CSMs - Catalytic Static Mixers
Drawing on the multi-disciplinary expertise at the CSIRO, we have delivered a new method for heterogeneous catalytic reactions - catalytic static mixers (CSMs). With simple and well established design this innovative solution aims to provide an elevated approach to tubular reactor technology. Using 3D printing capabilities, novel metal scaffolds are designed and manufactured before the catalyst is directly deposited via electroplating, cold spraying, or other deposition methods. The CSMs can be readily inserted into reactor tubes, allowing for easy changeover of catalyst. The benefits of utilising metal scaffolds, which have good mechanical stability, are significant and include:
SUPERIOR PROCESS CONTROL
In comparison to most catalyst bed systems, temperature within the newly designed CSM reactors are far more controllable. The design of the mixers ensure that pressure drop is low and mixing is efficient.
MADE TO ORDER
One of the main benefits of 3D printing is the flexibility of design. The static mixer geometry can be designed specific to the needs of each project, taking into account the properties of the reagent mixture and the fluid flow. Flow maldistribution, concentration and temperature hotspots can be avoided.
MORE COST EFFECTIVE
Using in house design and manufacture, tailor made 3D printing of metal mixers for tubular flow chemistry reactors can be several times cheaper than commercial static mixers of similar dimensions.
CSM reactors can be easily adapted to current manufacturing processes. This ensures that past manufacturing methods do not need to be altered in order to utilize this technology, making the process more fluid and accessible.
We have used this approach to prepare CSM reactors and tested them in hydrogenation (gas-liquid) and transfer hydrogenation (homogenous liquid) reactions. High Turn-Over-Frequencies and Space-Time-Yields were achieved without detectible leaching of the catalyst metal.