COURSE OBJECTIVE: To teach students to identify key variables needed to perform a more active, selective and stable catalyst that will contribute to the improvement of existing or development of new chemical, petrochemical and related processes effective in terms of saving raw materials, energy and environment.
COURSE IMPLEMENTATION PROGRAM:
Week 1: Introduction to catalysis -what is catalysis and what does it do, the importance of catalysis for the national economy, the division of catalytic reactions, the comparison of homogeneous and heterogeneous catalysis, Catalyst properties: activity, selectivity and stability of catalysts and their determination The essence of catalytic action, basic theories of the reaction path: collision theory, transition state theory.
Week 2: Homogeneous catalysis -acid-base catalysis: specific and general catalysis in a non-aqueous medium, acid and base catalyzed reactions. Catalysis with transition metal ions: activity, selectivity and deactivation of catalysts, reactions catalyzed by transition metal ions. Kinetics and mechanism of homogeneous-catalytic reactions.
Week 3: Heterogeneous catalysis -adsorption phenomena: criteria by which physical adsorption and chemisorption, associative and dissociative chemisorption, heat of adsorption, adsorption isotherms are distinguished. Theory of heterogeneous catalysis.
Week 4: Kinetics and mechanism of heterogeneous-catalytic reactions: reaction rate in a heterogeneous system. Assumption of reaction mechanism and choice of kinetic model. Empirical and mechanistic kinetic models. Influence of temperature on reaction rate in a heterogeneous system: apparent and real activation energy.
Week 5: Knowledge test.
Week 6: The overall rate of heterogeneous catalytic reactions -reaction regimes, the slowest process. Interphase transfer of substances -basic concepts, interphase transfer of substances and chemical reaction, interphase effectiveness factor. Intraphase mass transfer, types of diffusion: molecular, Knudsen and surface diffusion. Intraphase mass transfer and chemical reaction.
Week 7: Intrinsic effectiveness factor -experimental determination and theoretical calculation. Thermal effects during the process: temperature gradient through the fluid film around the catalyst particle, temperature gradient inside the catalyst particle. Resistance to the surface reaction.
Week 8: Catalyst activity - experimental methods for determining the reaction rate (catalyst activity), experimental reactors: integral and differential reactor, flow reactor and reactor with recirculation. Calculation of heat and mass transfer coefficients. Criteria for estimating the influence of mass and heat transfer on the overall reaction rate: interphase, intraphase and reactor gradients. Influence of diffusion on the stability of the catalyst.
Week 9: Catalyst selectivity -types of selectivity, influence of chemical and physical properties of catalysts on selectivity, course of intraphase diffusion and on process selectivity. Catalyst deactivation -types of deactivation, kinetics and mechanism of deactivation, mode of action of poisons on the catalyst surface, influence of diffusion on the deactivation rate. Catalyst deactivation and prevention.
Week 10: Knowledge test
Week 11: Composition and performance of catalysts -chemical composition: supports, promoters (structural, electronic, texture promoters and promoters that prevent catalyst poisoning); catalytically active substances: metals and alloys, semiconductors and insulators. The role and importance of the active component of the catalyst. Interaction of active phase and catalyst support.
Week 12: Approach to the problem of catalyst design, selection of catalyst components, modern methods of development of new catalytic systems. Catalyst preparation: precipitation and coprecipitation, impregnation, alloying. Catalyst treatment after synthesis: filtration, washing, drying, grinding and sieving of catalysts. Catalyst shaping: tableting, extrusion and pelleting. Calcination and catalyst thermal pretreatments.
Week 13: Determination of the physical properties of the catalyst -experimental methods for determining the specific surface area of the catalyst: BET method (static volumetric method), static gravimetric method, dynamic (gas chromatographic) method. Determination of catalyst active surface area, pore volume, pore volume distribution and effective diffusion coefficient.
Week 14: Determination of mechanical properties of catalysts -experimental methods and devices. Static and dynamic method for testing the mechanical strength of catalysts. Testing of mechanical strength on catalyst abrasion. Characterization of catalysts by spectroscopic methods.
Week 15: Knowledge test
In parallel with the lectures, students do exercises.
DEVELOPMENT OF GENERAL AND SPECIFIC COMPETENCIES OF STUDENTS: Encouraging students to learn independently and developing critical thinking. Specific competencies will include the application of acquired knowledge and the ability to independently plan research related to catalytic reaction engineering.
