WO2017186608A1 - Ferromagnetic materials for induction heated catalysis - Google Patents

Ferromagnetic materials for induction heated catalysis Download PDF

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WO2017186608A1
WO2017186608A1 PCT/EP2017/059586 EP2017059586W WO2017186608A1 WO 2017186608 A1 WO2017186608 A1 WO 2017186608A1 EP 2017059586 W EP2017059586 W EP 2017059586W WO 2017186608 A1 WO2017186608 A1 WO 2017186608A1
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ferromagnetic
susceptor material
catalyst
type structure
susceptor
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French (fr)
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Morten Gotthold VINUM
Peter Mølgaard MORTENSEN
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Haldor Topsøe A/S
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    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/08—Heat treatment
    • B01J37/082—Decomposition and pyrolysis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/002—Mixed oxides other than spinels, e.g. perovskite
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/74—Iron group metals
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    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
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    • B01J23/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/889—Manganese, technetium or rhenium
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    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/0242—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid flow within the bed being predominantly vertical
    • B01J8/025—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid flow within the bed being predominantly vertical in a cylindrical shaped bed
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    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/06—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen, e.g. water, acids, bases, ammonia, with inorganic reducing agents
    • C01B3/12—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen, e.g. water, acids, bases, ammonia, with inorganic reducing agents by reaction of water vapour with carbon monoxide
    • C01B3/16—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen, e.g. water, acids, bases, ammonia, with inorganic reducing agents by reaction of water vapour with carbon monoxide using catalysts
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
    • C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
    • C01B3/38—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts
    • C01B3/40—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts characterised by the catalyst
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10K—PURIFYING OR MODIFYING THE CHEMICAL COMPOSITION OF COMBUSTIBLE GASES CONTAINING CARBON MONOXIDE
    • C10K3/00—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide
    • C10K3/02—Modifying the chemical composition of combustible gases containing carbon monoxide to produce an improved fuel, e.g. one of different calorific value, which may be free from carbon monoxide by catalytic treatment
    • C10K3/026—Increasing the carbon monoxide content, e.g. reverse water-gas shift [RWGS]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00008—Controlling the process
    • B01J2208/00017—Controlling the temperature
    • B01J2208/00433—Controlling the temperature using electromagnetic heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2523/00—Constitutive chemical elements of heterogeneous catalysts
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
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    • C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
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    • C—CHEMISTRY; METALLURGY
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    • C01B2203/10—Catalysts for performing the hydrogen forming reactions
    • C01B2203/1041—Composition of the catalyst
    • C01B2203/1082—Composition of support materials
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Definitions

  • ChU + H2O CO + 3H2 When performing the steam reforming reaction, ChU + H2O CO + 3H2, at a relatively low pressure, such as 5 bar, the required maximum temperature would be between about 800°C and about 950°C. At a tar reforming reaction, C n H m + nH 2 0 ⁇ nCO + (m/2+n)H2, the required maximum temperature would typically be between about
  • the catalyst material can be any catalyst material according to the invention.
  • the catalyst material is not limited to catalyst material having relative size as compared to the reactor system as shown in the Figures.
  • the reactor unit 1 10 and the pressure shell 130 are made of non-ferromagnetic material.
  • the power source 140 is an electronic oscillator arranged to pass a high-frequency alternating current (AC) through the coil surrounding at least part of the catalyst material within the reactor system.

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  • Chemical & Material Sciences (AREA)
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Abstract

The invention relates to a susceptor material arranged for supporting catalytically active particles, said susceptor material being a ferromagnetic and porous material having a porosity in the range from about 10 to about 50%, a surface area of about 5 m2/g to about 100 m2/g and a Curie temperature above 650°C, where said susceptor material has a spinel type structure, an inverse spinel type structure or a perovskite type structure. The invention also relates to a catalyst material comprising the susceptor material of the invention and being impregnated with catalytically active particle; a reactor system for carrying out an endothermic catalytic chemical reaction, a method for carrying out an endothermic catalytic chemical reaction as well as a process for manufacturing a susceptor material.

