Design of packed bed reactors: guides to catalyst shape, size, and loading selection

The engineering design of packed bed based unit operations is very much influenced by the structure of the packing matrix, which in turn is governed by the shape, dimensions and the loading of the constituent particles. For, say, reactor applications, optimum design of catalyst pellet in terms of shape configuration, internal pores and available surface area can promote catalytic activity and the prevailing transport properties of the system. Moreover, at the design stage, fabrication cost, resistance to crushing and abrasion, as well as dust build-up should also be taken into account. Knowledge of the underlying factors should enable designers to engineer the optimum design for a given system with prescribed conditions. However, in view of the significance of pellet/packing design, this paper addresses certain issues, which would elucidate the task.