STUDENTS' TEACHING OBLIGATIONS AND THEIR PERFORMANCE: Attendance and active participation in lectures and exercises, as well as oral and written fulfillment of laboratory obligations.
CONDITIONS FOR OBTAINING A SIGNATURE: Regular attendance of all forms of teaching provided by the course program
TEACHING METHODS: In the form of lectures, laboratory exercises and consultations as needed.
METHOD OF EXAMINATION OF KNOWLEDGE AND EXAMINATION: 3 compulsory written tests during the semester through a colloquium and, if necessary, written and an oral exam.
METHOD OF MONITORING THE QUALITY AND PERFORMANCE OF COURSES: Quality and performance will be monitored through student surveys, interviews with students during classes, and their success in knowledge tests.
METHODOLOGICAL PREREQUISITES: Physical chemistry, Heat and mass balance, Transfer processes
COURSE LEARNING OUTCOMES:
After successfully completing the course the student will be able to:
- identify the key variables needed to make more active, selective and stable catalysts,
- understand the relationship between the structural and chemical properties of catalysts and their catalytic properties,
- develop kinetic models for homogeneous catalytic and heterogeneous catalytic reactions,
- distinguish macrokinetics from microkinetics,
- distinguish intermediate from intraphane gradients ,
- apply different criteria and experimental methods to determine the slowest degree of reaction,
- distinguish between different types of catalyst deactivation and their impact on productivity of reactor,
- select the appropriate laboratory reactor to determine catalytic properties
LEARNING OUTCOMES AT PROGRAM LEVEL:
Student will be able to:
- apply basic knowledge of natural sciences in identifying and describing simple engineering problems,
- organize and plan simple experiments using available laboratory equipment and devices,
- apply scientific methods in process analysis and modeling and product design,
- collect information from various sources,
- present the results of research related to the content of studies,
- select and apply appropriate mathematical/analytical/numerical methods in solving problems,
- apply basic information and communication technologies.
TEACHING UNITS WITH ASSOCIATED LEARNING OUTCOMES AND EVALUATION CRITERIA:
Teaching unit: Introduction to catalysis
Learning outcomes:
- students will be able to assess the importance of catalytic processes for the national economy,
- distinguish homogeneous from heterogeneous catalysis,
- distinguish the basic properties of the catalysts.
Evaluation criteria:
- students will be able to explain how and why the catalyst affects the reaction rate,
- understand the basic principles of homogeneous and heterogeneous catalysis,
- describe and explain different catalytic processes,
- apply catalytic solutions in industrial processes.
Teaching unit: Catalyst design
Learning outcomes: Students will be able to:
- identify the key variables needed to perform more active, selective and stable catalysts,
- understand the relationship between the structural and chemical properties of catalysts and their catalytic properties,
- determine the physical, chemical, mechanical and catalytic characteristics of the catalyst,
- explain the impact of deactivation processes on reactor productivity.
Evaluation criteria:
Students will be able to:
- analyze and explain the impact of catalyst composition on activity, selectivity and stability,
- explain the difference between the specific and active surface of the catalyst,
- explain the difference between activators and promoters,
- apply various analytical methods suitable for catalyst characterization,
- analyze the impact of catalyst preparation on activity life and stability,
Teaching unit: Kinetics and mechanism of heterogeneous-catalytic reactions.
Learning outcomes:
Students will be able to:
- distinguish physical adsorption from chemisorption,
- distinguish empirical from mechanistic kinetic models,
- develop kinetic models for heterogeneous catalytic reactions based on the analysis of the reaction mechanism,
- distinguish macrokinetics from microkinetics,
- evaluate the influence of interphase/intraphase gradients on the reaction rate,
- select and apply different criteria and experimental methods to determine the slowest degree of reaction.
Evaluation criteria:
Students will be able to:
- apply the Langmuir adsorption isotherm for the development of mechanistic kinetic models,
- explain the difference between real and apparent reaction rate,
- examine the influence of interphase and intraphase diffusion on the reaction rate,
- calculate the effective diffusion coefficient,
- calculate the interphase/intraphase effectiveness factor and to explain the difference,
- apply an appropriate experimental/theoretical criterion to assess the interphase/intraphase resistance to mass transfer,
- select the appropriate experimental reactor to determine the reaction rate.
Teaching unit: Catalyst properties
Learning outcomes:
- Students will understand how physical and chemical properties affect activity, selectivity and stability of catalysts.
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Fundamentals of Industrial Catalytic processes, C.H. Bartholomew, R.J.Faruto,, J.Wiley, New York, 2006.
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