Description

FERROMAGNETIC MATERIALS FOR INDUCTION HEATED CATALYSIS
FIELD OF THE INVENTION This invention relates to a susceptor material arranged for supporting catalytically active particles, a catalyst material for catalyzing an endothermic chemical reaction, a reactor system for carrying out an endothermic catalytic chemical reaction, a method for carrying out an endothermic catalytic chemical reaction as well as a process for manufacturing the susceptor material.
BACKGROUND OF THE INVENTION
Performing endothermic reactions will often be challenged by how efficient heat can be transferred to the reactive zone of the catalyst bed within a reactor unit. Conventional heat transfer by convection, conduction and/or radiation can be slow and will often meet large resistance in many configurations. This challenge can be illustrated with a tubular reformer in a steam reforming plant, which practically can be considered as a large heat exchanger with heat transfer as the rate limiting step. Induction heating is a potential means to circumvent this challenge, as magnetic fields are able to permeate many materials and therefore may induce magnetic heating directly within the active zone inside a reactor unit.
Typically, a catalyst material suitable for a given endothermic reaction is not inherently ferromagnetic, and inductively heated reactors may need to be combined with other heating means. In GB2210284 a method of performing endothermic catalytic reactions by inductively heating the catalyst for the reaction is described. GB2210284 discloses that an electrically conducting catalyst or catalyst support acts as secondary winding of a transformer with a ferromagnetic core, such that the ferromagnetic core passes centrally through the catalyst or catalyst support. The primary winding produces a mag- netic field in the core which induces a current into the catalyst. This current flow heats the catalyst. GB2210284 mentions that in addition to heating the catalyst by means of an induced electrical current, additional heat may be supplied to the endothermic reactions by methods known in the art. It is desirable to provide a susceptor material, a process for manufacturing the suscep- tor material, a catalyst material, a reactor system as well as a method arranged to facilitate induction heating of a catalytically active particle independently of whether the catalytically active particles themselves are ferromagnetic or not. Thereby, induction heat- ing of a broad variety of catalytically active particles is possible, thereby providing catalyst material arranged for catalysing a broad variety of different endothermic reaction.
It is also desirable to provide a catalyst material which in itself is ferromagnetic and thus suitable for being inductively heated. Thereby, inductive heating of the catalyst material is independent of the presence of further units of ferromagnetic material.
Moreover, energy efficiency is enhanced and high heating rates are obtainable by a ferromagnetic catalyst material.
BRIEF SUMMARY OF THE INVENTION
Induction heating is the process of heating an electrically conducting object (usually a metal) by magnetic induction, through heat generated in the object by eddy currents (also called Foucault currents) and/or hysteresis loss. An induction heater consists of an electromagnet, and an electronic oscillator which passes a high-frequency alternat- ing current (AC) through the electromagnet. The rapidly alternating magnetic field penetrates the object, generating electric currents inside the conductor called eddy currents. The eddy currents flowing through the resistance of the material heat it by Joule heating. Eddy current heating is also denoted ohmic heating. In ferromagnetic (and fer- rimagnetic and antiferromagnetic) materials like iron, heat may alternatively or addition- ally be generated by magnetic hysteresis losses. This is denoted ferromagnetic heating or hysteresis heating. The frequency of the alternating current to be used depends on the object size, material type, coupling (between the induction coil and the object to be heated) and the penetration depth. An induction coil comprising a conductor bent into the form of a plurality of loops or windings is an example of an electromagnet.
