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- Sprache: Englisch
Introduces major catalytic processes including products from the petroleum, chemical, environmental and alternative energy industries * Provides an easy to read description of the fundamentals of catalysis and some of the major catalytic industrial processes used today * Offers a rationale for process designs based on kinetics and thermodynamics * Alternative energy topics include the hydrogen economy, fuels cells, bio catalytic (enzymes) production of ethanol fuel from corn and biodiesel from vegetable oils * Problem sets of included with answers available to faculty who use the book Review: "In less than 300 pages, it serves as an excellent introduction to these subjects whether for advanced students or those seeking to learn more about these subjects on their own time...Particularly useful are the succinct summaries throughout the book...excellent detail in the table of contents, a detailed index, key references at the end of each chapter, and challenging classroom questions..." (GlobalCatalysis.com, May 2016)
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Table of Contents
Cover
PREFACE
ACKNOWLEDGMENTS
LIST OF FIGURES
NOMENCLATURE
CHAPTER 1: CATALYST FUNDAMENTALS OF INDUSTRIAL CATALYSIS
1.1 INTRODUCTION
1.2 CATALYZED VERSUS NONCATALYZED REACTIONS
1.3 PHYSICAL STRUCTURE OF A HETEROGENEOUS CATALYST
1.4 ADSORPTION AND KINETICALLY CONTROLLED MODELS FOR HETEROGENEOUS CATALYSIS
1.5 SUPPORTED CATALYSTS: DISPERSED MODEL
1.6 SELECTIVITY
CHAPTER 2: THE PREPARATION OF CATALYTIC MATERIALS
2.1 INTRODUCTION
2.2 CARRIER MATERIALS
2.3 INCORPORATING THE ACTIVE MATERIAL INTO THE CARRIER
2.4 FORMING THE FINAL SHAPE OF THE CATALYST
2.5 CATALYST PHYSICAL STRUCTURE AND ITS RELATIONSHIP TO PERFORMANCE
2.6 NOMENCLATURE FOR DISPERSED CATALYSTS
CHAPTER 3: CATALYST CHARACTERIZATION
3.1 INTRODUCTION
3.2 PHYSICAL PROPERTIES OF CATALYSTS
3.3 CHEMICAL AND PHYSICAL MORPHOLOGY STRUCTURES OF CATALYTIC MATERIALS
3.4 SPECTROSCOPY
CHAPTER 4: REACTION RATE IN CATALYTIC REACTORS
4.1 INTRODUCTION
4.2 SPACE VELOCITY, SPACE TIME, AND RESIDENCE TIME
4.3 DEfiNITION OF REACTION RATE
4.4 RATE OF SURFACE KINETICS
4.5 RATE OF BULK MASS TRANSFER
4.6 RATE OF PORE DIFFUSION
4.7 APPARENT ACTIVATION ENERGY AND THE RATE-LIMITING PROCESS
4.8 REACTOR BED PRESSURE DROP
4.9 SUMMARY
CHAPTER 5: CATALYST DEACTIVATION
5.1 INTRODUCTION
5.2 THERMALLY INDUCED DEACTIVATION
5.3 POISONING
5.4 COKE FORMATION AND CATALYST REGENERATION
CHAPTER 6: GENERATING HYDROGEN AND SYNTHESIS GAS BY CATALYTIC HYDROCARBON STEAM REFORMING
6.1 INTRODUCTION
6.2 LARGE-SCALE INDUSTRIAL PROCESS FOR HYDROGEN GENERATION
6.3 HYDROGEN GENERATION FOR FUEL CELLS
6.4 SUMMARY
CHAPTER 7: AMMONIA, METHANOL, FISCHER–TROPSCH PRODUCTION
7.1 AMMONIA SYNTHESIS
7.2 METHANOL SYNTHESIS
7.3 FISCHER–TROPSCH SYNTHESIS
CHAPTER 8: SELECTIVE OXIDATIONS
8.1 NITRIC ACID
