CRE Notes PDF

NPTEL – Chemical Engineering – Catalyst Science and Technology
Lecture 1
Introduction to catalysis
The science and technology of catalysis is of great significance as it affects our daily life. Four
major sectors of the world economy; petroleum and energy production, chemicals and polymer
production, food industry and pollution control, involve catalytic processes.
Fig. 1. Four major sectors of world economy that involve catalytic processes
Catalysts are used to produce fuels such as gasoline, diesel, heating oil, fuel oil etc. Production of
plastics, synthetic rubbers, fabrics, cosmetics etc. involve catalytic processes. The production of
clean energy from renewable energy sources, such as hydrogen for fuel cells and transportation
fuels from non-edible biomass are also catalyst dependent processes. Automobile emission
catalysts are used to reduce emissions of CO, NOx and hydrocarbons from mobile vehicles.
Catalysts are also used in the production of the polymers including adhesives, coatings, foams,
textile and industrial fibers. The pharmaceutical industry uses catalysts for production of drugs
that are used to save lives and improve the health of people. Catalysts are also widely used in
food processing. More than 90 % of industrial processes actually use catalysts in one form or the
other. Owing to expanding need of mankind, production in all sectors is increasing at a fast rate
and catalysis science and technology has a major contribution in this. Thrusts are being given in
the areas of catalyst upgrading to new and more efficient catalysts. Increasing catalyst life is
another area of importance to maximize catalyst efficiency.
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History : Catalyst technology has been used for many centuries. It ranged from inorganic
catalyst to make soaps to enzyme catalysts for producing wines, cheese and other food and
beverages. The industrial catalyst technology started with the large-scale production of sulfuric
acid on platinum catalyst in 1875. In subsequent years, various major catalytic processes were
invented. In 1903, ammonia oxidation on Pt gauge was developed by Ostwald for nitric acid
production. Another major breakthrough was ammonia synthesis with promoted iron in 1908-
1914 by Mittasch, Bosch and Haber.
Conversion of synthesis gas to liquid hydrocarbons by hydrogenation of CO, which was

developed in 1920-1940, was a major development in the energy sector. In petroleum industry,
the development of catalytic cracking process during 1935- 1940 changed the energy scenario.
This process used a solid catalyst in the petroleum industry for the first time. Subsequent decades
saw the development of various catalytic hydrocarbon processes such as catalytic naphtha
reforming (1950) and hydrotreating for removal of sulphur, nitrogen, metals from petroleum feed
stock (1960). With the discovery of Ziegler-Natta catalyst in 1955, the polymer industry grew
significantly. The first large scale industrial homogeneous catalytic process came up in 1960 in
the form of Walker process for making acetaldehyde from ethylene. The development of shape
selective catalysts such as molecular sieves or zeolites for cracking (1964) resulted in the
production of exclusively shape selective products. The other major development in catalysis was
in 1970-1980 for environmental pollution control. Noble metal catalysts were developed for
emission control of CO, NOx and hydrocarbons from automobiles. Vanadia-titania and zeolite
catalysts were developed for selective reduction of NOx. Catalysis is a continuously growing area
and discovery of new catalysts and their applications has led to major development in the
chemical industry.
The economic significance of the catalyst industry is enormous. The catalytic processes
contribute greater than 35% of global GDP. The world catalyst industry amounts to US $ 12
billion. It is expected to grow annually by 6 % to US $16 billion US$ in 2012. Polymerization
catalysts are expected to grow most rapidly due to significant expansion in polymer industry.
Enzyme and organometallic catalysts will also grow. Reduction of sulphur levels in fuels and
ongoing shifts towards heavy grade crude oil with high sulphur content is expected to contribute
to the growth of catalytic hydrocarbon industry.

Catalysis involves understanding of the thermodynamics, kinetics, electronic interaction, crystal

structure, reactor design and process development for a catalytic process. It is an interdisciplinary
area involving contribution from chemical engineers, chemists and material scientists for
successful implementation of the entire process starting from preparation of catalysts to final
utilization in a chemical reactor.
Catalytic reactions
In a thermodynamically feasible chemical reaction, when addition of a small amount a chemical

substance increases the rate of attainment of chemical equilibrium but the substance itself does
not undergo any chemical change, then the reaction is called a catalytic reaction. The substance
that enhances the reaction rate is called a catalyst. Catalysts work by providing alternative
mechanism involving a different transition state of lower energy. Thereby, the activation energy
of the catalytic reaction is lowered compared to the uncatalyzed reaction as shown in Fig 2.
Fig. 2 . Comparison of activation energies of exothermic catalytic and non-catalytic reactions

A catalyst accelerates both the rates of the forward and reverse reaction. Equilibrium of a
reversible reaction is not altered by the presence of the catalyst. For example, when oxidation of
SO2 is carried out in the presence of three different catalysts, namely Pt, Fe2O3 and V2O5 , the
equilibrium composition is the same in all three cases. Another important characteristic of
catalyst is its effect on selectivity. The presence of different catalysts can result in different
product distribution from the same starting material. For example, decomposition of ethanol in
the presence of different catalysts results in different products as shown below.
ethanol →
boron phosphate
ethylene+diethyl ether
ethanol 
Mo 2 C/carbon
→ hydrogen + acetaldehyde
Types of catalytic reactions
Catalytic reactions can be divided into two main types –
1. Heterogeneous
2. Homogeneous
Heterogeneous catalysis
In heterogeneous catalytic reaction, the catalyst and the reactants are in different phases.
Reactions of liquid or gases in the presence of solid catalysts are the typical examples.
An example is the Contact Process for manufacturing sulphuric acid, in which the sulphur
dioxide and oxygen are passed over a solid vanadium oxide catalyst producing sulphur
trioxide. Several hydrocarbon transformation reactions such as cracking, reforming,
dehydrogenation, isomerization also fall in this category.
Homogeneous catalysis
In a homogeneous catalytic reaction, the catalyst is in the same phase as the reactants.
Typically, all the reactants and catalysts are either in one single liquid phase or gas phase.
Most industrial homogeneous catalytic processes are carried out in liquid phase. Ester
hydrolysis involving general acid-base catalysts, polyethylene production with

organometallic catalysts and enzyme catalyzed processes are some of the important
examples of industrial homogeneous catalytic processes.
Relative significance
Catalytic processes have great significance and about 90 % of all chemical industry involves
catalytic processes. Of all the industrial catalytic processes, approximately 80 % involve the use
of solid catalysts, 17 % homogeneous catalysts and rest 3 % biocatalysts. Thus, heterogeneous
catalysts, particularly solid catalysts, dominate the industrial catalytic processes. Though the
contributions of homogeneous catalytic processes in chemical industry are significantly smaller
than that of heterogeneous catalytic processes, but because of high selectivities, homogeneous
process are finding increasing importance for production of many important value added products
such as manufacturing of tailor made plastics, fine chemicals, pharmaceutical intermediates etc.
Heterogeneous catalytic theory
In general, it is believed that the entire surface of the solid catalyst is not responsible for
catalyzing any reaction. Only certain sites on the catalyst surface actually participate in the
reaction and these sites are called active sites on the catalysts. These sites may be the unsaturated
atoms resulting from surface irregularities or atoms with chemical properties that enable the
interaction with the adsorbed reactant atoms or molecules. Activity of the catalyst is directly
proportional to the number of these active sites available on the surface and is often expressed in
terms of turnover frequency. Turnover frequency is defined as the number of molecules reacting
per active site per second at the condition of experiments.
A solid catalytic reaction A → B goes through the following steps. The steps are illustrated in
Fig 3.
1. Transportation of reactant (A) from bulk fluid to pore mouth on the external surface
of catalysts pellets
2. Diffusion of the reactant (A) from the pore mouth through the catalyst pores to the
immediate vicinity of internal catalytic surface
3. Adsorption of reactant (A) onto the catalyst surface
4. Reaction of (A) on the catalyst surface producing product (B)
5. Desorption of the product (B) from the surface

6. Diffusion of the product (B) from interior part of the pores to the pore mouth on the
external surface
7. Transfer of the product (B) from pore mouth on the external surface to the bulk fluid
Fig. 3. Steps in solid catalytic reactions.
The overall rate of reaction is equal to the rate of slowest step in the mechanism. When the mass
transfer and diffusion steps [1,2,6,7] are very fast compared to adsorption and reaction steps
[3,4,5], concentration in the immediate vicinity of the active sites is the same or indistinguishable
from that in the bulk fluid. Consequently, the transport or diffusion steps do not affect the overall
rate of the reaction. Alternatively, if reaction and diffusion steps are fast compared to the mass
transfer steps, then mass transfer does affect the rate of reaction. When mass transfer from the
bulk phase to the pore mouth is slow and affects the reaction rate, then changing the flow
conditions past the catalyst should change the overall reaction rate. In case of porous catalysts,
diffusion within the catalyst pores may limit the reaction rate. Under this condition external flow
does not affect the reaction rate but internal diffusion does affect.

