Oxidation of n-butane to maleic anhydride in a milli-structured fixed-bed reactor

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The concept of micro- or milli-structured fixed-bed reactors shall be investigated with the selective oxidation of n-butane to maleic anhydride as an example of a strongly exothermic, heterogeneously catalyzed reaction with industrial relevance. It is expected that the process can be intensified regarding catalytic activity and selectivity in such a reactor because of lower diffusion lengths and higher average temperatures than in conventional reactors. In contrast to micro-structured reactors with catalyst coated walls, the fixed-bed concept allows for the use of industrially proven catalytic materials and simple exchange of spent catalysts. Aim of the project is to determine the basis for a reactor scale-up through experimental and theoretical investigations. For this purpose, systematic measurements of conversion, product distribution, and pressure drop with fixed beds of different geometries and catalyst particles with variable size will be done. Additionally, residence time distribution measurements are necessary to investigate possible wall effects at low ratios of channel and catalyst particle diameter. The formulation of engineering models for design and scale up is enhanced by detailed numerical simulations of flow, reactions and heat transfer in the fixed bed using modern computational techniques such as the lattice-Boltzmann method. If the project goal can be reached, it is planned to continue the project with the aim of realizing a milli-structured fixed-bed at pilot scale.