesis by plant CO2 + H2O=HC + O2
Catalysis plays a key role in maintaining our environment
Chemical Industry ca. $2 bn annual sale of catalysts ca. $200 bn annual sale of the chemicals that are related products 90% of chemical industry has catalysis-related processes Catalysts contributes ca. 2% of total investment in a chemical process
Catalysis & Catalysts
Hetrogeneous Catalysis-Milestones in Evolution-1
3
1814- Kirchhoff-starch to sugar by acid. 1817-Davy-coal gas(Pt,Pd selective but not
Cu,Ag,Au,Fe) 1820s –Faraday H2 + O2 H2O(Pt);C2H4 and S 1836- Berzelius coins”Catalysis”; 1860-Deacon’s Process ;2HCl+0.5O2 H2O + Cl2; 1875-Messel.SO2 SO3 (Pt); 1880-Mond.CH4+H2O CO+3H2(Ni); 1902-Ostwald-2NH3+2.5O2 2NO+3H2O(Pt); 1902-Sabatier.C2H4+H2 C2H6(Ni). 1905-Ipatieff.Clays for acid catalysed reactions;
isomerisation, alkylation, polymerisation.
Milestones in Evolution-24
1910-20: NH3 synthesis (Haber,Mittasch) ; Langmuir 1920-30-Methanol syn(ZnO-Cr2O3); Taylor;BET 1930-Lang-Hinsh &Eley -Rideal models ;FTsyn;EO; 1930-50:Process Engg; FCC / alkylates;acid-base
catalysis;Reforming and Platforming. 1950-70: Role of diffusion; Zeolites, Shape Selectivity;
Bifunctional cata;oxdn cat-HDS; Syngas and H2 generation.
1970- Surface Science approach to catalysis(Ertl) 1990 - Assisted catalyst design using : -surface chem of metals/oxides, coordination chemistry - kinetics,catalytic reaction engg - novel materials(micro/mesoporous materials)
What is Catalysis5 Catalysis
Catalysis is an action by catalyst which takes part in a chemical reaction process and can alter the rate of reactions, and yet itself will return to its original form without being consumed or destroyed at the end of the reactions
(This is one of many definitions)
Three key aspects of catalyst action taking part in the reaction
• it will change itself during the process by interacting with other reactant/product molecules
altering the rates of reactions • in most cases the rates of reactions are increased by the action of catalysts;
however, in some situations the rates of undesired reactions are selectively suppressed
Returning to its original form• After reaction cycles a catalyst with exactly the same nature is ‘reborn’
• In practice a catalyst has its lifespan - it deactivates gradually during use
Catalysis & Catalysts
By providing an alternative pathway (or mechanism) with lower/ higher activation energy.
Catalyst Characteristic
1. Activity. The ability of a catalyst to increase the rate of a chemical reaction is called activity. A catalyst may accelerate a reaction to as high as 10^10 times.
2. Selectivity. The ability of the catalyst to direct a reaction to give a particular product.3. Small quantity. Only small quantity is need for a reaction.
4. Specific. One catalyst is need for specific reaction only
5. Physical properties may change during a reaction but no it does not take part in the reaction.
6. Catalyst doesn’t influence on the general stoichiometric coefficients.
7. Catalysts decrease activation energy thus increase the chemical rate.
8. Catalysts don’t influence on the equilibrium constant. They only reduce time of reaching the equilibrium and increase the rate of forward and back reaction.
Action of Catalysts8 Catalysis action - Reaction kinetics and
mechanism Catalyst action leads to the rate of a reaction to change.
