Electrically Conductive Shaped Catalyst Bodies for Use in a Chemical Reactor

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This invention provides electrically conductive shaped catalyst bodies designed for use in chemical reactors, particularly for processes requiring direct electrical heating. The catalyst bodies are formed from compacted mixtures of at least one catalytically active (or activatable) material and at least one electrically conductive material, allowing them to efficiently convert electric energy into the thermal energy needed to drive highly endothermic chemical reactions. The invention covers the composition, manufacturing process, and application of these shaped bodies, which can be used to form a directly electrically heatable catalyst bed inside fixed or moving bed reactors.

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

• In fixed bed or moving bed chemical reactors for highly endothermic reactions such as steam methane reforming (SMR), dry reforming of methane, alkane dehydrogenation, and pyrolysis of hydrocarbons.
• Implementation in chemical plants to replace fossil-fuel fired heating with electrically powered, renewable energy-driven heating in large-scale industrial processes.
• Electrically heated catalytic reactors for production of hydrogen, syngas, ethylene, and other key industrial chemicals.
• Endothermic gas phase reactions such as ethanol dehydration to ethylene or CO2 hydrogenation via the reverse water-gas shift reaction.
• Use in zero-emission or low-carbon chemical manufacturing by leveraging renewable electricity for process heating.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables direct electrical heating of catalyst beds, supporting decarbonization and a shift to renewable energy sources for chemical production.
• Reduces reliance on fossil fuels for providing the high temperatures needed in endothermic industrial reactions, helping to lower the industry's carbon footprint.
• Provides high catalytic activity and uniform heat generation within the reactor, potentially improving reaction efficiency and selectivity.
• Allows for flexible operation at high temperatures (well above 500°C) with controlled electrical parameters (high voltage/low amperage).
• Can be produced in versatile shapes and sizes (pellets, extrudates, rings, etc.) suitable for different reactor types and scalable for industrial use.
• Potentially lowers capital and operational expenditures by simplifying reactor design and reducing energy and fuel costs.
• Facilitates recycling and reprocessing due to simple and clear material compositions in the catalyst bodies.

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Inventors & Applicants

Patent Abstract

The present invention relates to electrically conductive shaped catalyst bodies for use in a chemical reactor comprising a mixture of at least two different solid materials, wherein the mixture comprises i) at least one catalytically active or activatable material, and ii) at least one electrically conductive material, wherein the sum of the volume fractions of all electrically conductive materials of the shaped catalyst bodies is in the range of from 0.2 to 0.35, and wherein the shaped catalyst bodies have a characteristic diameter in the range of from 1 mm to 50 mm, and wherein the sum of the mass fractions of all catalytically active or activatable materials and of the mass fractions of all electrically conductive materials of the shaped catalyst bodies is in the range of from 0.9 to 1. The present invention further relates to a process for preparing the electrically conductive shaped catalyst bodies, to the use of the electrically conductive shaped catalyst bodies 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 electrically conductive shaped catalyst bodies. The present invention further relates to a process for conducting a chemical reaction, which is catalyzed by the electrically conductive shaped catalyst bodies.