A New Way to Increase Catalyst Activity

Abstract

A new method for conducting a heterogeneous catalytic reaction in the gaseous phase is discussed. It eliminates the use of carriers and allows catalysis to be conducted via an aerosol of finely milled active catalytic materials. Problems associated with the strength and thermal stability of catalysts are thereby avoided. A high and constant catalytic activity is ensured for the aerosol catalyst by integrating the chemical reaction zone and the mechanical treatment zone. Thus, solid particles that move with the reactant flow or special devices that allow mechanical treatment of the catalyst particles may be located in the reactor. Such aerosol catalysis has been tested in processes involving partial and complete oxidation, recovery, vinylation, chlorination and dechlorination. Relative to traditional systems, i.e. placement of the active catalytic active material on the carrier, the reaction rate was increased by 4-5 orders of magnitude. The production of catalysts and the implementation of chemical reactions are thereby both simplified simultaneously.