8.2 HYDROGEN CYANIDE
8.3 THE CLAUS PROCESS: OXIDATION OF H
2
S
8.4 SULFURIC ACID
8.5 ETHYLENE OXIDE
8.6 FORMALDEHYDE
8.7 ACRYLIC ACID
8.8 MALEIC ANHYDRIDE
8.9 ACRYLONITRILE
CHAPTER 9: HYDROGENATION, DEHYDROGENATION, AND ALKYLATION
9.1 INTRODUCTION
9.2 HYDROGENATION
9.3 HYDROGENATION REACTIONS AND CATALYSTS
9.4 DEHYDROGENATION
9.5 ALKYLATION
CHAPTER 10: PETROLEUM PROCESSING
10.1 CRUDE OIL
10.2 DISTILLATION
10.3 HYDRODEMETALIZATION AND HYDRODESULFURIZATION
10.4 HYDROCARBON CRACKING
10.5 NAPHTHA REFORMING
CHAPTER 11: HOMOGENEOUS CATALYSIS AND POLYMERIZATION CATALYSTS
11.1 INTRODUCTION TO HOMOGENEOUS CATALYSIS
11.2 HYDROFORMYLATION: ALDEHYDES FROM OLEfiNS
11.3 CARBOXYLATION: ACETIC ACID PRODUCTION
11.4 ENZYMATIC CATALYSIS
11.5 POLYOLEfiNS
CHAPTER 12: CATALYTIC TREATMENT FROM STATIONARY SOURCES: HC, CO, NO
X
, AND O
3
12.1 INTRODUCTION
12.2 CATALYTIC INCINERATION OF HYDROCARBONS AND CARBON MONOXIDE
12.3 FOOD PROCESSING
12.4 NITROGEN OXIDE (NO
X
) REDUCTION FROM STATIONARY SOURCES
12.5 CO
2
REDUCTION
CHAPTER 13: CATALYTIC ABATEMENT OF GASOLINE ENGINE EMISSIONS
13.1 EMISSIONS AND REGULATIONS
13.2 CATALYTIC REACTIONS OCCURRING DURING CATALYTIC ABATEMENT
13.3 FIRST-GENERATION CONVERTERS: OXIDATION CATALYST
13.4 THE FAILURE OF NONPRECIOUS METALS: A SUMMARY OF CATALYST HISTORY
13.5 SUPPORTING THE CATALYST IN THE EXHAUST
13.6 PREPARING THE MONOLITH CATALYST
13.7 RATE CONTROL REGIMES IN AUTOMOTIVE CATALYSTS
13.8 CATALYZED MONOLITH NOMENCLATURE
13.9 PRECIOUS METAL RECOVERY FROM CATALYTIC CONVERTERS
13.10 MONITORING CATALYTIC ACTIVITY IN A MONOLITH
13.11 THE FAILURE OF THE TRADITIONAL BEADED (PARTICULATE) CATALYSTS FOR AUTOMOTIVE APPLICATIONS
13.12 NO
X
, CO AND HC REDUCTION: THE THREE-WAY CATALYST
13.13 SIMULATED AGING METHODS
13.14 CLOSE-COUPLED CATALYST
13.15 FINAL COMMENTS
CHAPTER 14: DIESEL ENGINE EMISSION ABATEMENT
14.1 INTRODUCTION
14.2 CATALYTIC TECHNOLOGY FOR REDUCING EMISSIONS FROM DIESEL ENGINES
CHAPTER 15: ALTERNATIVE ENERGY SOURCES USING CATALYSIS: BIOETHANOL BY FERMENTATION, BIODIESEL BY TRANSESTERIFICATION, AND H
2
-BASED FUEL CELLS
15.1 INTRODUCTION: SOURCES OF NON-FOSSIL FUEL ENERGY
15.2 SOURCES OF NON-FOSSIL FUELS
15.3 FUEL CELLS
15.4 TYPES OF FUEL CELLS
15.5 THE IDEAL HYDROGEN ECONOMY
INDEX
End User License Agreement
List of Tables
Chapter 10
TABLE 10.1 Typical Properties of Crude Oil Sources
Chapter 12
TABLE 12.1 Catalytic Oxidation Using Pt on a Monolith (M) Versus Thermal Combust...
TABLE 12.2 Light Temperatures for Various Families of Molecules Using a Pt Monol...
TABLE 12.3 Nominal Properties of Standard and Thin-Wall Cordierite Substrates
Chapter 13
TABLE 13.1 Nominal Properties of Standard and Thin-Wall Cordierite Substrates
TABLE 13.2 Nominal Properties of Standard and Thin-Wall Metallic Substrates
List of Illustrations
Chapter 1
Figure 1.1 Catalyzed and uncatalyzed reaction energy paths illustrating the lowe...
