Overcoming Stability Problems in Microwave-Assisted Heterogeneous Catalytic Processes Affected by Catalyst Coking

Microwave-assisted heterogeneous catalysis (MHC) is gaining attention due to its exciting prospects related to selective catalyst heating, enhanced energy-efficiency, and partial inhibition of detrimental side gas-phase reactions. The induced temperature difference between the catalyst and the comparatively colder surrounding reactive atmosphere is pointed as the main factor of the process selectivity enhancement towards the products of interest in a number of hydrocarbon conversion processes. However, MHC is traditionally restricted to catalytic reactions in the absence of catalyst coking. As excellent MW-susceptors, carbon deposits represent an enormous drawback of the MHC technology, being main responsible of long-term process malfunctions. This work addresses the potentials and limitations of MHC for such processes affected by coking (MHCC). It also intends to evaluate the use of different catalyst and reactor configurations to overcome heating stability problems derived from the undesired coke deposits. The concept of long-term MHCC operation has been experimentally tested/applied to for the methane non-oxidative coupling reaction at 700 degrees C on Mo/ZSM-5@SiC structured catalysts. Preliminary process scalability tests suggest that a 6-fold power input increases the processing of methane flow by 150 times under the same controlled temperature and spatial velocity conditions. This finding paves the way for the implementation of high-capacity MHCC processes at up-scaled facilities.