A first aspect of the invention relates to a susceptor material arranged for supporting catalytically active particles, where the susceptor material is a ferromagnetic and porous material having a porosity in the range from about 10% to about 50%, a surface area of about 5 m2/g to about 100 m2/g and a Curie temperature above 650°C, where said susceptor material has a spinel type structure, an inverse spinel type structure or a perovskite type structure. Advantageously, the Curie temperature is above 800°C, such as at or above 900°C, at or above 950°C or even higher. The porosity of the susceptor material ensures its suitability to be impregnated with cat- alytically active particles or elements, whilst the ferromagnetic properties provide the susceptor material the ability to being inductively heated. The porosity of the susceptor material is intrinsically connected to the surface area thereof. The porosity is in the range from about 10% to about 50%; a preferred subinterval is porosity between about 20% to about 45%, for example between 30% and 40%. A surface area of above about 5 m2/g is preferable, e.g. between 5 m2/g and 50 m2/g or between 5 m2/g and 20 m2/g.
A ferromagnetic and porous material with these parameters is suitable as support or carrier material for supporting catalytically active particles so that a catalyst material comprising the ferromagnetic and porous susceptor material impregnated with catalytically active particles will be both ferromagnetic and catalytically active. The porosity of the susceptor material ensures that an appropriate amount of catalytically active particles may be impregnated onto the susceptor material. Thereby, such a ferromagnetic and catalytically active material is suitable for inductive heating and catalyzing of endo- thermic reactions.
An estimation of the hysteresis heating is given by the formula: P=$>BdH*f, where P denotes the heating power transferred to the material, B the magnetic flux density, dH the change in the magnetic field strength, and f the frequency of the alternating magnetic field. Thus, the heating power transferred to the material by hysteresis heating is the area of the hysteresis curve times the frequency of the alternating magnetic field. An estimation of the ohmic/eddy current heating is given by
Figure imgf000005_0001
, where P denotes the heating power transferred to the material, Bm is the magnetic flux density induced in the material, I is a characteristic length of the material, σ is the conductivity of the material and f is the frequency of the alternating magnetic field. Thus, the heating power transferred to the material by eddy current heating is proportional to the magnetic flux density squared as well as the frequency of the alternating magnetic field squared. Paramagnetic materials have a very small magnetic flux density B when subject to an alternating magnetic field compared to ferromagnetic materials. Therefore, ferromagnetic materials are much more susceptible to induction heating than non-ferromagnetic materials, and either alternating magnetic fields of a lower frequency are usable for ferromagnetic materials compared to non-ferromagnetic materials or a lower frequency of the alternating magnetic field may be used. Generating a high-frequency magnetic field is relatively expensive energetically, so the use of a lower frequency of the magnetic field provides for cheaper heating of the material. Here, a high-frequency magnetic field is meant to be a field having a frequency in the MHz range, maybe from 0.1 or 0.5 MHz and upwards. Ferromagnetic material provides for further advantages, such as:
A ferromagnetic material absorbs a high proportion of the magnetic field, thereby making the need for shielding less or even superfluous.
Heating of ferromagnetic materials is relatively faster and cheaper than heating of non-ferromagnetic materials. A ferromagnetic material has an inherent or in- trinsic maximum temperature of heating, viz. the Curie temperature. Therefore, the use of a catalyst material which is ferromagnetic ensures that an endother- mic chemical reaction is not heated above a specific temperature, viz. the Curie temperature. Thus, it is ensured that the chemical reaction will not run out of control.
The term "ferromagnetic heating" is meant to denote heating substantially generated by magnetic hysteresis losses within a material upon subjecting it to an alternating magnetic field. The term "ferromagnetic heating" is synonymous to the term "hysteresis heating". The terms "eddy current heating", "ohmic heating", "resistive heating" and "Joule heating" are synonymous. Eddy current heating is the process by which the passage of an electric current through a conductor releases heat.
The term "susceptor" is meant to denote a material that absorbs electromagnetic energy and converts it to heat.
The term "spinel type structure" is meant to denote a structure with the generic formula A(2+)B2(3+)04. The term "perovskite type structure" is meant to denote a structure with the generic formula A(2+/3+)B(3+/4+)03. The term "inverse spinel type structure" is meant to denote a structure with the generic formula B(3+)(A(2+)B(3+))04. In an embodiment, the susceptor material is an oxide comprising oxygen and a mixture between at least one ferromagnetic element and a second, metallic element. The second, metallic element is suitable for providing a structure to the susceptor material. The term "a mixture between X and Y" is meant to denote a chemical compound which has X and Y as major components and possibly comprising further elements. Iron and mixtures between iron and other components respond very well to induction heating, due to their ferromagnetic nature. Eddy currents can, however, be generated in any conductor, and magnetic hysteresis can occur in any magnetic material.
