Micro-Reactor System for Complete Oxidation of Volatile Organic Compounds

Based on previous Computational Fluid Dynamics (CFD) design results, an 11 channel microreactor of dimensions (0.5 mm × 0.5 mm × 100 mm) (width × depth × length) and optimal manifold geometry was fabricated, coated with a newly-developed Au/SBA-15 catalyst and then integrated in an experimental rig specifically built for this research. Propane (as model volatile organic compound) oxidation experiments were conducted at three different flow velocities, 12.5, 15.4 and 17.5 m/min, respectively, at six temperatures, 150, 200, 225, 250, 275, and 300 °C, respectively. The catalyst was prepared by one-pot sol-gel synthesis of SBA-15 with MPTMS (3-mercaptopropyl-trimethoxy-silane) before loading with HAuCl4 gold precursor and then characterized by SEM/EDX, TEM and wide angle XRD. A novel catalyst coating technique was developed, using airbrush (0.3 nozzle) to spray a catalyst slurry into the microchannels that produced a thin, firm and uniform layer of Au/SBA-15 catalyst coating inside the microreactor. The experimental measurements revealed that propane conversion increased as the flow feed rates decreased and increased with increasing temperatures in the reactor. For the built microreactor and for the flows and temperatures set, the combustion of propane was possible with measurable conversions and reasonable reactor stability, the performance of the catalyst appeared to be central to the satisfactory operation of the reactor.