(674f) Process Intensification Using Novel Micro-Structured Heterogeneous Contacting Systems

Microfibrous Supported Catalysts/Sorbents(MSSM) provide for an excellent means of process intensification. Ozone conversion efficiency for aircraft cabin air purification will be used to demonstrate the enhanced heterogeneous contacting efficiency exhibited by these novel reactor systems. Theoretical performance comparisons between packed beds of various particle sizes (Voidage=35-40%), monoliths with varying cells per square inch (cpsi) and microfibrous entrapped catalyst reactors (Voidage> 75%) of various pleat factors (PF=actual area of microfibrous entrapped catalyst media used/Cross sectional area of reactor) have also been made and results showed significant benefits with use of MSSM. Experimental ozone conversions and pressure drops of MSSM compared with commercial aircraft ozone converters also showed significant improvements. Enhanced reactivity in MSSM resulted in about 60% reduction in catalyst requirements and significantly smaller reactor volumes. The present research aims at understanding the enhanced transport rates exhibited by these systems. These innovative materials are prepared in a wet lay process in which micron diameter fibers and 50-300 micrometer particles self-assemble/self-adjust to form extremely uniform structures with high voidages. The typical flow conditions used in these materials correspond to low particle Reynolds numbers. The small diameter particles used in microfibrous media reduce transport resistances; the uniformity and the high voidages inherently present in these materials lead to substantial reduction in channeling and axial dispersion compared to packed beds of similar particle sizes. The ease of pleating this media presents another big advantage which helps cut down the pressure drop considerably.