Lecture 2
Adsorption on solid surfaces
Importance of adsorption in solid catalysis
As discussed in the previous section, heterogeneous solid catalysis is strongly associated with
adsorption phenomenon. In solid catalysis, at least one of the reactant needs to be adsorbed on the
surface of the catalyst. Adsorption of a component ‘A’ on surface of material ‘B’ is defined as
preferential accumulation of the component ‘A’ on the surface of the material ‘B’. The
component ‘A’ is called adsorbate and surface ‘B’ is called adsorbent. The surfaces include both
external surface and internal surface due to the pores. For highly porous material, the internal
surface area due to the pores is much higher than the external surface area. The pores in a solid
material can be of different dimensions. Pores with diameter less than 2nm (20 A0) are called
micropores, pores in the range of 2- 50 nm (20 – 500 A0) are called mesopores, whereas pores
greater than 50 nm are called macropores. The pore size distribution of a catalyst is affected by
preparation condition and amount of loading of active component. Usually a wide pore size
distribution exists in a catalyst. However, catalyst can also be designed to have a very narrow
pore size distribution. Fig 1 shows the schematic representation of a typical porous solid catalyst
particle having both the mesopores and micropores. The active sites are dispersed throughout the
porous matrix. Under suitable conditions of temperature and pressure, a gas can gradually adsorb
on the solid surface and finally lead to its complete coverage.
Fig. 1. Schematic representation of typical porous support impregnated with active component

Why adsorption takes place on solid surface
In the bulk of the adsorbent, the molecules are associated with their neighbours equally in all
direction and the molecular forces are therefore balanced. However on the adsorbent surface, the
molecules are bounded to the inner molecules at one side leaving unbalanced molecular forces on
the other side. These unbalanced molecular forces on adsorbent surfaces create the attractive
force for the adsorbate molecules approaching the surface. These molecular forces are weak in
nature and called van der Waals attraction forces.
Types of adsorption
Depending on the nature of interaction, the adsorption can be of two types:
1. Physisorption
2. Chemisorption
The phenomenon of adsorbate molecules attaching themselves to adsorbent surface under the
influence of van der Waals forces is called physisorption or physical adsorption. The van der
Waals forces mainly consist of dipole –dipole interactions. This is an exothermic process with a
low enthalpy change known as heat of adsorption. This process resembles liquefaction and heat
of adsorption for physisorption is also known as heat of liquefaction.
At higher temperature, the adsorbed molecules can undergo electronic rearrangement with the
surface molecules. This phenomenon is called chemisorption. The electronic rearrangement may
include formation and breaking of chemical bonds. The electronic rearrangement occurs only
when there is significant interaction between adsorbate and the adsorbent molecules. Hence all
adsorbate will not be chemisorbed on all adsorbent surfaces. Chemisorption process is selective
and an adsorbate molecule will chemisorbed only on selected adsorbent. The adsorption
processes are shown in Fig 2. The Fig. 2(a) depicts the situation when the adsorbate molecule
approach any adsorbent surface under the influence of attractive forces created by the unbalanced
molecular forces on adsorbent surfaces. The Fig. 2(b) represents the phenomenon, when any
molecule is physisorbed on surface by van der Waals forces. No bond formation occurs in this
situation. A chemisorption situation is represented in Fig. 2(c) when there is a weak bond
formation between adsorbate and adsorbent molecule. As discussed above, the adsorbate
molecule will be chemisorbed only on selected adsorbent surface with which it can interact
significantly.

Adsorbate molecule
Unsaturated bond
a) At beginning of any adsorption Saturated bond
Bulk material
b) Any physisorbed condition
c) Any chemisorbed condition
Fig. 2. Schematic representation of different adsorption processes
Physisorption versus Chemisorption
1. Since physisorption involves only weak molecular interaction, the associated enthalpy
changes are small (in the range of 10 to 40 kJ /mol) . On the other hand, in case of
chemisorption, enthalpy change is quite large and can range from 80-400 kJ /mol.
2. The Fig. 3 compares the volume of gas adsorbed as a function of temperature under
physisorbed and chemisorbed conditions. In physisorption, the molecules are adsorbed on
surface by weak interaction. With increase in temperature, adsorbed molecules gain excess
energy and their tendency to escape from the surface increases. Hence volume of gas
adsorbed on the surface decreases with temperature as shown in Fig. 3. However, the
chemisorption involves higher interaction energy between adsorbate and adsorbent molecules
and hence is favored by temperature rise. Hence at low temperature range volume of
adsorbed gas increases with temperature. However, at higher temperature range as the
adsorbed molecules gains excess energy, rate of desorption becomes higher resulting in
decrease in adsorbed gas volume as shown in Fig. 3.

Volume of gas
adsorbed
Chemisorption
Physisorption
Temperature
Fig. 3. Volume of gas adsorbed as a function of temperature for physisorption and chemisorption processes
3. In case of chemisorption, since there is electronic interaction between adsorbate and

adsorbent molecules, only a monolayer of adsorbate can be formed on the adsorbent surface.
In case of physisorption, the first monolayer formed on the surface of the adsorbent can act
as adsorbing surface for formation of next layer of adsorbate and so on. This phenomenon is
called multilayer adsorption. The formation of monolayer and multilayers of the adsorbed
molecules on a surface is shown in Fig. 4. For the physisorption, volume of gas adsorbed
increases with pressure due to increase in concentration of adsorbate and formation of
multilayers. However for chemisorption process which corresponds to monolayer formation,
the effect of pressure is not significant.
Monolayer Multilayer Adsorbed

molecules
Solid surface
Fig. 4 . Monolayer and multilayer formation of the adsorbed molecules on a surface
4. Chemisorption is specific for adsorbate and adsorbent pair. Specific solid adsorbent can
undergo electronic interaction only with specific adsorbate gas molecule.
5. Physisorption is highly reversible while chemisorption can be irreversible.
6. Physisorption is important for estimating the total surface area. It also provides a basis for
estimating the pore volume and pore size distributions. On the other hand, chemisorption is
important in estimation of area of catalytic active sites as well as its dispersion.

Examples :
Physisorption : Adsorption of nitrogen on carbon or alumina.
Chemisorption : Adsorption of hydrogen on active platinum sites on any support.
Potential energy diagram of approaching molecule towards a solid surface
The potential energy variation of a molecular system as it approaches a solid surface can be
depicted by the potential energy diagram, where the potential energy is plotted as a function of
distance of the approaching molecule from adsorbent surface. When the molecule approaches the
surface, at first it becomes attracted by a weak attractive force resulting in relatively flat potential
minimum corresponding to non – dissociative physical adsorption. Then depending on extent of
interaction it can be carried to non-dissociative chemisorbed state and finally to stable dissociated
state. When the extent of interaction is less, the adsorbate molecules are only physically adsorb
on the adsorbent surface or may occur in non-dissociative chemisorbed state. If the interaction is
only van der Waals type then the adsorbates will be in physisorbed state. In case of stronger
electronic interaction the process may be directly carried on to dissociative chemisorption. If the
crossing points are below the line of zero potential energy as shown in Fig. 5, then the overall
process is non-activated. If they are above, the overall process requires activation.
Fig. 5. Potential energy diagram for non activated dissociative chemisorption

Lecture 5
Solid catalysts
Catalyst components
A solid catalyst consists of mainly three components :
1. Catalytic agent
2. Support /carrier
3. Promoters and Inhibitors
Catalytic agent:
These are the catalytically active component in the catalyst. These components generate
the active sites that participate in the chemical reaction. Activity of any catalyst is
proportional to the concentration of these active sites. Though concentration of the active
sites depends on the amount of catalytically active component, however, it is not always
directly proportional. Availability of active sites depends mainly on the dispersion of
catalytic agent. The dispersion is defined as ratio of total number of exposed
atoms/molecules of catalytic agent available for reaction to total number of
atoms/molecules of catalytic agent present in the catalyst sample.
Catalytic agents may be broadly divided in the following categories:
i. Metallic conductors ( e.g Fe, Pt, Ag, etc.)

ii. Semiconductors (e.g. NiO, ZnO,etc.)
iii. Insulators (e.g. Al2O3, SiO2,MgO etc.)
Metallic conductors: The metals that have strong electronic interaction with the
adsorbates are included in this category. The metals are used in various catalytic
reactions such as methanol synthesis, oxidation , hydrogenation and dehydrogenation
processes.

Examples of metal catalysts :
Cu for water gas shift reaction and methanol synthesis ; Ag for oxidation of ethylene to
ethylene oxide, Au for oxidation of methanol to formaldehyde; Fe for ammonia
synthesis; Pd and Pt for hydrogenation of olefins, dienes, aniline or nitriles as well as
dehydrogenation of alkanes, alcohols, cyclohexanes, cyclohexanols etc.
Semiconductors :
The oxides and sulfides of transition metals that have catalytic activity are included in
this category. Similar to conducting metals, they are also capable of electronic interaction
with adsorbed species and catalyze the same type of reactions. Usually the lower valence
band electrons participate in bonding. The upper conduction band separated by band gap
energy is empty unless electrons are promoted by heat or radiation. Semiconductor
characteristics may be intrinsic or induced by addition of foreign ion, creating cationic or
anionic vacancies. Common transition oxides and sulfides such as CuO, AgO, NiO CoO,
Fe2O3 , MnO, Cr2O3, FeS, V2O5 show conductivity. These materials participate in
catalytic reactions and reaction occurs through acceptation or donation of electrons
between the reactant material and catalysts. Few applications of semiconductor catalysts
are : CuO for oxidation of nitric oxides, NiO for dehydrogenation of alkanes, MnO2 for
oxidation of alcohols, and V2O5 for oxidation of hydrocarbons.
Insulators : Catalytic functions of insulators are different from that of conductor and
semi conductor materials. Insulators have large values of band gap energy and very low
concentration of impurity levels. The electrons remain localized in valence bonds and
redox type reactions involving electronic interaction as observed for metal or
semiconductor catalysts does not occur. However, insulators have sites that generate
protons, thereby, promote carbonium ion based reactions such as cracking, isomerization
or polymerization. Al2O3, SiO2, SiO2-Al2O3, zeolites, MgO, CaO, MgAl2O4, SiO-MgO
are few examples of the insulators used as catalysts.

Support or carrier
Support or carrier provides large surface area for dispersion of small amount of
catalytically active agent. This is particularly important when expensive metals, such as
platinum, ruthenium, palladium or silver are used as the active agent. Supports give the
catalysts its physical form, texture, mechanical resistance and certain activity particularly
for bifunctional catalysts. Area of the support can range from 1 - 1000 m2/gm. Common
supports are alumina, silica, silica-alumina, molecular sieves etc. The surface area of α -
alumina is in the range 1-10 m2/gm whereas the surface area for γ or η - alumina can be
in the range 100 – 300 m2/gm.
Support may be inert or interact with the active component. This interaction may result in
change in surface structure of the active agent and thereby affect the catalyst activity and
selectivity. The support may also exhibit ability to adsorb reactant and contribute to the
reaction process.
Promoters :
Promoters are generally defined as substances added during preparation of catalysts that
improve the activity or selectivity or stabilize the catalytic agents. The promoter is
present in a small amount and by itself has little or no activity.
Promoters are termed as physical or chemical promoter depending on the manner they
improve the catalyst performance.
The additives that maintain physical integrity of the support and/or deposited catalytic
agents are termed as physical promoters. For example, addition of small quantities of
alumina to an iron catalyst employed in ammonia synthesis prevents sintering of the iron
crystallites. Thus, for this catalyst, alumina is a physical promoter. The addition of K2O
to the same catalyst increases the intrinsic activity of the iron crystallites and therefore
acts as a chemical promoter. The promoter can be added during catalyst preparation or
during reaction.

