Structured Packings for Multiphase Catalytic Reactors

Reactor design for multiphase catalytic fixed bed reactors is always based on conflicting objectives. In the past, catalyst discovery and development preceded and motivated the selection of an appropriate multiphase reactor type. This type of sequential approach is increasingly been replaced by a parallel approach to catalyst and reactor selection. In nearly all respects, structured catalysts and reactors have the ability to outperform randomly packed reactors. Structured packings, apart from their advantages of high voidage and low-pressure drop, have the benefit of ease of scale-up and accurate description of the fluid mechanics. In this review we have evaluated the potential of using structured internals for multiphase catalytic reactions, which are currently carried out in randomly packed fixed bed reactors. Characteristics of various structured internals such as monoliths, corrugated sheet or gauze packings, knitted wire packings and foams are discussed in detail. Since designing a structured device for gas−liquid−solid contacting requires a sound knowledge of hydrodynamics and transport phenomena, a concise review of the above-mentioned structured packings and their characteristics based on hydrodynamics and transport phenomena is presented. Existing models (empirical, phenomenological and mechanistic) are outlined with respect to flow regime transition, pressure drop, liquid hold-up, gas−liquid interfacial area, gas to liquid mass transfer, liquid to solid mass transfer, residence time distribution (RTD), and heat transfer. The models are critically evaluated, and their limitations are discussed. An overview is given about what information is available, what needs to be evaluated and what kind of existing methodology can be applied in order to arrive at quantitative models for the physical parameters. Last, the structured internals are compared with each other and with randomly packed bed reactors, allowing a rational selection of the preferred packing for a given application.