Figure 1.2 Illustration of catalyzed versus noncatalyzed reactions.
Figure 1.3 Catalytic Fe–Ce redox reaction catalyzed by Mn.
Figure 1.4 Activation energy diagram for the non-catalytic thermal reaction of C...
Figure 1.5 Conversion of CO versus temperature for a noncatalyzed (homogeneous) ...
Figure 1.6 Particulate catalysts for fixed bed reactors: spheres, extrudates, an...
Figure 1.7 Adsorption isotherm (θCO) for CO on Pt for large, moderate, and low p...
Figure 1.8 Illustration of Langmuir–Hinshelwood reaction mechanism.
Figure 1.9 Illustration of Mars–van Krevelen reaction mechanism.
Figure 1.10 Illustration of Eley–Rideal reaction mechanism.
Figure 1.11 L–H kinetics applied to increasing PCO at constant PO2. Maximum rate...
Figure 1.12 Ideal dispersion of Pt atoms on a high surface area Al2O3 carrier. (...
Figure 1.13 Illustration of the sequence of chemical and physical steps occurrin...
Figure 1.14 Conversion versus temperature profile illustrating regions for chemi...
Figure 1.15 Relative rates of bulk mass transfer, pore diffusion, and chemical k...
Figure 1.16 Reactant concentration gradients within a spherical structured catal...
Chapter 2
Figure 2.1 (a) SEM of γ-Al2O3 (80,000× magnification) and (b) SEM of α-Al2O3 (80...
Figure 2.2 Three zeolites: (a) mordenite, (b) ZSM-5, and (c) Beta. (Reproduced f...
Figure 2.3 Ceramic and metallic (center image) monoliths of different shapes and...
Figure 2.4 Ceramic washcoated monoliths. (Reproduced from Chapter 2 of Heck, R.M...
Chapter 3
Figure 3.1 (a) Adsorption isotherm for nitrogen for BET surface area measurement...
Figure 3.2 Mercury penetration as a function of pore size of catalyst. (Reproduc...
Figure 3.3 Differential porosimetry for a porous catalyst. (Reproduced from Chap...
Figure 3.4 Particle size measurement using laser light scattering analysis. (Rep...
Figure 3.5 Thermal gravimetric analysis and differential thermal analysis of the...
Figure 3.6 Electron microprobe showing a two-washcoat-layer monolith catalyst. T...
Figure 3.7 SEM of γ-Al2O3 with its highly porous network. (Reproduced from Chapt...
Figure 3.8 X-ray diffraction patterns of γ- and α-Al2O3. (Reproduced from Chapte...
Figure 3.9 (a) Chemisorption isotherm for determining surface area of the cataly...
Figure 3.10 Transmission electron micrograph of Pt on TiO2. (Reproduced from Cha...
Figure 3.11 Transmission electron micrograph of Pt on CeO2. (Reproduced from Cha...
Figure 3.12 X-ray diffraction profile for different crystallite sizes of CeO2. (...
Figure 3.13 An XPS spectrum of various oxidation states of palladium on Al2O3. (...
Figure 3.14 NMR profile of a Y faujasite zeolite. (Reproduced from Chapter 3 of ...
Figure 3.15 DRIFT spectra of CO chemisorbed on different precious metal particle...
Chapter 4
Figure 4.1 Illustration of the three processes that can limit the reaction rate ...
Figure 4.2 Illustration showing how experimental rate measurements can be plotte...
Figure 4.3 Illustration showing how experimental rate measurements can be plotte...
Figure 4.4 Conversion versus temperature at different space velocities. Experime...
Figure 4.5 Arrhenius plot for determining activation energies. (Reproduced from ...
Chapter 5
Figure 5.1 Idealized cartoon of perfectly dispersed Pt on a high-surface γ-Al2O3...
Figure 5.2 Conceptual diagram of sintering of the catalytic component on a carri...
Figure 5.3 TEM of fresh and sintered Pt on Al2O3 in an automobile catalytic conv...
Figure 5.4 Idealized conversion versus temperature for various aging phenomena. ...
Figure 5.5 Illustration of the sintering of the catalyst carrier occluding the c...
Figure 5.6 Microscopy images of low surface area rutile (a) and high surface are...
Figure 5.7 (a) NMR profile of a thermally aged zeolite showing the loss of the S...
