Development of a microstructured reactor for heterogeneously catalyzed gas phase reactions: Part I. Reactor fabrication and catalytic coatings

Due to their superior heat transfer properties, microstructured reactors are well suited for performing strongly exothermic heterogeneously catalyzed gas phase reactions. In order to utilize the full potential of this reaction technology, a new low-cost manufacturing concept was developed, using a Ni–Ag–Sn solder system for bonding the individual structured steel platelets. Three different methods for depositing a VOx/γ-Al2O3 material on the micro-channels were investigated with respect to morphology, mechanical stability and catalytic behavior of the obtained coatings. Especially the influence of different binder materials (Al-tri-sec-butylate, tetraethoxysilane, hydroxypropyl cellulose and polyvinyl pyrrolidone) was analyzed. For evaluating the performance of the coatings, the oxidative dehydrogenation of propane (ODP) served as a sensitive test reaction. The modules and the catalytic coatings withstood the applied reaction conditions (400–600 °C at ambient pressure), which makes them safe and flexible tools for research activities and small scale production processes.