In an embodiment the at least one ferromagnetic element of the susceptor material is chosen from the list of: nickel, cobalt, iron and combinations thereof; and the second, metallic element is chosen from the list of: aluminum, lanthanum, magnesium, chromium, and combinations thereof. Here, nickel, cobalt and/or iron provide(s) the suscep- tor material with ferromagnetic properties, whilst aluminum lanthanum, magnesium and/or chromium provide the structural properties of the susceptor material.
In an embodiment, the susceptor material further comprises a third element. The third element is an element chosen between the list of: samarium, copper, manganese and combinations thereof. Whilst the second metallic element provides structural stability to the susceptor material, the third element provides a kind of defect in the structure, which provides improved characteristics of the susceptor material.
A second aspect of the invention relates to a catalyst material for catalyzing an endo- thermic chemical reaction in a reactor in a given temperature range T upon bringing a reactant into contact with the catalyst material. The catalyst material comprises a ferromagnetic and porous susceptor material and catalytically active particles impregnated on the ferromagnetic and porous susceptor material, where said ferromagnetic and porous susceptor material has a porosity in the range from 10 to 50%, a surface area of about 5 m2/g to about 100 m2/g and a Curie temperature above 650°C, and where said susceptor material has a spinel type structure, an inverse spinel type structure or a per- ovskite type structure. An advantage of the catalyst material comprising a ferromagnetic and porous susceptor material and catalytically active particles impregnated on the ferromagnetic and porous susceptor material is that the catalytically active particles may be heated from close contact with the ferromagnetic and porous susceptor material which is directly heated upon subjecting the ferromagnetic and porous susceptor material to induction heating. The direct contact between the catalytically active particles and the ferromagnetic susceptor material enables efficient heating of the catalytically active particles from solid material conduction from the induction heated ferromagnetic susceptor material. The catalytically active particles may thus be any appropriate paramagnetic, fer- romagnetic, ferrimagnetic or antiferromagnetic element. Hereby, the catalyst material of the invention provides for catalyzing a variety of different reactions.
Moreover, if the catalytically active particles are ferromagnetic themselves, they will be heated indirectly by the induction heating of the susceptor material as well as directly by the magnetic field. Hereby, an even faster heating rate of the catalytically active particles is achievable.
The outer dimensions of the catalyst material are typically in the range of cm, viz. between about 0.5 cm and about 15 cm. Larger sizes, e.g. up to about 10 cm or even 20 cm, are also conceivable. When pellet catalyst is used in tubular reformers, it is generally recognised that the ratio of the tube diameter to the diameter of catalyst pellets should be above 4-5. This ratio also applies in this case, so that the diameter or size of the reactor unit should be at least 4-5 times the size of the catalyst material in order to avoid excess pressure drop.
In an embodiment, the ferromagnetic and porous susceptor material is an oxide comprising oxygen and a mixture between at least one ferromagnetic element and a second, metallic element. The second, metallic element is suitable for providing a structure to the susceptor material. In an embodiment, the as least one ferromagnetic element is chosen from the list of: nickel, cobalt, iron and combinations thereof; and said second metallic element is chosen from the list of: aluminum, lanthanum, magnesium, chromium, and combinations thereof. In an embodiment, the catalytically active particles comprise nickel, ruthenium, rhodium, a combination of nickel and cobalt or a combina- tion of manganese and zirconium. Nickel, optionally in combination with cobalt, is suitable for catalysing steam reforming and tar reforming reactions, whilst a combination of manganese and zirconium is suitable for catalysing the reverse water gas shift reaction. Advantages of these embodiments correspond to those described in relation to the susceptor material.