This is realised by changing the course of reaction (compared to non-catalytic reaction)
Forming complex with reactants/products, controlling the rate of elementary steps in the process. This is evidenced by the facts that
The reaction activation energy is altered
The intermediates formed are different from
those formed in non-catalytic reaction
The rates of reactions are altered (both
desired and undesired ones)
Reactions proceed under less demanding conditions
Allow reactions occur under a milder conditions, e.g. at lower temperatures for those heat sensitive materials
Catalysis & Catalysts
reactant
reaction process
uncatalytic
product
ener
gy
catalytic
PHYSICAL ADSORPTION
10
Steps in a catalytic Reaction: - Diffusion of reactant (bulk, Film, surface) - Adsorption( physical chemical) -Surface reaction - Desorption and diffusion of products Physical Adsorption: - Van der Waals forces;BET surface area Pore Size distribution ( Wheeler, de Boer,
BJH) Influence of pore size on reaction order,
temperature coefficient, selectivity, Influence of poisons …
Types of Catalysts & Catalytic Reactions11
The types of catalysts Classification based on the its physical state, a catalyst can be
gas liquid solid
Classification based on the substances from which a catalyst is made Inorganic (gases, metals, metal oxides, inorganic acids, bases etc.) Organic (organic acids, enzymes etc.)
Classification based on the ways catalysts work Homogeneous - both catalyst and all reactants/products are in the same phase (gas or
liq) Heterogeneous - reaction system involves multi-phase (catalysts +
reactants/products) Classification based on the catalysts’ action
Acid-base catalysts Enzymatic Photocatalysis Electrocatalysis, etc.
Catalysis & Catalysts
Applications of Catalysis12
Industrial applicationsAlmost all chemical industries have one or more steps
employing catalysts Petroleum, energy sector, fertiliser, pharmaceutical, fine chemicals …
Advantages of catalytic processes Achieving better process economics and productivity
Increase reaction rates - fast Simplify the reaction steps - low investment cost Carry out reaction under mild conditions (e.g. low T, P) - low energy consumption
Reducing wastes Improving selectivity toward desired products - less raw materials required, less unwanted
wastes Replacing harmful/toxic materials with readily available ones
Producing certain products that may not be possible without catalysts Having better control of process (safety, flexible etc.) Encouraging application and advancement of new technologies and materials And many more …
Catalysis & Catalysts
Applications of Catalysis13
Environmental applications Pollution controls in combination with industrial processes
Pre-treatment - reduce the amount waste/change the composition of emissions Post-treatments - once formed, reduce and convert emissions Using alternative materials
… Pollution reduction
gas - converting harmful gases to non-harmful ones liquid - de-pollution, de-odder, de-colour etc solid - landfill, factory wastes
… And many more …
Other applications Catalysis and catalysts play one of the key roles in new technology
development.
Catalysis & Catalysts
Research in Catalysis14
Research in catalysis involve a multi-discipline approach Reaction kinetics and mechanism
Reaction paths, intermediate formation & action, interpretation of results obtained under various conditions, generalising reaction types & schemes, predict catalyst performance…
Catalyst development Material synthesis, structure properties, catalyst stability, compatibility…
Analysis techniques Detection limits in terms of dimension of time & size and under extreme conditions (T,
P) and accuracy of measurements, microscopic techniques, sample preparation techniques…
Reaction modelling Elementary reactions and rates, quantum mechanics/chemistry, physical chemistry …
Reactor modelling Mathematical interpretation and representation, the numerical method, micro-
kinetics, structure and efficiency of heat and mass transfer in relation to reactor design …
Catalytic process Heat and mass transfers, energy balance and efficiency of process …
Catalysis & Catalysts
Catalytic Reaction Processes15 Understanding catalytic reaction processes
A catalytic reaction can be operated in a batch mannerReactants and catalysts are loaded together in reactor and catalytic reactions (homo- or heterogeneous) take place in pre-determined temperature and pressure for a desired time / desired conversion
Type of reactor is usually simple, basic requirements Withstand required temperature & pressure Some stirring to encourage mass and heat transfers Provide sufficient heating or cooling
Catalytic reactions are commonly operated in a continuous manner
Reactants, which are usually in gas or liquid phase, are fed to reactor in steady rate (e.g. mol/h, kg/h, m3/h)
Usually a target conversion is set for the reaction, based on this target
required quantities of catalyst is added required heating or cooling is provided required reactor dimension and characteristics are designed
accordingly.