Negative promoters or inhibitors: Inhibitors act opposite to promoters. When added in

small amounts, these can reduce catalyst activity, selectivity or stability. Inhibitor is
particularly useful for reducing the activity of a catalyst for undesirable side reactions. In
oxidation of ethylene, ethylene dichloride is added to inhibit CO2 formation thus acting as
an inhibitor.
Industrial catalysts
Industrial catalysts can be broadly grouped into three categories:
1. Bulk catalysts : When the entire catalyst consists of the catalytically active
substance ,then the solid catalyst is called a bulk catalyst. Examples include silica-
alumina catalysts for catalytic cracking; iron- molybdate for oxidation of methanol
to formaldehyde; iron doped with alumina and potassium oxide for the synthesis of
ammonia.
2. Supported catalysts: In supported catalysts, the catalytically active materials are
dispersed over the high surface area support material. For example,
hydrodesulphurization is carried out over molybdenum oxide supported on
alumina.
3. Mixed agglomerates : These catalysts are agglomerated mixture of active substance
and support. These type of catalysts are used less frequently.

The typical surface area values of different supports and catalysts are summarized in
Table 1.
Table 1. Typical surface area values of different support and catalyst.
Support/catalyst BET surface Application

area
m2/g
Activated carbon 500-2000 Used as support for various process
Zeolites 500-1200 Used as catalyst and support
Al2O3-SiO2-Zeolites 100-600 Fluid catalytic cracking catalysts
Ni/Al2O3 100-150 Methanation catalyst
Cu/Zn/Al2O3 Methanol synthesis catalyst
MnOx/Al2O3 140-180 Catalyst for total oxidation of volatile

organic carbon
Fe/K/Al2O3 20 Ammonia synthesis catalyst
Determination of surface area using BET Equation
As discussed earlier (lecture 4), the BET equation describes the relationship between
volume adsorbed at a given partial pressure and the volume adsorbed at monolayer
coverage. BET equation can be written in the form :
p 1 c −1 p
= + --------------- (1)
v ( p0 − p ) vm c vm c p0
p = partial pressure ; po =saturation pressure at the experimental temperature ;

v = volume adsorbed at p; vm = volume adsorbed at monolayer coverage ; c =
constant

p
Monolayer coverage is determined using BET equation. The is plotted as a
v ( p0 − p )
p p
function of . The plot is linear in the range of relative pressures = 0.05 - 0.3. At
p0 p0
higher relative pressure p/po, the BET plot deviates from linearity as non-ideality or pore
condensation was not accounted for the derivation of BET equation.
Slope and intercept of this linear plot is used for determination of monolayer capacity vm .
The intercept and slope from the plot is given as
1 ( c − 1)
Intercept = Slope =
cvm cvm
1
Then the monolayer volume vm is given as , vm = ( STP )
slope + intercept
The total number of N2 molecules adsorbed corresponding to monolayer volume vm can

be calculated as
vm (m3 ) × 6.02 ×1023 (molecules / mol )

No. of N 2 molecules =
0.0224 (m3 / mol )
Now , each adsorbed N2 molecule occupies an area of surface comparable to its cross
section area of 0.162 nm2.
 vm (m3 ) × 6.02 ×1023 (molecules / mol ) 

SA ( m 2
)  3  ×16.2 ×10
−20
(m 2 / N 2 molecule)
 (0.0224 m / mol ) 
Or SA ( m 2 ) = vm ( m3 ) × 4.36 ×106 (m −1 ) = 4.36 × 106 vm

Solved problem :
1.Nitrogen was employed to determine the surface area of 1.0 g sample of silica gel and
results obtained shown in table below. The sample of silica gel was maintained at the
normal boiling point of liquid nitrogen (77K). One molecule of nitrogen occupies 16.2 ×
10-20 m2 area of plane surface. Calculate the specific surface area of silica gel by the BET
method. The saturated vapor pressure p0 of nitrogen at 77K is 101.3 kPa.
Equilibrium Pressure, p [kPa] 5.0 6.3 7.5 9.0 11.2
Volume adsorbed, (STP), V × 106 6.7 7.0 7.2 7.4 7.7

[m3]
Solution :
p 1 C −1 p
The BET equation in following form is used. = +
V ( p0 − p ) Vm C Vm C p0
p p
The is plotted as function of . The plot is shown in Fig. 3.
V ( p0 − p ) p0

Table 1. Calculation for plot of BET equation
v p po p/po p/[v(po-
p)]
m3 kPa kPa
m-3
6.7E-06 5 101.3 0.049 7.75E+03
7.0E-06 6.3 101.3 0.062 9.47E+03
7.2E-06 7.5 101.3 0.074 1.11E+04
7.4E-06 9 101.3 0.089 1.32E+04
7.7E-06 11.2 101.3 0.111 1.61E+04
Fig. 3. Linear plot of BET equation
Intercept = 943.5 m- 3 ; Slope = 137486 m- 3
1 1
Monolayer volume =
Vm = = 7.22 ×10−6 m3 (STP)
slope + intercept 137486 + 943.5
Then surface area for 1 gm sample can be determined as :

 7.22 ×10−6 m3 × 6.02 ×1023 molecules / mol 

SA  −6 3  ×16.2 ×10−20 m 2 / N 2 molecule
 22400 ×10 m / mol 
= 31.4 m2
As initially 1 gm sample was used, specific surface area of sample = 31.4 m2/g
Book reference
• S. Lowell, Joan E. Shields, Martin A. Thomas ,Characterization Of Porous Solids

And Powders: Surface Area, Pore Size And Density - Springer, 2006
• J.J. Carberry , Chemical and catalytic reaction Engineering, Dover Publications,
2001
• J. M. Thomas & W. J. Thomas, Principles and Practice of Heterogeneous Catalysi,
VCH, 1997
• Sam Zhang, Lin Li, Ashok Kumar, Materials Characterization Techniques, CRC
Press, 2009
• Y. Leng, Materials Characterization: Introduction to microscopic and spectroscopic
methods, John Wiley & Sons, 2008

Lecture 11
Pore analysis
In general, catalyst consists of pore in the range of, micropore, mesopore or macropore
depending on the preparation conditions and compositions. To determine the pore size
distribution within the catalyst, pore analysis is essential. Knowing the pore size
distribution gives an idea about accessibility of the reactants to the active sites. The pore
analysis consist of determining the average pore size, average pore volume and pore size
or pore volume distribution.
Total pore volume and average pore size
Total pore volume is defined as the liquid nitrogen volume at a certain p/po (=0.95).Total
gas adsorbed at certain p/po (=0.95) is converted to liquid volume assuming pores are
filled with liquid adsorbate
Vgas ( STP )
V p =Vliq = × 34.6 =Vgas × 1.54 × 10−3 cm 3
22.4 × 10 3
where , 34.6 cm 3 / mol = molar volume of liquid nitrogen
Average pore size can be estimated from the pore volume. Assuming cylindrical pore
2V p
geometry average pore radius (r) can be expressed as: r =
S
Pore size
(a) By gas adsorption

Pore size and pore size distribution can be determined using Kelvin equation. Kelvin
equation relates equilibrium vapor pressure (p) of a liquid contained in a capillary to
equilibrium pressure of the same liquid over a free surface (po) :
γ = surface tension of liquid nitrogen

θ = contact angle ( usually zero for liquid N 2 )
p −2γ Vliq cos θ Vliq = the molar volume of liquid nitrogen
ln = -------------------- (1)
po rRT r = radius of pore
R = gas constant
At any equilibrium pressure, p, the pore of radius less than ‘r’ will be filled with the
condensed vapor. Application of Kelvin equation to all points of an isotherm at relative
pressure greater than that corresponding to monolayer volume where capillary
condensation begins to occur, will yield information concerning the volume of gas
adsorbed in pores of different radii. For nitrogen as adsorbate and substituting values of
various constants, the Kelvin equation can be written as
P −2γ Vliq cos θ

ln =
Po rRT
p
Or rk ( nm ) = 0.41 log (2)
p0
γ = 8.72 mN/m
θ =0
Vliq 34.68 ×10−6 m3 / mol
=
T = 77 K
R=8.314 J / K mol
The ‘rk’ is the radius into which condensation occurs at the required relative pressure.
This radius is called Kelvin radius. However, Kelvin radius is not the actual pore radius
since some adsorption has already occurred on the pore wall prior to condensation
leaving a central core of radius rk . Conversely, an adsorbed film remains on the wall
when evaporation of the centre core takes place.
Condensed
liquid t
Adsorbed
2rk film
2r
Fig. 3. Schematic showing Kelvin radius and actual pore radius during pore condensation

Then if ‘r’ is the actual pore radius and the thickness of the adsorbed film is t (Fig. 3)
then
2γ Vliq p
r (nm) = rk + t = + t = 0.41 log + t (3)
p p0
RT ln
po
Pore size distribution can be obtained by the analysis of either adsorption or desorption
isotherm branches. Kelvin equation as described is applied to the desorption branch of
hysteresis loop as it is more appropriate to assign wetting angle to a pore filled with
liquid that possess a well defined meniscus. If ‘h’ is the effective height of a monolayer,
V 
then the thickness of adsorbed layer ‘t’ is given as t =   h . Here ‘V’ is the volume of
 Vm 
gas adsorbed and ‘Vm’is the volume of adsorbed monolayer. When the packing of
adsorbate is hexagonal, then for nitrogen h = 3.6 A0 and for cubic packing h= 4.3 A0 =
0.43 nm. The ‘t’ at a given relative pressure can also be calculated using Halsey equation
1 1
 3  3
 5  o  5 
t=
3.54 ×   ( A) =
0.354 ×   nm (4)
 2.303 × log p0   2.303 × log p0 
 p   p 
Pore size distribution
Most common method for determination of pore size distribution is BJH (Barrett-Joyner-
Halenda) method. Assumptions are:
(i) Condensation occurs in pores when a critical relative pressure is reached

corresponding to the Kelvin radius ‘rk’
(ii) When evaporation or condensation occurs, a multilayer of adsorbed film exist on the
pore wall and this film has same depth/thickness as the adsorbed film on a non porous
surface