In an embodiment of the catalyst material, the susceptor material further comprises a third element. The third element is an element chosen between the list of: samarium, copper, manganese and combinations thereof. Whilst the second metallic element pro- vides structural stability to the susceptor material, the third element provides a kind of defect in the structure, which provides improved characteristics of the susceptor material.
In an embodiment, the catalytically active particles comprise nickel, ruthenium, rho- dium, a combination of nickel and cobalt or a combination of manganese and zirconium. Nickel, optionally in combination with cobalt, is suitable for catalysing steam reforming and tar reforming reactions, whilst a combination of manganese and zirconium is suitable for catalysing the reverse water gas shift reaction. The Curie temperature of the susceptor material is chosen such that the susceptor material is ferromagnetic at temperatures up to at least an upper limit of the given temperature range T. The term "up to an upper limit of the given temperature range T" is meant to denote appropriate temperatures up to this upper limit, such as any temperature between the standard ambient temperature and the upper limit of the given tem- perature range T. T may be e.g. 650°C, 700°C, 800°C, 900°C or 950°C.
Alternatively, the Curie temperature of the ferromagnetic and porous susceptor material preferably equals an operating temperature at substantially the upper limit of the given temperature range T of the endothermic reaction. This provides for a self-regulating system in that the ferromagnetic catalyst material is heated to the equilibrium temperature and can easily be maintained at this temperature. This is due to the fact that the catalyst material will cycle between being paramagnetic and consequently practically non-heating at temperatures above the Curie temperature, and being ferromagnetic and thus heating at temperatures below the Curie temperature. Another aspect of the invention relates to a reactor system for carrying out an endo- thermic catalytic chemical reaction in a given temperature range T upon bringing a re- actant into contact with a catalyst material within the reactor system. The reactor system comprises a reactor unit arranged to accommodate catalyst material for catalyzing an endothermic chemical reaction in a given temperature range T upon bringing a reac- tant into contact with the catalyst material. The catalyst material comprises a ferromagnetic and porous susceptor material and catalytically active particles impregnated on the ferromagnetic and porous susceptor material, and the ferromagnetic and porous susceptor material has a porosity in the range from about 20 to about 30%, a surface area of about 2 m2/g to about 40 m2/g and a Curie temperature above 650°C. The susceptor material has a spinel type structure, an inverse spinel type structure or a perov- skite type structure. The ferromagnetic and porous susceptor material is susceptible for induction heating when subject to an alternating magnetic field and the ferromagnetic and porous susceptor material is ferromagnetic at temperatures up to an upper limit of the given temperature range T. The reactor system also comprises an induction coil arranged to be powered by a power source supplying alternating current and being positioned so as to generate an alternating magnetic field within the reactor unit upon energization by the power source. When the catalyst material within the system for carrying out of an endothermic catalytic reaction comprises a ferromagnetic and porous susceptor material comprising catalytically active particles, the catalytically active particles are heated from the heating of the ferromagnetic susceptor material. The catalytically active particles may thus be any appropriate paramagnetic or ferromagnetic element or combination of appropriate par- amagnetic or ferromagnetic elements. Hereby, the reactor system of the invention provides for catalyzing a variety of different reactions. An important feature of the induction heating process is that the heat is generated inside the object itself, instead of by an external heat source via heat conduction. Thus objects can be very rapidly heated. However, if the catalytically active particles are ferromagnetic themselves, they will be heated indirectly by the induction heating of the ferromagnetic susceptor material as well as directly by the magnetic field. Hereby, a very fast heating rate directly in the catalytically active particles is achievable as well. Moreover, a catalyst material which, upon being subjected to an alternating magnetic field, is ferromagnetic at relevant operating conditions, such as at all relevant temperatures up to the upper limit of the temperature range T, and possibly above, is advantageous as it will be explained below. The given temperature range T is preferably the range between about 400°C and about 950°C or a sub-range thereof. Advantageously, the Curie temperature of the susceptor material is above 800°C, such as at or above 900°C, at or above 950°C or even higher. In an embodiment, the Curie temperature of the ferromagnetic structured elements equals an operating temperature at substantially the upper limit of the given tempera- ture range T of the endothermic reaction.