Figure 5.8 Conceptual cartoon showing selective poisoning of the catalytic sites...
Figure 5.9 Conceptual cartoon showing masking or fouling of a catalyst washcoat....
Figure 5.10 XPS spectrum of the surface of a contaminated Pt on Al2O3 catalyst.
Figure 5.11 Electron microprobe showing the deposition location of the poisons w...
Figure 5.12 TGA/DTA in air of coke burn-off from a catalyst. (Reproduced from Ch...
Figure 5.13 TGA/DTA profile for desulfation of Pd on Al2O3 catalyst. (Reproduced...
Chapter 6
Figure 6.1 Illustration of industrial hydrogen generation process.
Figure 6.2 A series of metallic tubes filled with particulate catalysts bathed i...
Figure 6.3 Reduction or activation of Ni SR catalyst: H2O (steam)/H2 as a functi...
Figure 6.4 H2O/C versus temperature: a high H2O/CH4 ratio allows higher temperat...
Figure 6.5 WGS equilibrium: free energy and equilibrium constant for WGS as a fu...
Figure 6.6 Typical performance of a HTS WGS catalyst with respect to exit CO.
Figure 6.7 Reformer schematic for pure H2.
Figure 6.8 Overall process flow diagram for preformed natural gas to H2 and N2 f...
Figure 6.9 Monolith catalysts for H2 generation using PSA or PROX.
Figure 6.10 Illustration of a highly simplified catalyzed double pipe heat excha...
Figure 6.11 Preferential oxidation of 0.5% CO using a (Pt, Fe, Cu)/Al2O3 monolit...
Figure 6.12 Various catalytic processes for generating H2 and synthesis gas from...
Chapter 7
Figure 7.1 Simplified flow sheet for NH3 synthesis illustrating a “quench”-type ...
Figure 7.3 Illustration of methanol quench reactor design.
Figure 7.4 Illustration of staged cooling design.
Figure 7.5 Illustration of cooled tube reactor design.
Figure 7.6 Illustration of shell-cooled reactor design.
Figure 7.7 Flow sheet for methanol synthesis.
Figure 7.8 Bubble slurry reactor for Fischer–Tropsch.
Figure 7.9 Loop reactor for Fischer–Tropsch.
Chapter 8
Figure 8.1 Surface roughening (sprouting of PtRh gauze). (Reproduced from Chapte...
Figure 8.2 High-pressure NH3 oxidation/HNO3 plant with Pd getter gauze.
Figure 8.3 An expanded view of the reactor containing the stacks of oxidation an...
Figure 8.4 HCN process flow diagram.
Figure 8.5 The Claus process with staged reaction and liquid sulfur removal.
Figure 8.6 Elemental sulfur is reacted with dry air at 900°C producing SO2. Stag...
Figure 8.7 SO2/SO3 equilibrium as a function of temperature. (Reproduced from Ch...
Figure 8.8 Quench reactor for SO3 production with staged air injection for cooli...
Figure 8.9 The O2 process for ethylene oxide production.
Figure 8.10 Process for low methanol concentration process to formaldehyde over ...
Figure 8.11 Process using Ag catalyst.
Figure 8.12 Propylene to acrolein to acrylic acid process flow diagram. Tubular ...
Figure 8.13 Process for converting propylene to acrylonitrile.
Chapter 9
Figure 9.1 Illustration comparing difference between a semibatch stirred tank re...
Figure 9.2 Illustration of a semibatch stirred tank reactor (STR). The sparger (...
Figure 9.3 Illustration showing hydrogen consumption versus time during typical ...
Figure 9.4 Illustration of the mass transfer path taken by hydrogen as it diffus...
Figure 9.5 Kinetic rate for a catalytic slurry-phase batch reaction.
Figure 9.6 Linolenic oil shown as an example of an unsaturated fat molecule.
Figure 9.7 Sequential reactions at 140 and 200°C.
Figure 9.8 CATOFIN propane dehydrogenation to propylene using Cr2O3/Al2O3 cataly...
Figure 9.9 Flow diagram for dehydrogenation of ethyl benzene to styrene.
Chapter 10
Figure 10.1 Simplified illustration of the crude oil refining process. The desal...
Figure 10.2 Examples of metal-containing (nickel porphyrin) and sulfur-containin...
