Micro-engineered catalyst systems: ABB’s advancement in structured catalytic packings

ABB has advanced catalysis with micro-engineered catalyst (MEC) systems by providing a uniquely small particle size on a formable catalyst support through the integration of catalysis and reaction engineering. A mechanically strong catalytic web of micro-fibers has been engineered and shaped utilizing both computational fluid dynamics (CFD) and cold flow experiments to optimize flow characteristics. This article discusses techniques used for the development of novel catalytic structured packings for catalytic distillation applications. CFD models (verified through experiments performed on small-sized structures) were shown to be of great utility in screening new structure ideas. Results will illustrate achievement of both high gas–liquid contacting and bulk mixing at low pressure drop with the potential to provide enhanced catalyst utilization by taking advantage of the intrinsic MEC properties, particularly its high porosity and exposed geometric fiber and catalyst surface area. This was shown by the successful testing of one of these catalyzed structures in the selective hydrogenation of C4 acetylenes.