Catalytically Coated Support, Method for Its Preparation, and Reactor Equipped Therewith and Its Use

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes catalyst-coated supports featuring at least one porous catalyst layer with large, irregular cavities (macropores) and a uniform, highly adhesive coating. The invention also covers methods for manufacturing these advanced catalyst supports and their integration into reactors, notably microreactors. The structure of the porous catalyst layer improves stability, adhesion, and mass transport, making it highly suitable for high-performance chemical reactions in small-scale reactors.

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

• Chemical microreactors for highly exothermic or endothermic reactions
• Production of propene oxide via propene oxidation
• Synthesis of vinyl acetate from acetic acid and ethylene
• Oxidation reactions (e.g., ethylene to ethylene oxide, propene to acrolein/acrylic acid)
• Ammoxidation processes (e.g., acrylonitrile production)
• Hydrogenation reactions of organic compounds
• Reactions involving synthesis gas (e.g., Fischer-Tropsch synthesis, methanol synthesis)
• Catalytic treatment of exhaust gases
• Catalytic reactors in the fine chemicals and pharmaceuticals industries

BenefitsContent extracted from patent full text and abstract with AI.

• High adhesion strength of the catalyst layer prevents flaking and increases durability during reactor use and maintenance.
• Uniform layer thickness ensures consistent flow properties and efficient mass transfer, crucial for microreactors.
• Highly porous (macroporous) and cavity-rich structure enables better reactant access and heat/mass transfer, improving catalytic performance.
• Enhanced mechanical and thermal stability, even under reaction conditions, reducing downtime and maintenance.
• Allows effective scaling down to microreactor format, supporting process intensification and safer operation of explosive or highly reactive processes.
• Versatile manufacturing methods compatible with a wide range of catalyst and support materials.
• Can be applied in multi-layer configurations for tailored catalytic properties.

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Inventors & Applicants

Patent Abstract

The invention relates to catalyst-coated supports that comprise at least one porous and cavity-including catalyst layer, said cavities having irregular hollow spaces with dimensions of larger than 5 µm in at least two dimensions or with cross-sectional surfaces of at least 10 µm2. The catalyst coatings are characterized by an excellent adhesive pull strength and can preferably be used in microreactors.