(iii) Actual pore volume evaporation is composed of the volume evaporated out of the
central core plus the volume desorbed from the film left on the pore walls
Steps for determination of pore size distribution are as follows:
1. p/p0 and Vgas (STP, cm3/g) data obtained directly from isotherm.
2. Then Kelvin radius ‘rk’is calculated from Kelvin equation using zero wetting
angle for N2 from equation(2).
3. Then, the film thickness t calculated from Halsey equation (4) at each p/p0.
4. Then the pore radius r calculated from equation (3).
5. Mean values of rk and r in each decrement are calculated from successive entries.
6. Change in film thickness Δt is calculated from difference of successive values of t .
7. Then ΔVgas , that is the change in adsorbed volume between successive p/po values,
is determined by subtracting successive values .
8. Thereafter, ΔVliq that is the volume of liquid corresponding to ΔVgas is calculated as
follows
∆Vgas
∆Vliq = ∆Vgas × 1.54 × 10−3 cm 3 / g
× 34.6 =
22.4 × 10 3
9. Then ΔtΣS is determined. This represents the volume change of the adsorbed film
remaining on the walls of the pores from which the central core has previously
evaporated . This volume is the product of the film area ∑S and the decrease in film
depth Δt
10. Actual pore volume evaporated, Vp. is then determined. Actual pore volume
evaporated is composed of the volume evaporated out of the centre core plus the
volume desorbed from the film left on the pore walls, For a pore of length L,
Vliq π rk2 L + ∆t ΣS
∆=
2
−
V p  −   ∆Vliq − ( ∆t ΣS × 10−4 )  cm 3 / g
r
Now , V p = π r 2 L . By combining
=
 
 rk 

11. The surface area of the pores walls can be calculated from pore volume by :
2V p
=
S −
× 104 m 2 , Vp in cm3/g and r in A0
r
An elaborate example of pore size distribution work table can be seen in Lowell et al. for
more understanding.
(a) (b)
0.04
Pore Volume (cc/g*nm)
0.03
0.02
0.01
0
0 5 10 15 20 25 30 35 40
Pore Diameter (nm)
Fig. 4. Pore volume distribution of titania samples calcined at 400 0C
(a) differential (b) cumulative
Pore size distribution can be represented both in differential and cumulative ways. The
Fig. 4(a) shows the differential BJH pore distribution of titania sample calcined at 400 0C.
The figure shows that for the given sample pores were in the range of 2-10 nm. The
corresponding cumulative pore distribution is shown in Fig. 4(b).
(b) By mercury intrusion
For macropores materials with pore diameter greater than 50 nm, the mercury intrusion
method is preferred. Due to non-wetting nature of mercury on oxide supports, intrusion is
met with resistance and mercury is forced to enter the pores of material under pressure.
The pore radius ‘r’ is related to the applied pressure P as
( −2γ cos θ )
P = -----------------(5)
r

The wetting or contact θ angle between mercury and solid is on average lies in the range
130-1400 and surface tension of mercury is 0.48 N/m2. p is in atm and r in nanometers.
As can be observed from equation (5) smaller the pore radius higher is the pressure
needed for mercury to intrude in the pore. At low pressure of 0-2 atm, mercury
penetrates voids between particles. At moderate pressure range of 3-500 atm large
macro pores are filled. At further higher pressure range of 500-2000 atm, smaller macro
pores and large mesopores are progressively filled. This technique is satisfactory for
pores down to 3-5 nm dia . Maximum diameter that can be measured is usually 105 nm.
Mercury intrusion method is carried out in the instrument known as mercury porosimeter.
In a typical mercury porosimeter data, volume of mercury penetrating into pores is
plotted as a function of applied pressures.
Mercury r2 r3
r1
Sample
Pressure 1 Pressure 2 Pressure 3
Pressure 1< Pressure 2 < Pressure 3 as r1 > r2 > r3
Fig. 5. Intrusion of mercury into pores of various sizes. Here ‘r’ represents the radius of pores.
The pressure required for filling up the pores as a function of pore size is schematically
shown in Fig.5. As pore radius decreases in the order r1 > r2 > r3, requried pressure for
filling the pores increases in order of Pressure 1< Pressure 2 < Pressure 3.The available
instruments can measure pore size up to 2 nm using a maximum operating pressure of
about 400 MPa.

Table 1. Typical pore volume values of different support and catalyst.
Support/catalyst Pore Application

volume
cm3/g
Activated carbon 0.6-0.8 Used as support for various process
Zeolites 0.5-0.8 Used as catalyst and support
Al2O3-SiO2-Zeolites 0.1-0.9 Fluid catalytic cracking catalysts
Book reference
• S. Lowell, Joan E. Shields, Martin A. Thomas ,Characterization Of Porous Solids

And Powders: Surface Area, Pore Size And Density - Springer, 2006
• J.J. Carberry , Chemical and catalytic reaction Engineering, Dover Publications,
2001
• J. M. Thomas & W. J. Thomas, Principles and Practice of Heterogeneous Catalysis,
VCH, 1997
• Sam Zhang, Lin Li, Ashok Kumar, Materials Characterization Techniques, CRC
Press, 2009

Lecture 19
Reaction mechanism and kinetic study
Reaction mechanism and rate equations
For irreversible gas phase reaction A ( g ) → B ( g ) , global rate for catalyst particles is
expressed in terms of temperature and concentration of A in bulk gas stream which can
be measured or specified directly. Global rates of catalytic reactions are usually
expressed per unit mass of catalyst.
Power law model
For homogeneous reaction, power law form of rate equation is used where rate is
function of concentration and rate is determined by fitting data to the equation. The
exponents on the concentration is the apparent order of the reaction and ‘k’ is the kinetic
constant or reaction rate constant which is independent of concentration and depends on
temperature.
For reactions A+B → C+D
dC
γa =
− a =kC αA C Bβ
dt
Here α is the order with respect to A and β is the order with respect to B
This power law approach can also be used for solid catalytic reactions. This analysis is
simple. The major disadvantage of this method is that it ignores all the factors associated
with adsorption and reaction mechanism on surface of solid catalyst. Hence, power law
kinetics fails to adequately describe any solid catalytic process and the rate equation
derived from mechanistic model is more preferred. Power law kinetics is preferred as a
mode of obtaining preliminary value of rate parameters for solid catalyzed reactions.
Langmuir-Hinshelwood –Hougen-Watson(LHHW) model
The rate equation derived from mechanistic model that simulates the actual surface
phenomenon during the process is preferred for reactions involving solid catalysts. The
Langmuir-Hinshelwood–Hougen-Watson(LHHW) approach is one of the most
commonly used way of deriving rate expressions for fluid solid catalytic reactions. The
advantages of this method are that :
(1) Rate derived by this method takes into account the adsorption-desorption process
occurring over the surface along with the surface reaction.
(2) Rate equation derived can be extrapolated more accurately to concentrations lying
beyond the experimentally measured values.
During this method of derivation of rate expression, all the physical transport steps like
mass transfer from bulk phase to catalyst surface or diffusion of reactants from pore
mouth to interior pore (intraparticle diffusion) are excluded. Thus, it is assumed that the
external and internal mass transport processes are very rapid relative to the chemical
rate process occurring on or within the catalyst particle. The chemical rate depends on :
(1) chemisorption steps
(2) surface reaction steps
(3) desorption steps
This simple kinetic model assumes isothermal condition about and within catalyst that is
temperature gradient is zero.
In LHHW model development, the rate equation is first derived in terms of surface
concentration of adsorbed species and vacant sites. Then, these surface concentrations are
related to the fluid or bulk concentration that is directly measurable.
For the reaction A + B  C + D
Let ra = rates of adsorption ( g mol/s.gm of

catalyst)
rs = rates of surface reaction ( g mol/s.gm of catalyst)
rd =rates of desorption ( g mol/s.gm of catalyst)
C AS = concentration of adsorbed A on surface ( g mol/gm of catalyst)
C BS = concentration of adsorbed B on surface (gmol/gm of catalyst)
C cs = concentration of adsorbed C on surface (g mol/gm of catalyst)
C DS = concentration of adsorbed D on surface (g moles/gm of catalyst)
CO = total concentration of active sites on surface (g mol/gm of catalyst)
CV = concentration of vacant sites on surface (g mol/gm of catalyst)
C A = concentration of A in bulk gas phase (g mol/cm3)
Similarly C B , CC , C D are the concentrations of B,C,D in the bulk gas phase,

respectively.
Let the reaction follows the mechanism given below ;
(1) A + S  A.S --- Adsorption of reactant A on surface vacant site S

(2) B + S  B.S --- Adsorption reactant B on surface vacant site S
(3) A.S + B.S  C.S + D.S --- Surface reaction between adsorbed A and B
(4) C.S  C + S --- Desorption of product C from surface creating a vacant
site
(5) D.S  D + S ---Desorption of product D from surface creating a vacant
site
Among the various steps described, the slowest step controls the overall rate of reaction
and the other remaining steps are assumed to be at near equilibrium conditions. This
approach greatly simplifies the overall rate expression, reducing the number of rate
constants and equilibrium constants to be determined from experimental data. Further
each step in this method is assumed to be elementary and the number of sites is conserved
in each step.
Therefore, the controlling step can be either of the following:
(1) Surface reaction