Figure 10.3 The HDM/HDS process flow diagram. Inset shows presulfided catalyst a...
Figure 10.4 Catalyst deactivation by HDM metal deposition (masking) and coking.
Figure 10.5 Controlled O2 addition in coked catalyst regeneration.
Figure 10.6 Faujasite zeolite.
Figure 10.7 Schematic of FCC reactor with catalyst regenerator.
Figure 10.8 Process flow diagram for naphtha reforming.
Figure 10.9 Regeneration and rejuvenation of (Pt, Re)/γ-Al2O3 + Cl reforming cat...
Chapter 11
Figure 11.1 Hydroformylation process using a cobalt homogeneous catalyst.
Figure 11.2 Dow (Davy McKee) LP Oxo Selector process using the Rh catalyst.
Figure 11.3 Monsanto acetic acid process.
Figure 11.4 Phillips loop reactor.
Figure 11.5 TiCl3/MgCl2 process for polyethylene.
Chapter 12
Figure 12.1 (a) VOC abatement process with heat integration. (b) VOC abatement w...
Figure 12.2 Slipstream reactor concept used for VOC abatement design.
Figure 12.3 Catalyst abatement of food processing fumes.
Figure 12.4 SCR with V2O5 and a metal-exchanged zeolite: 1.1 NH3/NO and zeolite.
Figure 12.5 SCR reactor schematic. It would be worth mentioning that the widenin...
Figure 12.6 Ozone abatement reactor design.
Chapter 13
Figure 13.1 Gasoline-relative engine emissions and temperature as a function of ...
Figure 13.2 Monolith catalyst housed in a metal canister secured in the exhaust....
Figure 13.3 Optical micrographs of double-layered washcoated ceramic monoliths. ...
Figure 13.4 Conversion proceeding axially down the channel of a monolith with po...
Figure 13.5 Temperature profiles (ΔT/ΔL) for an exothermic reaction down the axi...
Figure 13.6 Simultaneous conversion of HC, CO, and NOx for TWC as a function of ...
Figure 13.7 Oxygen sensor response output as a function of air/fuel ratio. (Repr...
Figure 13.8 Electron microprobe scan of an automotive catalyst contaminated with...
Figure 13.9 Close-coupled TWC catalyst, under-floor TWC, and oxygen sensors conn...
Chapter 14
Figure 14.1 NOx–particulate trade-off with emission regulations.
Figure 14.2 Electron microprobe scans of the washcoat of an aged diesel oxidatio...
Figure 14.3 Wall flow filter. Soot particulates deposit on the porous wall, whil...
Figure 14.4 SCR with Cu and Fe zeolites.
Figure 14.5 Schematic of simplified diesel exhaust aftertreatment system. A dies...
Figure 14.6 Chemistry of NOx reduction in using BaO to capture NO2 during lean o...
Figure 14.7 Deactivation of the NOx trap by sulfur oxide poisoning.
Figure 14.8 Driving profile for a LNT. During lean mode (fuel economy), NO is co...
Chapter 15
Figure 15.1 Biodiesel production process.
Figure 15.2 A comparison of power generation for a coal-fired power plant, gasol...
Figure 15.3 A single cell of the PEM fuel cell.
Figure 15.4 Voltage–current profile for the PEM fuel cell. The curve with the ma...
Figure 15.5 A PEM single cell and arranged in a “stack.” Each cell is separated ...
Figure 15.6 Ideal H2 economy with the sun providing energy for a photovoltaic de...
Guide
Cover
Table of Contents
Begin Reading
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INTRODUCTION TO CATALYSIS AND INDUSTRIAL CATALYTIC PROCESSES
ROBERT J. FARRAUTO
Earth and Environmental Engineering Department Columbia University New York, New York
LUCAS DORAZIO
BASF CorporationIselin, New Jersey
C.H. BARTHOLOMEW
Department of Chemical EngineeringBrigham Young University Provo, Utah
Copyright © 2016 by John Wiley & Sons, Inc. All rights reserved.
A joint publication of the American Institute of Chemical Engineers, Inc. and John Wiley & Sons, Inc.
Published by John Wiley & Sons, Inc., Hoboken, New Jersey.
Published simultaneously in Canada.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 750-4470, or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, or online at http://www.wiley.com/go/permission.
Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages.
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Library of Congress Cataloging-in-Publication Data:
Names: Farrauto, Robert J., 1941- author. | Dorazio, Lucas, author. | Bartholomew, C. H., author.
