(522f) Interface Reaction Engineering and Modeling for Zeolite-Enzyme Tandem Flow Reactor

Tandem catalysis using alcohol oxidase and Fe-ZSM-5 enables the selective oxidation of methane to formaldehyde under mild conditions, followed by urea-formaldehyde polymer formation. However, the conventional batch-type reactor is limited by slow reaction rates due to gas-liquid mass transfer constraints and the sequential nature of the catalytic steps. To address these challenges, we developed a continuous flow reactor that embeds both catalysts within a porous carbon paper membrane via spray coating and enzyme immobilization. This structured platform facilitates spatially organized tandem catalysis and enhances interfacial transport across gas, liquid, and solid phases. To support reactor design and optimization, we developed a reaction–transport model that integrates mass transfer, spatial catalyst distribution, and reaction kinetics to identify rate-limiting steps. The model enables systematic exploration of key parameters—including membrane porosity, catalyst loading, and flow conditions—to predict methane conversion and product formation along the flow path. Experimental data validated the model, and simulation insights were used to refine the reactor configuration for improved performance. This approach presents a promising strategy for intensifying tandem catalytic processes under ambient conditions by combining membrane-enabled reactor design with kinetic modeling.

Keywords: reaction engineering, membrane reactor, tandem catalysis, methane partial oxidation, sustainable catalysis, green chemistry