(2) Adsorption
(3) Desorption
Now total concentration of active sites on surface, CO , will be the summation

concentrations of all sites on which either reactants or products are adsorbed and the
concentration of vacant sites.
∴ CO = CV + C AS + C BS + CCS + C DS
Where, CV is the concentration of vacant sites.
Case 1 : Rate is surface reaction controlling
The surface reaction is the slowest step and is the rate controlling. According to the
mechanism, surface reaction occurs between adsorbed A and adsorbed B producing
adsorbed C & adsorbed D.
AS + BS  CS + DS
The rate of surface reaction is given as
=rS k S C AS C BS − k S' CCS C DS k s = rate constant for forward surface reaction
k S' = rate constant for reverse surface reaction
 k S' 
= k S C AS C BS − CCS C DS 
 kS 
 1  kS
= k S C AS C BS − CCS C DS   KS = (1)
 KS  k S'
Now, since all the other steps are considered to be in equilibrium, therefore concentration
of adsorbed species can be obtained as follows.
For adsorption steps and desorption steps :
C AS CCS
From step (1) KA = From step (4) K C =
C A.CV CC .CV
C BS C DS
From step (2) KB = From step (5) K D =
C B .CV C D .CV
K A , K B , K C , K D are adsorption equilibrium constants.
Then, the adsorbed phase concentrations can be written as
C AS = K AC ACV CCS = K C CC CV
C BS = K B C B CV C DS = K D C D CV
Substituting all these value in equation (1)
 1   K 
rS =k S C AS C BS − CCS C DS  =k S  K AC ACV . K B C B CV − C CC CV . K D C D CV 
 KS   KS 
 K K 
=or, rs k S  K A K B C AC B CV2 − C D CC C D CV2 
 KS 
 KC K D 
=or rS k S K A K B C AC B − CC C D  CV2 (2)
 KS K AKB 
Now , CO = C AS + C BS + CCS + C DS + CV
CO = K AC ACV + K B C B CV + K C CC CV + K D C D CV + CV
=CV [1 + K AC A + K B C B + K C CC + K D C D ]
CO
CV = (3)
1 + K AC A + K B C B + K C C C + K D C D
For the reaction A+B  C+D , at equilibrium , the overall equilibrium constant is
CC C D
K= .
C AC B
All concentrations correspond to the equilibrium conditions in gas phase.
( C / K C CV )( C DS / K DCV )
K = CS =
CCS C DS K A K B CV2
.
( C AS / K ACV )( C BS / K BCV ) C AS C BS K C K D CV2
KAKB CCS C DS
Or , K = .K  KS = (4)
KC K D S C AS C BS
Substituting (3) &(4) in equation (2),
 1  CO2
=rS k S K A K B  C AC B − CC C D 
  ( 1 + K AC A + K B C B + K C C C + K D C D )
2
K
1
C AC B − CC C D
rS = k S K A K B C
2 K (5)
( 1 + K AC A + K B C B + K C C C + K D C D )
O 2
The above rate expression can also be derived in terms of bulk partial pressure.
Case 2: Rate is adsorption control
(a) Adsorption of A controlling
Let adsorption of A be the slowest step so that adsorption of B, surface reaction and
desorption of C are at equilibrium.
Adsorption of A is given as
A + S  AS
=
Rate of adsorption ra ka C ACV − kd C AS
 k 
=ra ka C ACV − d C AS 
 ka 
 1  ka
=
Or, ra ka C ACV − C AS  KA = (adsorption equilibrium constant for A)
 KA  kd
 1 C AS 
=ra ka CV C A −  (6)
 K A CV 
Now as other steps are in equilibrium :
CCS C DS
KS =
C AS C BS
C BS C C
KB = K C = CS K D = DS
C B CV CC CV C D CV
C BS = K B C B CV CCS = K C CC CV C DS = K D C D CV
Then ,
CCS C DS K C CC CV . K D C D CV K C K D CC C D CV
C AS = = =
K S C BS K S K B C B CV KS KB CB
Substituting value in equation (6)
 1 K C K D CC C D CV 
=ra ka CV C A − 
 K ACV K S K B CB 
 K C K D CC C D 
=ra ka CV C A − 
 K S K A K B CB 
 1 CC C D 
=ra ka CV C A −  (7)
 K CB 
KS KAKB
K= = Overall equilibrium constant.
KC K D
Now C 0 =CV + C AS + C BS + CCS + C DS
K C K D CC C D CV
=
CV + . + K B C B CV + K C CC CV + K D C D CV
KS KB CB
 K K K C C  
=CV 1 + C D A  C D  + K B C B + K C CC + K D C D 
 K S K A K B  CB  
 K C C 
=CV 1 + A C D + K B C B + K C CC + K D C D 
 K CB 
CO KS KAKB
CV = K =
K A CC C D KC K D
1+ + K B C B + K C CC + K D C D
K CB
Substituting value of CV in equation (7)
C C 
CA −  C D 
ra = ka C 0  KC B  (8)
K C C
1 + A C D + K B C B + K C CC + K D C D
KC B
For a given catalyst C 0 is constant.
Similarly expression when desorption of product is the rate controlling step can be
derived. For desorption of C controlling the whole reaction, the rate expression can be
derived as
C C 
C AC B −  C D 
rd = kd C 0 K  K 
1 + K AC A + K B C B + K C KC AC B + K D C D
Eley Rideal model
Apart from power law and Langmuir-Hinshelwood models, other kinetic models are also
used to fit the data. EleyRideal model depicts the reaction mechanism in which one
reactant species (say A) is adsorbed while the second reactant species (say B) is not
adsorbed on the catalyst surface. The reaction then occurs when the passing gas
molecules of B in gas phase directly reacts with the adsorbed species A. The schematic
representation is shown in Fig. 1.
Fig. 1. Eley Rideal mechanism for reaction of adsorbed A with gas phase B producing product AB
(1) A + S  AS
(2) AS + B (g) → P
Assuming that step 2, the reaction between adsorbed A and gas phase B is irreversible
and the rate determining step, then the rate of reaction can be written as
r = k CAs CB (9)
The concentration of adsorbed A can be given as CAS = K A CA CV
Now , CO = CAS + CV = K A CA CV + CV = CV (1 + K A CA )
CO
CV =
1 + K A CA
K A C A CO
CAS =
1 + K A CA
Substituting value of CAS in equation (9)
kCO K A CA CB
=r k=
CAS CB
1 + K A CA
If the products are chemisorbed then the reaction may become reversible as shown below.

AS + B(g) 
k

 PS
k b
PS → P + S
Then the rate expression can be written as
=r k CAs CB − k b CPs
The concentration of adsorbed product is CPS = K P CP CV
CO = CAS + CPs + CV = K A CA CV + K p CP CV + CV = CV (1 + K A CA + K P CP )
CO
CV =
1 + K A CA + K P CP
K A C A CO
=CAS K=
A CA CV
1 + K A CA + K P CP
K P C P CO
=CPS K=
P CP CV
1 + K A CA + K P CP
Substituting CAS and CPS in rate expression,
 1  k
=
r k CAs CB − k b C=
Ps k  CASCB − CPS  =
K
 K  kb
 K A C A CO 1 K P C P CO 
r k  CB − 
 (1 + K A CA + K P CP ) K (1 + K A CA + K P CP ) 
 KP 
 K A CA CB − CP 
r = kCO  
K
1 + K A CA + K P CP
Estimation of model parameters
The various parameters in the kinetic models such as rate constants, reaction orders, and
equilibrium constants are derived by fitting the experimental data. The optimal values of
the parameters in the rate equation of a heterogeneous reaction are determined
traditionally by using gradient or direct search methods. For success of this method, a
very good initial estimate of the parameters is required. This proves to be difficult in most
cases. If the initial estimates are far from the global optima, then it is likely that the
gradient or direct search method will not converge at all or will converge to local optima.
Recently genetic algorithm (GA) is increasingly applied in estimation of kinetic
parameters. The major advantage of this method is that it is not dependent on the initial
estimate of the parameters. GA performs a multi-directional search.
Book Reference
• J. M. Smith, Chemical Engineering Kinetics, McGrawHill Book Company, 1981

• J.J. Carberry, Chemical and catalytic reaction Engineering, Dover Publications, 2001
• H. S. Fogler, Elements of Chemical reaction engineering, Prentice Hall of India,1999
• R. J. Farrauto and C. H. Bartholomew, Fundamentals of Industrial catalytic
Processes, Blackie Academic & Professional, 1997
Lecture 20
Analyzing data from laboratory reactors
The objectives of analyzing data include

• Determining catalyst activity, selectivity and stability
• Determining the effect of important process variables such as temperature,
pressure, reactant concentrations
• Finding a rate equation
Elimination of mass transfer and pore diffusion limitations
In a solid catalyzed reaction, the presence of mass transfer and pore diffusional
resistances can significantly affect the rate of the reaction. The details will be discussed
in lecture no. 22 to 24. To ensure that no internal or external mass transfer resistances are
present under the operating conditions, preliminary experiments are carried out.
Elimination of mass transfer limitations
For checking if external mass transfer is affecting the rate of reaction, conversion data is
obtained by increasing the flow rate of the feed but keeping the W/FAO constant. Fig. 5
shows the plot of conversion as a function of linear velocity of fluid at constant W/FAO at
a given temperature, usually the highest temperature is used during reaction.
Fig. 5. Typical plot of conversion as a function of linear velocity of fluid at constant W/FAO and temperature
It can be observed that at low fluid velocity, conversion increases with increasing fluid
velocity and subsequently becomes constant at higher flow rates, implying that external
mass transfer does not affect the rate of reaction at this fluid velocity. Due to external
mass transfer limitation the concentration of reactant near catalyst surface is lower than
the bulk phase concentration. The effect is maximum at lower fluid velocity when the
resistance to transport is considerable. With increase in fluid velocity, the turbulence
effectively enhances the mixing in fluid phase and the concentration of reactant near the
catalyst surface approaches the bulk phase concentration. Consequently reaction rate
increases increasing the conversion. At high velocity due to high turbulence the mass
transfer limitation is totally removed and the reactant concentration near the catalyst
surface becomes equal to that of bulk phase concentration and the conversion reaches the
maximum limiting values. Thereafter any change in fluid velocity does not affect the
conversion as shown in the figure. Kinetic study should always be carried out at
conditions where the effect of external mass transfer on conversion is negligible.
Elimination of pore diffusion limitations
rp ρp
Weisz criterion Rs2 ≤ 1 can be used to determine the significance of intraparticle
Cs De
diffusion. Here Rs=pellet radius; rp=observed rate; ρp = pellet density, Cs = surface
concentration; De effective diffusivity. Reactions should be carried out at the conditions
when Weisz criterion is satisfied so that the intraparticle diffusion could be neglected for
these operating conditions. This is discussed in details in lecture no. 24. The effectiveness
of porous catalyst can also be determined experimentally by measuring conversion with
successively smaller catalyst pellets until no further change in conversion occurs. The
pore diffusion resistance decreases the concentration within the pellets thereby decreasing
the conversion. The pore diffusion resistance is considered to be negligible for the
catalyst size range for which the conversion does not change with size. For study of
intrinsic reaction kinetics, catalyst pellet size is chosen where the intraparticle diffusion
could be neglected.
Elimination of homogeneous phase reaction and deactivation
When reaction is carried out over a fixed bed of solid catalyst there may be possibility of
non-catalytic homogeneous reactions occurring in gas phase. If any non-catalytic
homogeneous reactions occur along with heterogeneous catalytic reactions, then data
collected will give erroneous kinetics for the heterogeneous reaction. Hence, reaction
should be carried out in an empty reactor without using any catalyst to determine the
contribution of homogeneous phase reactions, if any, at the desired operating conditions.
Kinetic study should be carried out at operating conditions for which contribution of
homogeneous phase reactions is negligible.
In addition, deactivation studies should be carried out by operating the reactor for long
run lengths. If any significant deactivation occurs, than it should be taken into account for
further analysis.
Integral analysis of rate data

