Due to its excellent heat transfer ability, the micro-channel reactor with coated phase-pure M1 catalysts can achieve reactor productivity nearly 5 times higher than that of a traditional fixed-bed reactor under the same reaction conditions in oxidative dehydrogenation of ethane (ODHE).
A method is described to incorporate a zeolite ZSM-5 layer as a potential catalytic coating or membrane into tubular supports by the in situ crystallization of a previously deposited silica layer. The silica layer simultaneously provides nucleation sites and functions as a nutrient source giving coatings with excellent uniformity and controllable coating thickness. The ability to control the simultaneous dissolution of the silica layer in conjunction with nucleation and growth processes was found important in controlling the morphology of the zeolite crystals contained in the final zeolite coating. The formation of a AE4 mm coating containing AE300 nm crystals was obtained at high silica dissolution and nucleation rates. A continuous intergrown zeolite layer of AE7.6 mm was obtainable at high silica dissolution rates in the presence of sodium.
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