Catalysis & Catalysts
Catalytic Reaction Processes16
General requirements for a good catalyst Activity - being able to promote the rate of desired reactions Selective - being to promote only the rate of desired reaction
and also retard the undesired reactions Note: The selectivity is sometime considered to be more important than the activity and sometime it is more difficult to achieve
(e.g. selective oxidation of NO to NO2 in the presence of SO2)
Stability - a good catalyst should resist to deactivation, caused by
the presence of impurities in feed (e.g. lead in petrol poison TWC. thermal deterioration, volatility and hydrolysis of active
components attrition due to mechanical movement or pressure shock
A solid catalyst should have reasonably large surface area needed for reaction (active sites). This is usually achieved by making the solid into a porous structure.
Catalysis & Catalysts
Example Heterogeneous Catalytic Reaction Process
17
The long journey for reactant molecules to
.travel within gas phase . cross gas-liquid phase boundary. travel within liquid phase/stagnant layer. cross liquid-solid phase boundary. reach outer surface of solid. diffuse within pore. arrive at reaction site. be adsorbed on the site and activated. react with other reactant molecules, either
being adsorbed on the same/neighbour sites or approaching from surface above
Product molecules must follow the same track in the reverse direction to return to gas phase
Heat transfer follows similar track
gas phase
poreporous solid
liquid phase /stagnant layer
gas phasereactant molecule
Catalysis & Catalysts
Solid Catalysts18
Catalyst composition
Active phase Where the reaction occurs (mostly metal/metal oxide)
Promoter Textual promoter (e.g. Al - Fe for NH3 production) Electric or Structural modifier Poison resistant promoters
Support / carrier Increase mechanical strength Increase surface area (98% surface area is supplied within
the porous structure) may or may not be catalytically active
Catalysis & Catalysts
CatalystAct
ive
phas
e
Support
Prom
oter
Solid Catalysts19
Some common solid support / carrier materials
Alumina Inexpensive Surface area: 1 ~ 700 m2/g Acidic
Silica Inexpensive Surface area: 100 ~ 800 m2/g Acidic
Zeolite mixture of alumina and silica, often exchanged metal ion present shape selective acidic
Catalysis & Catalysts
Other supports Active carbon (S.A. up to 1000 m2/g) Titania (S.A. 10 ~ 50 m2/g) Zirconia (S.A. 10 ~ 100 m2/g) Magnesia (S.A. 10 m2/g) Lanthana (S.A. 10 m2/g)
poreporous solid
Active site
Solid Catalysts20
Preparation of catalysts Precipitation
To form non-soluble precipitate by desired reactions at certain pH and temperature
Adsorption & ion-exchange
Cationic: S-OH+ + C+ SOC+ + H+
Anionic: S-OH- + A- SA- + OH-
I-exch. S-Na+ + Ni 2+ S-Ni 2+ + Na+
Impregnation
Fill the pores of support with a metal salt solution of sufficient concentration to give the correct loading.
Dry mixing
Physically mixed, grind, and fired
Catalysis & Catalysts
precipitate or deposit
precipitation
filter & wash the resultingprecipitate
Drying& firing
precursorsolution
Support
add acid/basewith pH control
Support
Drying & firing
Pore saturated pellets
Soln. of metal precursor
Am
ou
nt
ad
sorb
ed
Concentration
Support
Drying & firing
Solid Catalysts21
Preparation of catalysts Catalysts need to be calcined (fired) in order to decompose the precursor
and to received desired thermal stability. The effects of calcination temperature and time are shown in the figures on the right.
Commonly used Pre-treatments Reduction
if elemental metal is the active phase
Sulphidation if a metal sulphide is the active phase
Activation Some catalysts require certain activation steps in order to receive the best
performance. Even when the oxide itself is the active phase it may be necessary to pre-treat the
catalyst prior to the reaction
Typical catalyst life span
Can be many years or a few mins.
Catalysis & Catalysts
0
25
50
75
100
500 600 700 800 900
Temperature °C
BE
T S
.A.
m2/g
0
40
0 10Time / hours
BE
T S
.A.
Act
ivit
y
Time
Normal use
Induction period
dead