In this method a series of run are made in a packed bed at a fixed initial concentrations
CA0 and a fixed temperature while varying the catalyst mass W and/or initial molar flow
rate FA0 to generate a range of W/FA0 values at different conversions XA. A rate equation
is then selected for testing using the design equation for packed bed reactor.
x Af
W dX A
FAo
= ∫
0
−rA (1)
First simpler rate equations such as zero order, first order, second order irreversible are
tried. Mechanistic reaction models can also be tested. The W/FA0 and the right hand
integral in equation (1) are evaluated numerically and plotted to test for linearity (Fig 1).
Linearity of the plot is used as criterion for judging if the selected rate equation is a
useful model for the data i.e consistent with the data. If not then another rate equation
may be tried.
W/FA0
x Af
dX A
∫0
− rA
Fig. 1. Typical plot of W/FA0vs integral value for linearity test in integral analysis of rate data
Differential analysis of rate data

In this method, the data are collected as in the previous case. A plot of conversions XA
versus W/FAo is made for each set of runs at a fixed temperature (Fig 2) . A best fit of
data is made.Tangent to the fitted curve are drawn at regular interval along the curve
corresponding to the best fit. The slopes of this tangent are evaluated which correspond to
dX A
the reaction rate −rA =
d(W / FAo )
T constant
XA
Tangent slope=-rA
W/FA0
Fig. 2. Typical plot of XA vs W/FA0 for determination of rate from tangent slope in differential analysis of data
Tangents can be evaluated more accurately by differentiating the equation for best fit of
data and evaluating the derivative at various intervals over the data set. Values of –rA
versus CA are plotted to determine the reaction orders. For example for an irreversible
reactions in which data are fitted by a simple power rate law − rA =
kC An , a plot of ln(-rA)
vs lnCA is linear with a slope of order n. The rate constant value can be determined from
the intercept. If rate vs temperature data available then it is possible to determine the
apparent activation energy from Arrhenius equation k = A exp(-E/RT). The slope of the
plot of ln k vs 1/T gives the activation energy E of the reaction.
ln k Slope = E
1/T
Fig. 3. A typical Arrhenius plot for determination of activation energies
Linear and nonlinear regression of rate data

k p A pB
For a Langmuir –Hinshelwood type rate equation −rA = , the value
1 + K Ap A + K BpB
of rate law parameters k, KA, KB cannot be analyzed as simply as in power law kinetics.
The rate law parameters can be determined by linear least square or nonlinear least square
method. In linear least square method, the above LH rate equation can be linearized by
dividing throughout by pA and pB and inverting it as shown below:
p ApB 1 K A K
− =+ p A + B pB
rA k k k
The parameters can be estimated by multiple regression technique using the following
equation for N experimental runs. For the ith run :
Yi =
ao + a1 X1i + a 2 X 2i
The best values of the parameters a0, a1 and a2 are found by solving following three
equations
N N N
∑ Yi =
Nao + a1 ∑ X1i + a 2 ∑ X 2i
=i 1 =i 1 =i 1
N N N N
∑ ∑
X1i Yi = ao X1i + a1 X1i
2
∑ ∑
+ a 2 X1i X 2i
=i 1 =i 1 =i 1 =i 1
N N N N
∑
X 2i Yi = ∑ ∑
ao X 2i + a1 X1i X 2i + a 2 X 2i
2
∑
=i 1 =i 1 =i 1 =i 1
The above LH rate equation can also be solved by non-linear regression analysis. Usually
linearized least square analysis is used to obtain the initial estimates of the rate
parameters and used in non-linear regression. In non linear analysis the rate law
parameters are first estimated to calculate the rate of reaction ‘rc’. Then the values of rate
law parameters that will minimize the sum of the squares of difference of the measured
reaction rate rm and the calculated reaction rate rc , that is the sum of (rm-rc)2 for all data
points, are searched. If there are N experiments with K number of parameter values to be
determined then the function to be minimized is given by σ =∑ 2

N
( rim − ric ) 2
i =1 N−K
Here rim and ric are the measured and calculated reaction rate for ‘i’th run respectively.
The parameter values giving the minimum of the sum of squares, σ 2 , can be searched by
various optimization techniques using software packages.
Initial rate analysis
Initial rate analysis for a reaction may be done to understand the mechanism of a reaction.
Initial rate is defined as the rate at zero conversion. It is obtained by extrapolation of the
rate vs conversion data to zero conversion. For higher accuracy, the conversion data are
collected at very low conversion region. In this method, the dependence of initial rate
data on partial pressure or total pressure of the reactant is studied.
Consider the reaction A+B C+D
The rate expression derived from Langmuir Hinshelwood model when surface reaction is
controlling is
1
CA CB − CC C D
rS = k S K A K BCO2 K (2)
(1 + K A CA + K BCB + K CCC + K D CD )
2
Now at zero conversion all the product concentration will tend to zero, hence putting CC
=0 & CD =0, the rate expression [2] simplifies to
CA CB
ri = k S K A K BCO2 (3)
(1 + K A CA + K BCB )
2
whereri is the initial rate. Now, if a equimolal initial concentration of CA and CB is used
pA
then CA=CB . Then assuming ideal gas mixture, CA = , where p A is the partial
RT
pressure of A.
pB
Similarly CB = where p B is the partial pressure of B .
RT
pt
Now since it is an equimolal mixture, then at initial condition. p=
A p=
B where pt is
2
the total pressure.
pt
Or C=
A C=
B
2RT
Then substituting CA and CB in equation [3] becomes
2
 pt 
 
ri = k S K A K BCO2  2RT 
2
 pt pt 
1 + K A + KB 
 2RT 2RT 
 k K K C2 
p 2t  S A 2 B2 O 
Or ri =  4R T 
2
  KA + KB  
1 +  2RT  p t 
   
Ap 2t
ri =
Or
[1 + Bp t ] 2
k S K A K BCO2 K + KB
Where A = 2 2 and B = A
4R T 2RT
On plotting initial rate ri as a function of total pressure pt , a typical curve as shown in

Fig 4A is obtained. Hence if kinetic data for a reaction give similar plot then it can be
deduced that the reaction is surface reaction controlled.
When adsorption of A is controlling the dependence of initial rate on total pressure can
Ap t
be derived in similar way as ri =
1 + Bp t
k a CO K
Where A = and B = B
2RT 2RT
For this mechanism a typical plot of initial rate ri as a function of total pressure pt is
shown in Fig 4B. When reaction data satisfy this plot then the reaction is said to be
adsorption A controlling. In similar way other models can be tested for fitting.
However, it should be noted that though the initial rate analysis is simple and can reduce
the number of rate expressions to be tested against the experimental but cannot substitute
a differential or integral analysis. It should be used as only as preliminary kinetic analysis
method.
A B
ri ri
Pt Pt
Fig. 4.Typical plot for initial rate vs total pressure for reactions A + B  C + D when equimolal mixture of A and B is
used.A ) surface reaction controlling B) adsorption of A controlling
Book Reference
• J. M. Smith, Chemical Engineering Kinetics, McGrawHill Book Company, 1981

• H. S. Fogler, Elements of Chemical reaction engineering, Prentice Hall of India.,
1999
• R. J. Farrauto& C. H. Bartholomew, Fundamentals of Industrial catalytic Processes,
Blackie Academic & Professional, 1997
• O. Levenspiel , Chemical reaction engineering, John Wiley & sons. 1995
• J.J. Carberry ,Chemical and catalytic reaction Engineering, Dover Publications, 2001.
Lecture 21
Solved example
1. A catalytic reaction, A → 4B is studied in a packed bed reactor using various

amount of catalysts. The out let concentration and corresponding conversion is given
in following Table 1. Given FA0 = 2 mol / h and CA0 = 0.1 mol / litre
The rate equations for this reaction can be calculated using

i. Integral method of analysis
ii. Differential method of analysis
Table 1:
Runs 1 2 3 4 5
Catalysts used, kg 0.02 0.04 0.08 0.12 0.16
CA,out, mol/litre 0.075 0.061 0.045 0.035 0.028
XA 0.07 0.15 0.25 0.33 0.36
(i) For integral analysis

