Heterogeneous Catalyst-Pellet Hybrids for Continuous-Flow Operations

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Hydrogenation reactions are of widespread industrial importance, with significant interest in converting the currently used batch processes (typically using Pd/C heterogeneous catalysts) into continuous processes due to the numerous advantages related to continuous manufacturing. Progress in the commercial implementation of high throughput and robust continuous processes for heterogeneously catalysed organic transformations is limited by lack of a suitable catalyst support, both on the macroscale, i.e. pellet, powder etc., and the nanoscale, i.e. nanoparticle and pore size and shape. This project would aim to explore the feasibility of a promising novel carbon based spherical catalyst support developed at University of Leeds, namely Polymer-Based Spherical Activated Carbon (PBSAC), for continuous flow hydrogenation reactions on a lab scale, with a view to explore self-optimisation, automation and scale-up depending on the success at smaller scales. The deposition, activity and overall suitability for continuous flow processes of a range of current and promising future heterogeneous catalysts coated onto the outer surface of PBSAC will be studied and optimised - including but not limited to palladium nanoparticles, graphitised nanofibers based systems (GNFs), Metal-Organic Frameworks (MOFs) and Supported Ionic-Liquid Phase (SILP) Catalysts. The principle idea being to design robust, active heterogenous catalyst for integration into industrially applicable reactor platforms; packed bed, trickle bed, CSTRs, with the end goal of generating a commercially viable catalyst product.