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Process intensification and sustainability

Several research topics have been investigated in the field of structured catalysts and reactors. LCCP members have pioneered the development of novel structured catalyst with conductive honeycomb supports, suitable for replacing conventional packed beds of catalysts pellets in externally cooled multitubolar reactors with substantially enhanced heat exchange properties. The concept, which promises great potential either for intensification of existing chemical processes or for development of more sustainable new processes, has been demonstrated both theoretically and experimentally both at the lab- and at the pilot scale. The industrial interest is documented by joint publications, patents, conference presentations and research contracts with Corning, Lonza (now Polynt), Eni and Total.
The LCCP has also investigated heat, mass and momentum transfer properties of metallic and ceramic open-cell foams (or sponges) which are promising supports in the field of catalysis for energy and environmental protection. Correlations for estimation of heat and mass transfer and friction factor coefficients have been determined which cover a wide range of materials, cell densities (pores per inch) and void fractions.
An overview on the main activities carried out by the LCCP in this field can be found in a recent review paper authored by the group (Current Opinions in Chemical Engineering 5 (2014) 55).
The group has also developed a know-how on washcoating deposition techniques of catalyst layers of different composition (e.g. Al2O3, ZrO2, TiO2) onto supports with different geometries (slabs, tubes, honeycomb, foams), and recently authored a review paper on this subject (Catalysis Science & Technology 4 (2014) 2846).
The LCCP has contributed to the development of the "FTMR-technology", a new reactor configuration for the Fischer-Tropsch synthesis which is at the heart of the Small-Scale GTL technology developed by Eni. Such a technology is based on the adoption of externally cooled multitubular reactors loaded with highly conductive honeycomb monoliths.
In 2009, the LCCP has organized the International Symposium on Structured Catalysts and Reactors (ICOSCAR 3).
Since 2012, the LCCP is the national coordinator of the project "IFOAMS" (Intensification of Catalytic Processes for Clean Energy, Low-emission Transport and Sustainable Chemistry using Open-cell Foams as Novel Advanced Structured Materials), funded by the Italian Ministry of Education, University and Research as PRIN (Research Project of National Interest).

Faculties involved in the project are: Gianpiero Groppi, Enrico Tronconi, Carlo Giorgio Visconti.