The design equations for packed bed reactor is given as
x Af
W dX A
FAo
= ∫
0
−rA
Assuming a first order kinetics −rA =

kCA and substituting
x Af
W dX A
Then
FAo
= ∫
0
kCA
CAO (1 − X A ) 4 −1
Now CA = Where ε= = 3
1 + εA X A
A
1
ɛA is the fractional change in volume of the system between no conversion and complete
conversion of reactant A.
1 + εA X A
x Af x Af
W dX A 1
Or=
FAo ∫0=
kCA kCAO ∫ (1 − X ) dX
0 A
A
For first order irreversible reaction for plug flow, integrated from of RHS for any
constant of ε A is as follows.
W 1
Or kCAO= (1 + εA ) ln −ε X (1)
FAO (1 − X A ) A A
Substituting values of C AO , FAO , ε A in equation (1)
W 1
=
  k 4 ln − 3X A
 20  (1 − X A )
 W    1 
Hence plotting   k  vs  4 ln − 3X A  a straight line is obtained.
 20    (1 − X A ) 
It suggests that assumption of first order kinetics is correct. The rate constant can be
obtained from slope of the plot which is 95.8 litres/hr.kg catalyst
The rate equation can be written as −rA =

kCA =[95.8 litres/hr.kg catalysts] C A
0.8 y = 95.8x
1 0.6
4 ln − 3X A
( XA )
1 − 0.4
0.2
0
0 0.002 0.004 0.006 0.008 0.01
W
 k
 20 
W   1 
Fig. 6. Plot of  k  4 ln − 3X A 
(1 − X A )
vs in integral analysis of data
 20   
(ii) For differential analysis
dX A
−rA =
d(W / FAo )
W W/FAo XA - rA (Calculated from

slope Fig 7A)
0.02 0.01 0.07 7.2
0.04 0.02 0.15 6.1
0.08 0.04 0.25 4.3
0.12 0.06 0.33 3.1
0.16 0.08 0.36 2.3
The XA vs W/FAO plot is shown in Fig 7(A) and used to calculate rate.
0.45
8
0.4
0.35
A BB y = 95.6x
6
0.3
-rA
0.25 4
XA
0.2
0.15 2
0.1
0.05 0
0
0 0.02 0.04 0.06 0.08 0.1
0 0.02 0.04 0.06 0.08
W/FAO CA
Fig. 7. Plots for differential analysis of data (A) XA vs W/FAO (B) rA vs CA plot
If − rA is plotted against CA a straight line is obtained of slope k (Fig 7B). Since the line
is straight line passing through origin, the order of the reaction is one as also obtained
from integral analysis.
Hence the rate is −rA =

kCA =[95.6 litres/hr.kg catalysts] C A
Lecture 18
Reactor types and catalysts test
Reactor types
Reactors can be classified based on different criterion such as size, reactor material,
methods of charging and discharging or type of fluid flow. For fluid – solid
heterogeneous system reaction rate is based on mass of solid catalyst rather than on
reactor volume. In laboratory scale, the reactions are carried out in micro reactors with
diameters ranging from 1 – 5 mm for testing up to 0.1 – 1gm of catalysts. In industry,
diameter and height of reactors can vary from 1 to 10 m and 2 to30 m respectively. The
reactor materials also vary depending on usage. Laboratory reactors are usually made of
glass, quartz or stainless steel with few mm wall thicknesses. The large industrial reactors
depending on usage are usually made of mild steel or stainless steel or other alloys. The
wall thickness can range from of 6-15 mm depending on process pressure. Depending on
the operation, reactor can be batch, mixed flow or packed bed type. The choice of reactor
depends on the type of reaction. For examples, many hydrogenation reactions are carried
out in CSTR while many of the solid catalysts are tested in packed bed reactor. Reactor
selection also depends on the type of catalyst and its activity, selectivity and deactivation
behavior. The schematic diagram of different type of reactors is shown in Fig 1.
For study of catalytic reactions in laboratory different reactors are used. For example
fluid-solid catalytic reactions are studied in (1) packed bed reactors heated in furnace, (2)
Carberry reactors equipped with rotating catalyst basket and cooling or heating jacket or
(3) Berty reactor with internal circulation and cooling or heating jacket. For reactions
involving gas-liquid-solid, slurry CSTR with cooling or heating jacket or packed bed
reactor with downflow, upflow or countercurrent flow of gas and liquids are used.
Laboratory reactors are mainly used for measuring reaction kinetics and catalyst activity
at different conditions of temperature and pressure.
Fixed bed reactor
The fixed bed or packed bed reactors are most commonly used for study of solid catalyst.
A fixed bed reactor usually consists of a cylindrical vessel packed with catalyst pellets
and easy to design and operate. The metal support grid and screen is placed near the
bottom to support the catalyst. Inert ceramic balls are placed above the catalyst bed to
distribute the feed evenly.
Advantages of packed bed or fixed bed reactor include ideal plug flow behavior, lower
maintenance cost and reduced loss due to attrition and wear. Heat management is very
important aspect for design of fixed bed reactor. Poor heat distribution may result in non
uniform reaction rates and consequently low reactant conversion. Poor heat transfer may
also result in generation of hot spots and thermal degradation of catalyst. However, the
situations are observed more in large fixed bed and for highly exothermic or endothermic
reactions when temperature control is difficult. The regeneration or replacement of
catalyst is also difficult in fixed bed reactors and process needs to be shutdown. Another
major disadvantage of packed bed reactor is plugging of bed due to coke deposition
which results in high pressure drop. High pressure drop is also observed for small beads
or pellets of catalysts. However, increase in pellet size increases the pore diffusion
limitation.
Catalyst pellet sizes are usually in the range of 1 to 10 mm. Non-uniform packing of
catalysts can cause channeling of fluids leading to poor heat and mass transfer. The
column to particle diameter is maintained in between 10 to 20 to minimize channeling.
The bed voidage is usually 70 to 90 %. Plug flow behavior is ensured by maintaining
ratio of reactor length to catalyst particle diameter greater than 50. The allowed pressure
drop is less than 0.5 inch water per foot of bed depth. Usually the ratio of bed height to
diameter is maintained greater than 0.5.
For better heat management for very highly exothermic (or endothermic) reaction the
multitubular reactor is used with catalyst packed inside the tubes. The cooling (or
heating) fluid flows through the shell side. The length is limited by allowable pressure
drop. The multitubular reactor has high surface area for heat transfer per unit volume. For
determination of heat transfer and mass transfer properties several correlations are
available in literature.
Fluidized bed reactors
In fluidized bed reactor catalyst pellets of average size less than 0.1 mm are fluidized by
the reactant fluid. The linear velocity is maintained above the minimum fluidization
velocity required to obtain the fluidized bed. As the superficial velocity increases, the bed
expands and become increasingly dilute. At high enough linear velocity, the smallest
catalyst particles escape from the bed and have to be separated from exhaust gases and
recycled.
In fluidized bed, heat transfer is much better resulting in more uniform temperature
compared to packed bed reactor. Frequent regeneration of catalyst can be done without
any shutdown of the process. However, fluidized bed is a complicated system to operate
and requires extensive investments and high operating and maintenance cost. Other major
disadvantages are attrition and loss of catalysts due to fluidized condition. Modeling of
fluidized bed flow is complex. The fluidized bed is assumed to consist of bubble and
emulsion phases which can be modeled respectively by plug flow and CSTR, as the
emulsion phase is assumed to be well mixed. Correlation for heat and mass transports are
available in literature. The reactor is extensively used for catalytic cracking process.
Carberry reactor or Berty reactor
For catalytic investigations, reactors equipped with rotating basket or fixed basket with
internal circulation can be used. These CSTR type reactors are used to minimize the
inherent mass and heat transfer limitations observed in fixed-bed reactors. These reactors
are frequently used in industry to evaluate reaction mechanism and reaction kinetics. The
most common type of reactors used are Carberry and the Berty reactors.
The main feature of the Carberry reactor is that the catalyst particles are contained
in a spinning basket or embedded in the blades of a spinning agitator. The mounted
catalyst is rapidly rotated resulting in good mixing between reactants in fluid phase and
the solid catalyst. This minimizes the mass transfer and heat transfer resistances. The
basket or impellers can spin up to 2,500 rpm.
The Berty reactor uses an internal recycling to achieve perfectly mixed behavior. The
catalyst is contained in a fixed bed basket through which the reacting gases circulate.
The catalyst basket is equipped with large diameter impellers rotated in order to circulate
gases & liquids past solid catalysts. An internal recirculation rate of 10 to 15 times of the
feed rate effectively eliminates external diffusion resistance and temperature gradient.
Retaining the solid catalyst in a spinning woven wire mesh basket allows gas / liquid
circulation with low pressure drop. Circulating the reactants past the catalyst minimize
wearing & breakage.
Multiphase reactors
Slurry reactors
The catalytic reaction can also be carried out in two–phase or three –phase stirred tank
reactors also known as slurry reactors. In three –phase reactor, gas and liquid reactants
are brought into contact with solid catalyst particles. In two–phase reactor, fluid phase is
usually liquid reactant in contact with the solid catalyst. The reaction of gaseous reactant
with catalyst is usually carried out in fixed bed reactor. In three –phase slurry reactor the
gaseous reactant and solid catalysts are dispersed in continuous liquid phase by
mechanical agitation using stirrer. The efficient stirring ensures nearly uniform
composition throughout the reactor. This kind of reactor is used in hydrogenation,
oxidation, halogenations and fermentation process. The advantages include nearly
isothermal operation and good heat and mass transfers. The use of powder catalysts
having high activity minimizes the intraparticle diffusion limitation. The reactors can be
operated in batch, semi batch or continuous mode. In three – phase system bubbles of gas
rise through agitated slurry. Solid particles are in size range of 0.01to 1.0 mm. The solid
concentration can be up to 30 vol. %. Lower concentration is also used. In hydrogenation
of oil with nickel catalyst, the solid content is 0.5 vol. %. The external transport effects
are important in slurry reactors and details are discussed in lecture no. 30. Hydrogenation
of oils is carried out in slurry of nickel catalyst particles. Industrial hydrogenation
reactors are usually of the size in the range of 500-200 L. The reactors are operated up to
pressure of 200 atm and temperature of 350 0C. The reactors are equipped with internal
agitator, gas inlet, facility for insitu sampling and heater or cooler for temperature
control.
Trickled bed reactors
In trickled bed reactor gaseous and liquid reactants flow co-currently downward over a
packed bed of solid catalyst particles. The liquid is distributed across the reactor cross
section by a distributor plate. The gas enters at the top and distributed along with the
liquid. The liquid flows downward by gravity and drag of the gas. For low liquid flow
rates and low to moderate gas flow rates, the gas phase is continuous with liquid trickling
down forming film over the solid catalyst. The thickness of the liquid film has been
estimated to vary between 0.01 and 0.2 mm. This flow regime is known as a trickle flow
regime. The fluid approaches plug flow leading to higher conversion than slurry reactors
for the same reactor volume. Other advantages include ease of installation, minimal
catalyst handling and low catalyst attrition as in packed bed reactor. Disadvantages
include maldistribution of flow resulting in channeling or bypassing, possibility of non
uniformity in packing, incomplete contacting or wetting and intraparticle diffusion
resistance. Catalyst bed depth is limited by pressure drop, catalyst crush strength and
maximum adiabatic temperature increase for stable operation. The reactor length to
diameter ratio can vary between 1 and 10 depending on the allowable pressure drop.
Other parameters important for trickled bed include void fraction of bed, holdup for
phases, wetting efficiency (fraction of catalyst wetted by liquid), gas – liquid mass
transfer coefficient, liquid–solid mass transfer coefficient, liquid and gas mixing, pressure
drop and heat transfer coefficients. The wetting efficiency of the catalyst is important for
reaction rate and increases with increasing liquid rate. The trickle bed reactor is most
commonly used for hydrogenation and hydrodesulfurization reactions.
Bioreactors
In bioreactor live cells or enzymes are used as catalyst to perform the biochemical
reactions. Bioreactor operations are limited by the conditions favorable for the biological
systems. Most living cells can tolerate only mild conditions of temperature and pH.
Hence in bioreactors stringent control of temperature, pH or any contamination is needed.
Bioreactor may have two phases, liquid-solid as in anaerobic process or three phases, gas,
liquid and solid as in aerobic process. The solid phase typically contains the cells
(bacteria, fungi, algae etc.) that serve as biocatalyst. The density of biocatalytic phase is
close to water. The biocatalyst can also be used in immobilized form in which cells are
trapped within solid or semi solid structure such as porous particles or gel. Liquid is
primarily water with dissolves the feed and products. In aerobic bioreactor the gas phase
consists of primarily air and product gas CO2. Bioreactors are mainly operated in batch
or semi batch mode allowing better control of process parameters. Increasing number of
bioreactor is operated in continuous mode such as in wastewater treatment, lactic acid
production, production of human insulin etc.
a) Carberry reactor b) Berty reactor
c) Packed bed reactor d) Multi tubular reactor e) Fluidized bed reactor
g) Agitated slurry reactor f) Trickled bed reactor
Fig. 1. Schematic diagram of different type of reactors
Catalyst tests
Activity and selectivity
The performance of catalyst is characterized by its activity for reaction and selectivity for
a product. The activity of a catalyst for a reaction at specified conditions is generally
expressed in terms of rate of reaction at that condition over the catalyst. The catalyst that
shows higher rate of reaction at the given conditions is said to have higher activity. For
solid catalyzed reaction, rate can be defined as, r = g mol of reacted /s. g of catalyst.
Here mass of solid is used because amount of catalyst is important. The reactor volume
that contains the catalysts is of secondary importance. Activity is also expressed in terms
of conversion of a reactant achieved. Higher the conversion at given conditions, higher is
the activity of the catalyst for that reaction. The conversion can be defined as follows
Moles of reactant in inlet stream- Moles of reactant in outlet stream

