Structured catalytic wall microreactor for efficient performance of exothermic reactions

A novel microreactor with structured catalytic wall (SCWMR) has been developed for highly exothermic, gas/solid reactions and tested for the selective acetylene hydrogenation. The reactor design is similar to the so-called “slit microreactor”. The structured catalyst consisted of Pd-nanoparticle embedded in a thin ionic liquid layer supported on activated carbon fibres (ACF) cloths. It was placed between two aluminium plates forming an empty slit (thickness ∼300 μm). The gas mixture flows above the catalyst through the slit allowing a low pressure drop of 15 kPa/m for flows up to 3.3 × 10−6 m3/s. The catalyst can be easily replaced on demand. The acetylene hydrogenation as a model of exothermic reaction was carried out in the SCWMR at conversions up to 100%. The reactor temperature between 150 and 210 °C was maintained by circulation of oil from a thermostat and remained constant confirming the efficient heat exchange without hot-spot formation. The reaction performance was optimized varying flow rates and temperatures. The selectivity of ∼70% was obtained at conversion of 96.5% under steady-state at 200 °C without any catalyst deactivation over 10 h on stream.