A Portable Microreactor System to Synthesize Hydrogen Peroxide
DOD-Army STTR Phase I Contract W911NF-06-C-0097
This STTR Phase I program addresses design, development, fabrication and testing of a safe, convenient and economical catalytic microreactor that is capable of generating vaporous hydrogen peroxide (VHP) on demand by direct synthesis of hydrogen and oxygen that could be generated by electrolysis of water aboard a portable hydrogen peroxide generator. Phase I will consist of two major and distinct tasks carried out in parallel: 1) design, development and fabrication of a microreactor, and 2) development of a suitable catalyst for the direct synthesis reaction in the vapor phase. The catalyst developed will be properly deposited/ loaded inside the channels of the microreactor. An experimental unit will then be built to carry out the microreactor performance tests and the results will be evaluated. The operating conditions will be optimized to achieve the best hydrogen peroxide yields and throughputs possible. At the end of the Phase I program, an estimate of the size and cost of a large-scale unit to be built in Phase II will be developed. The program will also identify further research or research and development needs for improvement of the new process.
The Army uses vaporous hydrogen peroxide (VHP) as a means of treating enclosed areas (buildings, aircraft, tanks) that have been contaminated by pathogens such as anthrax or chemical agents such as mustard gas. Currently commercially produced hydrogen peroxide comes generally as a water solution of 35% or 50% concentrations. Large volumes of these solutions with a significant fraction of inert (water) must be transported over a long distance to remote areas, properly stored and then evaporated to generate VHP for the Army applications when required.
A significance of this innovation is the direct production and utilization of vaporous hydrogen peroxide without involving a liquid phase. According to this innovation the hydrogen peroxide will be generated instantly, continuously and on demand in a portable unit directly in the vapor phase, which will then be immediately deployed for area decontaminations. This process eliminates all the cost and inconveniences associated with the liquid (solution) phase production of hydrogen peroxide. Upon successful demonstration of the single microreactor developed in Phase I of this program, it will be numbered up in Phase II, with all necessary compressors, pumps, bowers, fittings and controls. This numbered-up unit would have enough capacity to deliver vaporous hydrogen peroxide directly, and on demand, to decontaminate an interior space of at least 5,000 cu ft.
Hydrogen peroxide, a multi-billion dollar commodity of industry, is traditionally produced as a solution in water and in the liquid phase with fairly involved stages of reaction and separation involving organic solvents and alkylated anthraquinones. Transportation of large volumes of these water solutions (35 or 50%) must be transported over a long distance for many applications, at a significant cost. If vaporous hydrogen peroxide is needed it also requires and additional step and cost for evaporation of the transported solution. The vapor phase direct synthesis process for production of hydrogen peroxide, once successfully developed, therefore offers a potentially attractive alternative to the current technology.
The current U.S. market for hydrogen peroxide is $500 million. The pulp and paper industry uses 60% of it, water treatment consumes 13%, the chemical industry uses 8%, and the textile industry uses 7% of the material. Vaporized hydrogen peroxide is also used as a deodorant in the water treatment industry.