Metal Supported Powder Catalyst Matrix and Processes for Multiphase Chemical Reactions
A catalytic membrane composite that includes porous supported catalyst particles durably enmeshed in a porous fibrillated polymer membrane is provided. The porous fibrillated polymer membrane may be manipulated to take the form of a tube, disc, or diced tape and used in multiphase reaction systems. The supported catalyst particles are composed of at least one finely divided metal catalyst dispersed on a porous support substrate. High catalytic activity is gained by the effective fine dispersion of the finely divided metal catalyst such that the metal catalyst covers the support substrate and/or is interspersed in the pores of the support substrate. In some embodiments, the catalytic membrane composite may be introduced to a stirred tank autoclave reactor system, a continuous flow reactor system, or a Parr Shaker reaction system and used to effect the catalytic reaction.
1 . A continuous flow reaction system for multiphase reactions having at least three phases, said reaction system comprising:
a catalytic article comprising a porous fibrillated polymer membrane that includes supported catalyst particles durably enmeshed within the porous fibrillated polymer membrane, said catalytic article being in the form of diced tape;
a liquid phase comprising at least one liquid phase reactant;
a gas phase comprising at least one gas phase reactant; and
a reaction vessel in the form of a continuous loop and being configured for continuous flow of the liquid phase reactant and the gas phase reactant across and through the catalytic article.
2 . The reaction system of claim 1 , wherein the catalytic article is not configured as a contactor.
3 . The reaction system of claim 1 , wherein the reaction system is configured for hydrogenation.
4 . The reaction system of claim 1 , wherein the porous fibrillated polymer membrane is insoluble to reactants and products in the multiphase chemical reaction.
5 . The reaction system of claim 1 , wherein the porous fibrillated polymer membrane comprises polytetrafluorethylene (PTFE), poly(ethylene-co-tetrafluoroethylene) (ETFE), ultra-high molecular weight polyethylene (UHMWPE), polyparaxylylene (PPX), polylactic acid and any combination or blend thereof.
6 . The reaction system of claim 1 , wherein the porous fibrillated polymer membrane comprises polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), modified PTFE, or a PTFE copolymer.
7 . The reaction system of claim 1 , wherein the porous fibrillated polymer membrane comprises expanded polytetrafluoroethylene (ePTFE).
8 . The reaction system of claim 1 , wherein the porous fibrillated polymer membrane has a porosity from about 30% to about 95%.