A Catalytically Active or Activatable Mixture of Shaped Catalyst Bodies and Electrically Conductive Bodies for Use in a Chemical Reactor with Direct Electrically-Resistive Heating

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This invention introduces a specially designed mixture of shaped catalyst bodies and electrically conductive bodies for use inside chemical reactors. By precisely controlling the size ratio and distribution of the two types of bodies, the mixture allows for efficient direct electric resistive heating of the catalyst bed, eliminating the need to use fossil fuels for heating. This enables effective heating for highly endothermic catalytic chemical reactions (those that require a lot of heat), using renewable electricity for a lower carbon footprint.

Use CasesContent extracted from patent full text and abstract with AI.

• Steam methane reforming (SMR) or other hydrocarbon reforming processes in chemical plants using electric heating instead of fossil fuels.
• Dehydrogenation reactions such as the production of ethylene, propylene, or other olefins from alcohols or alkanes.
• Pyrolysis of hydrocarbons to produce chemicals or fuels in an energy-efficient, electrically heated reactor.
• Reverse water-gas shift reactions for carbon conversion applications.
• Any highly endothermic catalytic reaction in the chemical industry where direct electric heating could replace gas or oil-fired heating systems.
• Green production of syngas and other platform chemicals with integration of renewable energy sources.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables chemical reactors to be directly electrically heated, allowing for the replacement of fossil fuel-based heating with renewable electricity, reducing greenhouse gas emissions.
• Improved energy efficiency by directly heating the catalyst bed, which reduces energy losses compared to external heating methods.
• Flexible and tunable design permits optimal heat distribution and homogeneous temperature in the catalyst bed, leading to more consistent reaction outcomes.
• High compatibility with existing shaped catalyst bodies and standard industrial reactor designs.
• Potentially safer and more controllable operation due to the elimination of open flames or combustion devices inside the reactor.
• Facilitates the transition of the chemical industry towards decarbonization and compliance with environmental regulations.

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Patent Abstract

The present invention relates a catalytically active or activatable mixture for use in a chemical reactor comprising (i) shaped catalyst bodies comprising a catalytically active or activatable material, and (ii) electrically conductive bodies, wherein the ratio (dcat / dcon) between the characteristic diameter of the shaped catalyst bodies dcat and the diameter of the electrically conductive bodies dcon is in the range of from 1.5 to 3, and wherein the shaped catalyst bodies have a characteristic diameter dcat in the range of from 1 mm to 50 mm, and wherein the diameter of unshaped electrically conductive bodies is the average diameter determined by sieving according to DIN 66165, and where the characteristic diameter of shaped catalyst bodies and the characteristic diameter of shaped electrically conductive bodies is defined by the product of the diameter of a circumscribed sphere dcss surrounding the shaped body and the sphericity Ψch of the convex hull of the shaped body. The present invention further relates to a process for preparing the catalytically active or activatable mixture, to the use of the catalytically active or activatable mixture as part of a directly electrically heatable catalyst bed or as directly electrically heatable catalyst bed in a chemical reactor and to a chemical reactor for conducting a chemical reaction containing a catalyst bed comprising or consisting of the catalytically active or activatable mixture. The present invention further relates to a process for conducting a chemical reaction, which is catalyzed by the shaped catalyst bodies of the catalytically active or activatable mixture.