Title: Introduction to catalysis and industrial catalytic processes / Robert J. Farrauto, Lucas Dorazio, C. H. Bartholomew.
Description: Hoboken : John Wiley & Sons, Inc., 2016. | Includes index. Identifiers: LCCN 2015042209 (print) | LCCN 2015044585 (ebook) | ISBN
9781118454602 (cloth) | ISBN 9781119089155 (pdf) | ISBN 9781119101673 (epub) Subjects: LCSH: Catalysis.
Classification: LCC QD505 .F37 2016 (print) | LCC QD505 (ebook) | DDC 660/.2995–dc23
LC record available at http://lccn.loc.gov/2015042209
To my wife Olga (Olechka) who has been a partner, friend, and critic over the precious years we have been together. She has provided love, understanding, focus, and a new vision to life. I thank my loving daughters, Jill Marie and Maryellen, and their husbands Glenn and Tom. I am fortunate to have inspiring grandchildren Nicky, Matt, Kevin, Jillian, Owen, and Brendan and stepdaughters Elena and Marina. I want to acknowledge my brother John (wife Noella) and sister Marianna (husband Ron) who have supported me emotionally through all of our years together. I am forever grateful to my parents who raised me as a proud Italian-American with a desire to help others.
Robert J. Farrauto
To my wife Cara, whose encouragement and support helped complete this project, and to my young children Lauren and Zach for their support and genuine interest in my career.
Lucas Dorazio
To my loving wife, friend, and critic, Karen, of over 49 years, who has supported me in all good things and forgiven my faults and mistakes; my 5 children and 10 grandchildren who have brought me mostly joy, been a constant source of fun and entertainment, and have given me understanding, support, love, excitement, inspiration, and challenges that have led to my growth; my loving, supportive brothers and sisters (all 7); and my dad and mom who taught me to love learning, life, and the Christian way. I especially dedicate this work (an offspring of our earlier book) to my son Charles who died unexpectedly on September 25, 2014 and who greatly touched and brightened the lives of his family, friends, and coworkers.
Calvin H. Bartholomew
PREFACE
“Simplicity is the ultimate sophistication.”
THESE WORDS of Leonardo da Vinci were recently quoted by Steve Jobs of Apple in the book by Walter Isaacson. Simplicity was the first guiding principle in the preparation of this introductory book. The second guiding principle was to share our considerable industrial and academic experience in working with and teaching about catalysis fundamentals and industrial catalytic processes.
All of us authors have worked in industry and academia, two of us as technical consultants. Dr. Farrauto was affiliated with BASF (formerly Engelhard), Iselin, New Jersey for 37 years having worked in environmental, chemical, petroleum, and alternative energy fields and is now Professor of Practice in the Earth and Environmental Engineering Department at Columbia University in the City of New York. Dr. Dorazio, a research engineer at BASF (New Jersey), has worked in catalysis research and in scale-up of catalysts for the chemical, petroleum, and environmental fields. He is also Adjunct Professor in the Chemical Engineering Department at New Jersey Institute of Technology (NJIT). Dr. Bartholomew, Professor Emeritus in the Chemical Engineering Department at Brigham Young University, Provo, Utah, worked for a year at Corning Glass (with Dr. Farrauto) in auto emissions control after which he taught and conducted research and consulting for 41 years in catalyst design/deactivation and reactor/process design for environmental cleanup and synthetic fuel production. He continues to be active in writing, teaching short courses, and consulting. All of us have been widely engaged in various degrees of teaching industrial catalysis at the undergraduate and graduate levels. Bartholomew and Farrauto have coauthored the widely used text and reference book entitled “Fundamentals of Industrial Catalytic Processes,” a more advanced, in-depth version of the topics in the current book and a likely sequel to this book.
Industrial catalytic applications are seldom taught in undergraduate chemistry and chemical engineering programs, a surprising fact, given the large number of commercial processes that utilize catalysis. Thus, we accepted the challenge of writing a book that would introduce senior level undergraduates and new graduate students to this exciting field of catalytic processes, which is fundamental to chemical engineering and chemistry as practiced in industry. The need for a thorough understanding of fundamental principles of chemistry and catalysis is given. The transition of this knowledge to their commercial applications is our objective, especially for the many chemistry and chemical engineering students who spend much of their careers working in industry with catalytic processes. We also include the many professionals of varying disciplines who suddenly find themselves with a new assignment of working on a catalytic process without previous training in the basics of catalysis and catalytic processes.