Conversion (%) ×100
Moles of reactant in inlet stream
For supported metal catalysts, defining activity in terms of metal sites is more useful as
the metal sites actually act as the active sites for chemical reactions. Hence, activity is
often expressed in terms of turnover frequency or TOF. TOF is defined as the number of
molecules reacting per active site per second (s-1). Though the TOF value is expected to
be constant for a particular metal catalyst for a given reaction at specified conditions,
however, in reality significant difference may be observed due to differences in catalyst
preparation, metal support interaction, crystallite size, surface structure and morphology
etc.
Total no. of molecules reacting

TOF = s −1
total no. of metal sites × seconds
The next important parameter determining the performance of catalyst is selectivity for a
particular product. The selectivity of a product X can be defined in several ways. One of
the definitions is shown below:
Moles of product X
Selectivity of X ( % )
= ×100
Total moles of all products
The performance of catalyst is tested in a suitable experimental setup. Fig. 2 shows a

schematic diagram of a simple experimental setup for studying gas phase reaction over
solid catalysts. Typically, solid catalysts are tested in a tubular down-flow reactor. A
simple manometer or any pressure gauge can be included before the reactor to ensure that
the pressure drop is within acceptable limits. All the reactants are combined in a mixer
and sent to the reactor where it comes in contact with the catalyst bed. The product gases
or liquids are usually analyzed using a gas chromatograph equipped with suitable
columns. The columns are selected so that the product compounds are separated
efficiently giving distinct peaks that can be easily identified and quantified. Further
detector type and temperature as well as carrier gas type and flow rates are also important
parameters determining the retention time and peak area in a chromatograph. Catalytic
tests are carried out at predetermined range of temperature, pressure, feed composition
and total flow rates depending on reactions. The catalysts amount range to be used is also
fixed according to the requirement.
8
9
3 6
1
5
7
3
11
10
2
1 & 2. Reactant gas cylinders

3. Mass flow controller for control flow or reactant gas
5. Silica gel trap for removing any moisture present in gas mixture
6. Mixer for well mixing of all the reactant gases EXIT
12
7. Manometer to monitor any pressure drop
8. Thermocouple to measure catalyst bed temperature
GC for
9. Thermo well to hold the thermocouple product
10. Quartz reactor holds the catalyst bed analysis
11. Furnace to maintain the reaction temperature
12. Product collector
Fig. 2. Schematic diagram of a typical experimental setup
2.3.2.1 Collecting data from laboratory reactors
Kinetic data are collected for the following purposes:
– Determination of activity-selectivity and deactivation data for catalyst selection

– Determination of reaction mechanism and kinetic parameters for understanding the
reaction at the fundamental level so the reaction process can be modeled which can be
used for design of reactors.
Investigation of the reaction kinetics is done at steady state conditions for most active and
selective catalyst. The effect of temperature and partial pressures of reactants on the
activity and selectivity is investigated in the desired temperature range. The process of
data collection typically involve three major steps :
1. Selection of a reaction and catalyst

2. Selection of reactor type
3. Analysis of data
Selection of reaction Selection of Selection of Collection Analysis of

and catalysts reactor process of data data
Reactor design and Rate Reaction

process optimization expression mechanism
Fig. 2. Steps for obtaining and analyzing kinetic data
To measure the specific catalytic activity or intrinsic reaction kinetics, the data must be
collected in absence of any pore diffusion limitations, mass transfer limitations or heat
transfer limitations. For analysis of data collected in the presence of mass transfer or heat
transfer limitations, suitable criterion should be included during analysis. Deactivation of
catalysts should be also avoided during data collection. These will be discussed in detail
in later sections. Further data should be collected over a wide range of temperature and
reactant concentrations to provide adequate reaction model that can be applicable at wide
temperature and concentration range.
Mode of reactor operations
Reactors can be operated in two ways:
1. Integral mode
2. Differential mode
Integral reactors
When a reactor is operated at high conversion, the reactor is said to be an integral reactor.
When reaction takes place in a packed bed reactor at high conversion there is possibility
of wide variation of conversion and reaction rate within the reactor even under isothermal
conditions. Hence, the integral form of design equation is to be used. This is the basis for
design for an ideal packed bed reactor.
x Af
W dX A
FAo
= ∫
0
−rA (1)
Differential reactors
When the reaction in a tubular reactor is carried out at very low conversions, the changes
in conversion and reaction rate across the reactor are small enough to be neglected and
the rate can be considered constant across the reactor. Then the rate in above equation [1]
can be considered constant and taken out of the integral and the equation can be
simplified to
W X
= A
FAo −rA
This above equation is same as for mixed flow reactor or CSTR. In this case analysis of
data is simplified.

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NPTEL – Chemical Engineering – Catalyst Science and Technology

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Conversion of synthesis gas to liquid hydrocarbons by hydrogenation of CO, which was

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Catalysis involves understanding of the thermodynamics, kinetics, electronic interaction, crystal

In a thermodynamically feasible chemical reaction, when addition of a small amount a chemical

Fig. 2 . Comparison of activation energies of exothermic catalytic and non-catalytic reactions

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Types of catalytic reactions

Catalytic reactions can be divided into two main types –

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Heterogeneous catalytic theory

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Fig. 3. Steps in solid catalytic reactions.

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Adsorption on solid surfaces

Importance of adsorption in solid catalysis

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Why adsorption takes place on solid surface

Depending on the nature of interaction, the adsorption can be of two types:

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a) At beginning of any adsorption Saturated bond

b) Any physisorbed condition

c) Any chemisorbed condition

Fig. 2. Schematic representation of different adsorption processes

Physisorption versus Chemisorption

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3. In case of chemisorption, since there is electronic interaction between adsorbate and

Monolayer Multilayer Adsorbed

Fig. 4 . Monolayer and multilayer formation of the adsorbed molecules on a surface

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Physisorption : Adsorption of nitrogen on carbon or alumina.

Chemisorption : Adsorption of hydrogen on active platinum sites on any support.

Potential energy diagram of approaching molecule towards a solid surface

Fig. 5. Potential energy diagram for non activated dissociative chemisorption

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Catalytic agents may be broadly divided in the following categories:

i. Metallic conductors ( e.g Fe, Pt, Ag, etc.)

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Examples of metal catalysts :

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Negative promoters or inhibitors: Inhibitors act opposite to promoters. When added in

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Table 1. Typical surface area values of different support and catalyst.

Support/catalyst BET surface Application

Activated carbon 500-2000 Used as support for various process

Zeolites 500-1200 Used as catalyst and support

Al2O3-SiO2-Zeolites 100-600 Fluid catalytic cracking catalysts

Ni/Al2O3 100-150 Methanation catalyst

Cu/Zn/Al2O3 Methanol synthesis catalyst

MnOx/Al2O3 140-180 Catalyst for total oxidation of volatile

Fe/K/Al2O3 20 Ammonia synthesis catalyst

Determination of surface area using BET Equation

p = partial pressure ; po =saturation pressure at the experimental temperature ;

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The intercept and slope from the plot is given as

The total number of N2 molecules adsorbed corresponding to monolayer volume vm can