Catalysts, in microchannel apparatus, and reactions using same

Abstract

The present invention provides new microreactor systems, catalysts, and chemical processes. Methods of making novel catalysts and reaction apparatus are also described.

1 . An apparatus comprising:
 a microchannel;   a graded catalyst disposed in the microchannel;   wherein the graded catalyst has a varying thermal conductivity such that the thermal conductivity in one part of the graded catalyst is at least 25% higher than in another part of the catalyst.   
   
   
       2 . The apparatus of  claim 1  wherein the graded catalyst varies gradually in thermal conductivity. 
   
   
       3 . The apparatus of  claim 1  wherein the microchannel comprises an inlet and an outlet and wherein the graded catalyst has a higher thermal conductivity nearer the outlet as compared to nearer the inlet. 
   
   
       4 - 27 . (canceled) 
   
   
       28 . A method of forming a catalyst microinsert, comprising:
 adding a catalyst precursor into a mold;   wherein the mold has at least one dimension of 5 mm or less;   forming a monolithic catalyst microinsert; and   removing the monolithic catalyst microinsert.   
   
   
       29 . The method of  claim 28  further comprising the step of binder removal to form pores. 
   
   
       30 . The method of  claim 28  wherein the step of adding a catalyst precursor comprises multiple steps and wherein a graded catalyst is formed. 
   
   
       31 . A method of making catalytic apparatus, comprising:
 applying a magnetic or electric field to a microchannel; and   loading or orienting particles in the microchannel under the influence of the magnetic or electric field.   
   
   
       32 . The method of  claim 31  wherein the step of applying a magnetic or electric field orients support particles in a microchannel; and
 further comprising depositing a catalyst layer on the support particles.   
   
   
       33 . Apparatus made by the process of  claim 31 . 
   
   
       34 . (canceled) 
   
   
       35 . Microchannel reactor apparatus comprising:
 a microchannel; and   hollow or porous catalyst particles disposed in the microchannel, wherein the porous catalyst particles comprise large pores within the individual particles;   wherein the microchannel has a cross sectional area;   wherein the large pores are defined as a pore size of at least 1% of the particle size; and   wherein the hollow or porous catalyst particles have a volume average particle cross-section that is 1 to 40% that of the cross sectional area of the microchannel.   
   
   
       36 . A method of making the microchannel reactor apparatus of  claim 35  comprising pouring the hollow or porous catalyst particles into microchannel. 
   
   
       37 . The microchannel reactor apparatus of  claim 35  comprising metallic hollow or porous catalyst particles. 
   
   
       38 . The microchannel reactor apparatus of  claim 35  wherein the particles are spherical. 
   
   
       39 . Apparatus comprising:
 a microchannel,   high aspect ratio particles disposed within the microchannel,   wherein the high aspect ratio particles are oriented within the microchannel such that at least 40% by mass of the high aspect ratio particles are substantially oriented in one direction that is perpendicular to a wall of the microchannel.   
   
   
       40 . The apparatus of  claim 39  wherein the high aspect ratio particles comprise a thermally conductive material. 
   
   
       41 . Apparatus for conducting a chemical reaction, comprising: an open flow path having a cross sectional area comprising at least one dimension of 5 mm or less, wherein the cross sectional area is perpendicular to a direction of flow;
 a catalyst defining at least a portion of one wall of the open flow path within the cross sectional area comprising at least one dimension of 5 mm or less, such that no point within the cross sectional area in the open flow path is more than 5 mm away from the catalyst; and   a element disposed in the open flow path, wherein the element is selected from the group consisting of flow disruptors and micromixers; and wherein   the micromixer, if present, comprises a catalyst.   
   
   
       42 . The apparatus of  claim 41  comprising a flow disrupter selected from the group consisting of a bar above the catalyst, corkscrew, wire, or a strand pulled up from catalyst felt. 
   
   
       43 . (canceled) 
   
   
       44 . The apparatus of  claim 39  wherein the high aspect ratio particles comprise a magnetic material. 
   
   
       45 . The apparatus of  claim 1  wherein the microchannel comprises an inlet and an outlet and wherein the graded catalyst has a lower thermal conductivity nearer the outlet as compared to nearer the inlet.