Our goal is to explain the fundamental principles of catalysis and their applications of catalysis in a simple, introductory textbook that excites those contemplating an industrial career in chemical, petroleum, alternative energy, and environmental fields in which catalytic processes play a dominant role. The book focuses on non-proprietary, basic chemistries and descriptions of important, currently used catalysts and catalytic processes. Considerable practical examples, recommendations, and cautions located throughout the book are based on authors’ experience gleaned from teaching, research, commercial development, and consulting, including feedback from many students and associates. Suggested readings (reviews, books, and journal articles) are included at the end of each chapter to encourage interested readers to deepen their knowledge of these topics. Process diagrams have been simplified to provide an overview of principal process units (e.g., reactors and separation units) and important process steps, including reactant and product streams. Nevertheless, it should be recognized that commercial engineering process flow sheets include many other details and specifications, for example, piping, pumps, valves, heat exchangers, and other process equipment needed to operate and control the plant, including special equipment for plant start-up, catalyst pretreatment, purges, safety, regeneration, and so on.
Chapters 1–5 introduce the reader to basic principles of catalysis, including reaction kinetics, simple reactor design concepts, and catalyst preparation, characterization, and deactivation. Accompanying each chapter are questions and suggested readings. Chapters 6–15 describe by category applications and practice in the industry, including process chemistry, conditions, catalyst design, process design, and catalyst deactivation problems for each catalytic process. Chapter 6 describes hydrogen and syngas generation processes for different end applications. Processes for the synthesis of ammonia, methanol, and hydrocarbon liquids (Fischer–Tropsch process) are presented in Chapter 7. Processes for selective catalytic oxidation to (a) commodity chemicals, including nitric, cyanic, and sulfuric acids, formaldehyde, and ethylene oxide, and (b) specialized products such as acrylic acid, maleic anhydride, and acrylonitrile are presented in Chapter 8. Catalytic processes for hydrogenation of vegetable oils, olefins, and functional groups for highly specialized products are presented in Chapter 9. Catalytic processes in refining of petroleum to fuels are presented in Chapter 10. Selected commercial processes utilizing (a) homogeneous catalysts, (b) commercial enzymes, and (c) polymerization catalysts are described in Chapter 11. Chapters 12, 13, and 14 summarize features of important processes for catalysts used in environmental control of gaseous emissions from (a) stationary sources (e.g., power plants) and mobile sources, including (b) gasoline- and (c) diesel-fired vehicles. The final chapter 15 gives a brief summary of (1) catalytic processes for production of bio diesel and ethanol fuels from edible biomass which will ultimately find application to production of similar fuels from non-edible cellulosic biomass and (2) catalyst technology for the emerging hydrogen economy with emphasis on fuel cell technology.
New York, New YorkIselin, New JerseyProvo, Utah22 November 2015
Robert J. FarrautoLucas DorazioCalvin H. Bartholomew
ACKNOWLEDGMENTS
Drs. Farrauto and Dorazio acknowledge BASF (and Engelhard) for their strong leadership in the field of catalysis. We also acknowledge our students at Columbia University and NJIT, respectively, who have provided course and teaching evaluations that have been invaluable in showing us the need for a simple approach to catalysis and industrial processes.
Dr. Bartholomew is grateful for the financial support of his research, teaching, and writing endeavors by Brigham Young University and of his research by DOE, NSF, GRI, and many companies. He wishes to acknowledge the opportunity to work with distinguished colleagues and friends on the Faculty (especially in the Chemical Engineering Department and Catalysis Laboratory) and some 200+ bright, creative, hardworking graduate and undergraduate students and postdoctoral fellows who worked with him under his direction at BYU. He has also enjoyed the stimulation of teaching more than 750 company professionals during dozens of short courses on catalysis, deactivation, and Fischer–Tropsch synthesis. He wishes to acknowledge the collaboration with and friendship of Dr. Robert Farrauto over the past 42 years, first at Corning Glass, then on a landmark paper, and now two books addressing industrial catalytic processes; he is especially grateful for Bob’s patience with him during the long process of preparing the first and second editions of Fundamentals of Industrial Catalytic Processes.
