ABSTRACT:A new method for conducting a heterogeneous catalytic reaction in the gaseous phase is discussed. It eliminates the use of carriers and allows catalysis to be conducted via an aerosol of finely milled active catalytic materials. Problems associated with the strength and thermal stability of catalysts are thereby avoided. A high and constant catalytic activity is ensured for the aerosol catalyst by integrating the chemical reaction zone and the mechanical treatment zone. Thus, solid particles that move with the reactant flow or special devices that allow mechanical treatment of the catalyst particles may be located in the reactor. Such aerosol catalysis has been tested in processes involving partial and complete oxidation, recovery, vinylation, chlorination and dechlorination. Relative to traditional systems, i.e. placement of the active catalytic active material on the carrier, the reaction rate was increased by 4-5 orders of magnitude. The production of catalysts and the implementation of chemical reactions are thereby both simplified simultaneously.

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Factors influencing changes in the properties of catalyst surfaces at decreasing particulate (particle) size down to 100 nm and finer were described. The potential properties of carrier-based nano-catalysts, such as their activity, strength and thermal resistance, have been analyzed and the advantages of employing aerosol nano-catalysts (AC) without carriers but possessing nano-sized particulates (particles) discussed. Experimental data on AC obtained for a fluidized bed wherein different classes of reactions were undertaken for an optimal concentration of nano-particle catalysts (4–10 g/m3 of the reaction volume) were described. Some experimental data obtained for a new AC variant involving a vibrofluidized (vibrating) bed were examined. Decreasing the optimal catalyst concentration to less than 1 g/m3 of the reaction volume tripled the product yield per cubic metre.

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This article shows the benefits of new technology for the implementation of gas-phase chemical reactions by aerosol nanocatalysis. The influence of new managing factors such as the concentration of catalyst, frequency, amplitude of motion of catalyst particles, dispersive material, etc. This enhances the process management and increases the rate of reaction per mass of catalyst in the 104-106 times. The selectivity of chemical transformations increases by 10-20%. Sometimes, new valuable products of the reaction are formed.