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IbD PU Deliverable 3.1 processes. The catalytic plate concept in a reactor involves a series of metal plates coated on one or both sides with thin catalyst layers. Metal plates coated with a suitable catalyst are arranged in such a manner that exothermic and endothermic reactions take place in alternate channels. These channels typically have a height of order of millimeters and a catalyst thickness of the order of microns, as shown in Figure 52. The key benefit of this design approach is that the heat source and heat sink are brought into close thermal proximity, thereby short circuiting the heat transfer process. This design minimizes the heat and mass transfer resistances resulting in a significant size reduction of the equipment. However, high temperature can affect the CPR since high temperatures can potentially deactivate the catalysts and jeopardize the CPR (Baldea and Pattison (2014)). Figure 52. A pair of adjacent channels in the catalytic plate reactor (Process Intensification Group, 2015). The CPR can be applied in steam reforming, hydrogenation, and hydrocarbon cracking. Steam reforming of methane with methane catalytic combustion was performed in a CPR by Zanfir and Gavriilidis (2003). Due to the heat up from a suitable amount of fuel and catalyst activity in the combustion channel and heat transfer increasing based on the short distance between the heat source and heat sink, the CPR represented an important improvement in transverse temperature gradients in comparison to the conventional reformers. They also suggested a CPR which was properly designed with flowrates, channel heights, catalyst loadings, and thickness presented advantages in steam reforming. Sigurdsson and Kær (2012) used reactant bypass flow in a CPR for hydrogen production and studied the pressure drop and flow maldistribution in the CPR with a coated wire mesh catalyst. The ratio of wire mesh catalyst width to reactor width had effect on bypass flow which could significantly influence the reactor’s performance. Zanfir and Gavriilidis (2001) and (2002) also presented a series of numerical investigations of the influence of parameters, 51PDF Image | Solids handling for intensified process technology
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