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CSMs - Catalytic Static Mixers Challenge The current methods for heterogeneous catalysis using packed bed reactors pose many limitations. Fluid flow through the bed, as well as temperature and concentration gradients, can often be highly non-uniform, making heat control difficult - especially on large scale. For liquid phase applications, pressure drop along the bed can also be highly problematic. The size and shape of catalyst particles determine the performance of the catalytic reaction and the physical processes occurring inside the reactor such as fluid flow, mixing and heat, and mass transfer, often leading to undesirable limitations. A different approach is needed. Working with additive manufacturing experts, CSIRO are utilising state-of-the art technology to develop a hierarchical catalytic reactor approach. This new method involves a tailored mixing solution which can be addressed by the 3D printed design of the static mixer married with a range of active catalyst coatings for different catalytic reactions. Additionally the tubular design of the continuous flow reactor provides superior process control compared with packed bed columns or stirred batch vessels. These processes make this technology a versatile and efficient tool for R&D and production. Capability Drawing on the multi-disciplinary expertise at the CSIRO, we have delivered a new method for heterogeneous catalytic reactions - catalytic static mixers (CSMs). With simple and well established design this innovative solution aims to provide an elevated approach to tubular reactor technology. Using 3D printing capabilities, novel metal scaffolds are designed and manufactured before the catalyst is directly deposited via electroplating, cold spraying, or other deposition methods. The CSMs can be readily inserted into reactor tubes, allowing for easy changeover of catalyst. The benefits of utilising metal scaffolds, which have good mechanical stability, are significant and include: SUPERIOR PROCESS CONTROL In comparison to most catalyst bed systems, temperature within the newly designed CSM reactors are far more controllable. The design of the mixers ensure that pressure drop is low and mixing is efficient. Detail of 3d printer printing a metal piece MANUFACTURING www.csiro.au
Transcript

CSMs - Catalytic Static Mixers

ChallengeThe current methods for heterogeneous catalysis using packed bed reactors pose many limitations. Fluid flow through the bed, as well as temperature and concentration gradients, can often be highly non-uniform, making heat control difficult - especially on large scale. For liquid phase applications, pressure drop along the bed can also be highly problematic. The size and shape of catalyst particles determine the performance of the catalytic reaction and the physical processes occurring inside the reactor such as fluid flow, mixing and heat, and mass transfer, often leading to undesirable limitations.

A different approach is needed. Working with additive manufacturing experts, CSIRO are utilising state-of-the art technology to develop a hierarchical catalytic reactor approach. This new method involves a tailored mixing solution which can be addressed by the 3D printed design of the static mixer married with a range of active catalyst coatings for different catalytic reactions. Additionally the tubular design of the continuous flow reactor provides superior process control compared with packed bed columns or stirred batch vessels. These processes make this technology a versatile and efficient tool for R&D and production.

CapabilityDrawing on the multi-disciplinary expertise at the CSIRO, we have delivered a new method for heterogeneous catalytic reactions - catalytic static mixers (CSMs). With simple and well established design this innovative solution aims to provide an elevated approach to tubular reactor technology. Using 3D printing capabilities, novel metal scaffolds are designed and manufactured before the catalyst is directly deposited via electroplating, cold spraying, or other deposition methods. The CSMs can be readily inserted into reactor tubes, allowing for easy changeover of catalyst. The benefits of utilising metal scaffolds, which have good mechanical stability, are significant and include:

SUPERIOR PROCESS CONTROL In comparison to most catalyst bed systems, temperature within the newly designed CSM reactors are far more controllable. The design of the mixers ensure that pressure drop is low and mixing is efficient.

Detail of 3d printer printing a metal piece

MANUFACTURINGwww.csiro.au

CONTACT USt 1300 363 400 +61 3 9545 2176 e [email protected] w www.csiro.au

FOR FURTHER INFORMATIONCSIRO Manufacturing Dr Christian Hornung Research Scientist t +61 3 9545 2532 e [email protected] w research.csiro.au/floworks

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MADE TO ORDEROne of the main benefits of 3D printing is the flexibility of design. The static mixer geometry can be designed specific to the needs of each project, taking into account the properties of the reagent mixture and the fluid flow. Flow maldistribution, concentration and temperature hotspots can be avoided.

MORE COST EFFECTIVE Using in house design and manufacture, tailor made 3D printing of metal mixers for tubular flow chemistry reactors can be several times cheaper than commercial static mixers of similar dimensions.

RETRO-FITTING CSM reactors can be easily adapted to current manufacturing processes. This ensures that past manufacturing methods do not need to be altered in order to utilize this technology, making the process more fluid and accessible.

We have used this approach to prepare CSM reactors and tested them in hydrogenation (gas-liquid) and transfer hydrogenation (homogenous liquid) reactions. High Turn-Over-Frequencies and Space-Time-Yields were achieved without detectible leaching of the catalyst metal.

The technology can be adapted for a number of different manufacturing sectors including:

• Pharmaceuticals

• Fine chemicals

• Food products / Supplements

• Polymer and agrochemicals

SEM image of a CSM palladium layer deposited by electroplating


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