Caracterización de catalizador Fe-Mo industrial para producción de formaldehído.
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Date
2025
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Publisher
Universidad de Concepción
Abstract
El presente trabajo consistió en evaluar la actividad catalítica de muestras industriales de catalizador Fe-Mo utilizadas en la oxidación parcial de metanol para la producción de formaldehído, con el fin de determinar su potencial de reutilización en planta. Las muestras analizadas correspondieron a remanentes de campañas productivas anteriores, almacenadas en bodega sin uso previo, cuyo potencial de aprovechamiento operativo era desconocido. Se realizó una caracterización físico química mediante ensayos en reactor de laboratorio (Laboratorio CarboCat), análisis de reducción a temperatura programada (TPR) y análisis de área superficial BET, con el propósito de establecer relaciones entre la actividad catalítica y las propiedades estructurales de las muestras.
A partir de los ensayos en el reactor de laboratorio, se establecieron tres categorías de desempeño: alto, moderado y bajo, en función de la conversión de metanol. 24% de las muestras alcanzaron un desempeño comparable al del catalizador nuevo, mientras que otro 24% presentaron un rendimiento aceptable, permitiendo su consideración para reutilización en futuras campañas. El 52% restante fueron clasificadas como no reutilizables, proponiéndose su revalorización externa. Los análisis TPR confirmaron que todas las muestras mantienen especies reducibles, sin evidencias de desactivación total, mientras que los resultados BET mostraron estructuras macroporosas estables, aunque con diferencias en área superficial que podrían relacionarse con alteraciones durante el almacenamiento prolongado.
Finalmente, se realizó una evaluación económica preliminar que evidenció un ahorro estimado de hasta un 25% respecto al escenario de compra total de catalizador nuevo. Los resultados obtenidos respaldan la viabilidad técnica y económica de reutilizar parte del inventario disponible, proponiendo una metodología replicable en futuras campañas. Se recomienda a la empresa complementar esta evaluación con estudios de composición y análisis estructurales más detallados, con el fin de comprender con mayor precisión las causas del desempeño diferenciado entre muestras.
The present undergraduate thesis focused on evaluating the catalytic activity of industrial Fe-Mo catalyst samples used in the partial oxidation of methanol for formaldehyde production, with the objective of determining their potential for reuse in the production plant. The samples analyzed were remnants from previous production campaigns, stored without prior use, whose operational value was unknown. A physicochemical characterization was conducted through a laboratory reactor testing (in CarboCat Laboratory), temperature-programmed reduction (TPR) analysis, and BET surface area measurements, aiming to establish relationships between catalytic activity and the structural properties of the samples. Based on the pilot reactor tests, the samples were classified into three performance categories: high, moderate, and low, according to their methanol conversion levels. A total of 24% of the samples exhibited performance comparable to that of the fresh catalyst, while another 24% showed acceptable activity, making them suitable candidates for reuse in future campaigns. The remaining 52% were deemed non-reusable and were proposed for external valorization. TPR analysis confirmed that all samples retained reducible species, with no evidence of complete deactivation, while BET results indicated stable macroporous structures. However, differences in surface area may be attributed to structural alterations during extended storage. Finally, a preliminary economic assessment estimated a potential savings of up to 25% compared to the scenario of purchasing only new catalyst. The findings support the technical and economic feasibility of reusing part of the existing inventory, providing a replicable methodology for future campaigns. It is recommended that the company complement this evaluation with detailed compositional and structural analyses to better understand the underlying causes of the observed performance differences among samples.
The present undergraduate thesis focused on evaluating the catalytic activity of industrial Fe-Mo catalyst samples used in the partial oxidation of methanol for formaldehyde production, with the objective of determining their potential for reuse in the production plant. The samples analyzed were remnants from previous production campaigns, stored without prior use, whose operational value was unknown. A physicochemical characterization was conducted through a laboratory reactor testing (in CarboCat Laboratory), temperature-programmed reduction (TPR) analysis, and BET surface area measurements, aiming to establish relationships between catalytic activity and the structural properties of the samples. Based on the pilot reactor tests, the samples were classified into three performance categories: high, moderate, and low, according to their methanol conversion levels. A total of 24% of the samples exhibited performance comparable to that of the fresh catalyst, while another 24% showed acceptable activity, making them suitable candidates for reuse in future campaigns. The remaining 52% were deemed non-reusable and were proposed for external valorization. TPR analysis confirmed that all samples retained reducible species, with no evidence of complete deactivation, while BET results indicated stable macroporous structures. However, differences in surface area may be attributed to structural alterations during extended storage. Finally, a preliminary economic assessment estimated a potential savings of up to 25% compared to the scenario of purchasing only new catalyst. The findings support the technical and economic feasibility of reusing part of the existing inventory, providing a replicable methodology for future campaigns. It is recommended that the company complement this evaluation with detailed compositional and structural analyses to better understand the underlying causes of the observed performance differences among samples.
Description
Tesis presentada para optar al título de Ingeniero/a Civil Químico/a.
Keywords
Metanol, Formaldehído, Catalizadores, Economia circular