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In this study, a new arranged catalyst support with distinct open pore morphology has been fabricated via thermal oxidation of an FeCrAl alloy with an aim to address mass transfer limitations that conventional supports have due to their internal porosity. Subsequent characterization tests including, drop shape analysis, X-ray diffraction, X-ray photoelectron spectroscopy and scanning electron microscopy revealed that the support formed upon thermal oxidation for 1 hour at 930C, 1 hour at 960C and 2 hours at 990C embodies advantageous support characteristics. Preliminary tests were performed using palladium (active component) deposited on the new support in representative three phase hydrogenation reactions of 2-methyl-3-butyn-2-ol or 2-methyl-3-buten-2-ol. Absence of mass transfer limitations was verified for 2-methyl-3-buten-2-ol hydrogenation at 35-50C, 1200 rpm stirring speed and 0.46 MPa pressure of hydrogen in a 300 ml semi-batch reactor using ethanol as solvent. The study paves the way to the development of arranged catalysts based on FeCrAl alloy fibers for structured reactors. / Chemical Engineering

Doctor of Philosophy / Department of Chemical Engineering / Mary E. Rezac / Membrane reactor is a device that simultaneously carrying out reaction and membrane-based separation. The advantageous transport properties of the membranes can be employed to selectively remove undesired products or by-products from the reaction mixture, to break the thermodynamic barrier, and to selectively supply the reactant. In this work, membrane reactor technology has been exploited with robust H₂ selective polymeric membranes in the process of hydrogenation and dehydrogenation. A state-of-the-art 3-phase catalytic membrane contactor is utilized in the processes of soybean hydrogenation and bio-oil hydro-deoxygenation, where the membrane functions as phase contactor, H₂supplier, and catalytic support. Intrinsically skinned asymmetric Polyetherimide (PEI) membranes demonstrated predominant H₂permeance and selectivity. By using the PEI membrane in the membrane contactor, soybean oil is partially hydrogenated efficiently at relatively mild reaction conditions compared with a conventional slurry reactor. In the hydroprocessing of bio-oil using the same system, the membrane successfully removed water, an undesired component from bio-oil by pervaporation. The more industrially feasible membrane-assisted reactor is studied in the alkane dehydrogenation process. Viable polymeric materials and their stability in elevated temperatures and organic environment are examined. The blend polymeric material of Matrimid® 5218 and Polybenzimidazole (PBI) remained H₂permeable and stable with the presence of hydrocarbons, and displayed consistent selectivity of H2/hydrocarbon, which indicated the feasibility of using the material to fabricate thermally stable membrane for separation. The impact of membrane-assisted reactor is evaluated using finite parameter process simulation in the model reaction of the dehydrogenation of methylcyclohexane (MCH). By combining tested catalyst performance, measured transport properties of the material and hypothetical membrane configuration, by using a membrane assisted packed-bed reactor, the thermodynamic barrier of the reaction is predicted to be broken by the removal of H₂. The overall dehydrogenation conversion can be increased by up to 20% beyond equilibrium. The predicted results are justified by preliminary experimental validation using intrinsically skinned asymmetric Matrimid/PBI blend membrane. The conversions at varied temperatures partially exceeded equilibrium, indicating successful removal of H₂by the blend membrane as well as decent thermal stability of the membrane at elevated temperatures with the presence of hydrocarbons. The successful outcome of membrane contactor and membrane-assisted reactor using robust polymeric membranes shows the effectiveness and efficiency of membrane reactors in varied application. The future work should be focusing on two direction, to further develop durable and efficient membranes with desired properties; and to improve the reactor system with better catalytic performance, more precise control in order to harvest preferable product and greater yield.

Doctor of Philosophy / Department of Chemical Engineering / Mary E. Rezac / Catalytic membrane reactors are a class of reactors that utilize a membrane to selectively deliver reactants to catalysts integrated in the membrane. The focus of this research has been on developing and characterizing polymeric catalytic membranes for three-phase hydrogenation reactions, where the membrane functions as a gas/liquid phase contactor allowing selective delivery of hydrogen through the membrane to reach catalytic sites located on the liquid side of the membrane. The benefit of conducting three-phase reactions in this manner is that delivering hydrogen through the membrane to reach catalytic sites avoids the necessity of hydrogen dissolution and diffusion in the liquid phase, which are both inherently low and often described as causing mass-transfer and reaction rate limitations for the reactive system. This work examines two types of membrane reactor systems, porous polytetrafluoroethylene and asymmetric Matrimid membranes, respectively, for the ruthenium catalyzed aqueous phase hydrogenation of levulinic acid. The highly hydrophobic PTFE material provides an almost impermeable barrier to the liquid phase while allowing hydrogen gas to freely transport through the pores to reach catalytic sites located at the liquid/membrane interface. Catalytic rates as a function of hydrogen pressure over the range 0.07 to 5.6 bar are presented and shown to be higher than those of a packed bed reactor under similar reaction conditions. An increasing catalytic benefit was obtained operating at temperatures up to 90 °C, which is attributed to increased hydrogen permeability and avoidance of the decreasing solubility of hydrogen in water with increasing temperature. The membrane reactor was shown to be stable with no decrease in catalytic activity over 200 hours of operation. The Matrimid membrane reactor work demonstrates the feasibility of applying an integrally-skinned asymmetric membrane for an aqueous phase hydrogenation reaction and focuses on the impact that membrane hydrogen permeance and catalyst loading have on catalytic activity. The non-porous nature of the separating layer in the Matrimid membrane allowed successful operation up to 150 °C. The overall catalytic rates were approximately an order of magnitude lower than those achieved in the PTFE membrane reactor system due primarily to significantly lower hydrogen permeances, nevertheless rates were still higher than control experiments. This work also focuses on characterizing Matrimid/solvent thermodynamic relationships for a variety of organic solvents, looking at sorption, diffusion, and polymer relaxation behavior in thin films ranging from 0.1 to 2.0 µm in thickness using quartz crystal microbalance techniques. Diffusion coefficients at infinite dilution for water and C1-C6 alcohols are given as a function of van der Waals molar volume and a clear dependency is shown ranging from 2E-11 to 6.5E-13 cm²/s for water and hexanol, respectively, for 0.26 µm thick films. Diffusion coefficients for all studied vapor penetrants displayed a marked dependence on thickness spanning approximately two orders of magnitude for each respective vapor penetrant over the range 0.1 to 1.0 µm. Chemically cross-linking Matrimid is a method to mitigate some of the relatively high sorption and swelling behavior exhibited in the presence of sorbing species. An in-depth analysis on the vapor phase ethylenediamine cross-linking of Matrimid films and its impact on diffusion, sorption, and relaxation is also described.