When performing the steam reforming reaction, ChU + H2O CO + 3H2, at a relatively low pressure, such as 5 bar, the required maximum temperature would be between about 800°C and about 950°C. At a tar reforming reaction, CnHm + nH20 ^ nCO + (m/2+n)H2, the required maximum temperature would typically be between about
750°C and about 950°C, whilst the pressure would be between 1 and 30 bar. The reverse water gas shift reaction, CO2 + H2 ^ CO + H2O, typically requires a maximum temperature between about 400°C and about 750°C at a pressure between 1 and 30 bar. Thus, preferred temperature sub-ranges of the given temperature range T are the range between about 750°C and about 950°C, the range between about 800°C and about 950°C, or the range between about 400°C and about 750°C. However, other sub-ranges of the range from about 400°C to about 950°C are conceivable depending on which reaction is to be carried out in the reactor system. In an embodiment, the reactor system comprises a pressure shell arranged to pressurize the reactor unit in order to obtain a pressure within the reactor unit of between about 5 bar and about 30 bar.
In an embodiment, the induction coil is placed within the reactor unit, around the reac- tor unit or around a pressure shell enclosing the reactor unit. In some embodiments the reactor unit is able to be pressurized in itself or the endothermic reaction is to take place without being pressurized. In this case, the induction coil may be placed within the reactor unit or around the reactor unit. In other embodiments, the reactor unit is not in itself able to provide the necessary pressure for a required reaction; in this case, the reactor unit may be placed within a pressure shell, and the induction coil may be placed within the reactor unit, on the outside of the reactor unit but within the pressure shell or outside the pressure shell. If the induction coil is placed within the reactor unit, it is preferable that it is positioned at least substantially adjacent to the inner wall(s) of the reactor unit in order to surround as much of the catalyst material as possible. In the cases, where the induction coil is placed within the reactor unit, windings of the reactor unit may be in physical contact with catalyst material. In this case, in addition to the induction heating, the catalyst material may be heated directly by ohmic/resistive heating due to the passage of electric current through the windings of the induction coil. The re- actor unit and, if present, the pressure shell are typically made of non-ferromagnetic material.
In an embodiment, the distance between windings of said induction coil is varied along a length of the reactor unit. Hereby, induction heating is graded due to the varying dis- tance between windings of said induction coil. This is advantageous in that induction heating is effective and may render high temperatures, also in the vicinity of the inlet of the reactor unit. High temperatures at the inlet of the reactor unit may cause carbon formation at the catalyst, if the catalyst temperature is higher than the equilibrium temperature of the chemical reaction. The graded heating is to take place so that the heating is less intensive at the inlet to the reactor and becomes more intensive towards the outlet. In an embodiment, the graded heating can be done by varying the distance between windings of said induction coil. Thus, the distance between successive windings should be larger towards the inlet end of the reactor than towards the outlet end. In an embodiment, the catalyst material within the reactor unit comprises two or more types of catalyst materials along the catalyst bed, said two or more types of catalyst material having different Curie temperatures. This is an alternative or additional approach to obtain graded heating within an inductively heated reactor unit. When the catalyst material closest to the inlet of the reactor unit has a lower Curie temperature than the catalyst material closest to the outlet of the reactor, it is possible to control the maximum temperature achievable within the reactor so that it is less close to the inlet end than further along the reactor unit.
A further aspect of the invention relates to a method for carrying out an endothermic catalytic chemical reaction in a given temperature range T in a reactor system. The reactor system comprises a reactor unit arranged to accommodate catalyst material for catalyzing an endothermic chemical reaction in a given temperature range T upon bringing a reactant into contact with the catalyst material. The catalyst material comprises a ferromagnetic and porous susceptor material and catalytically active particles impregnated on the ferromagnetic and porous susceptor material. The ferromagnetic and porous susceptor material has porosity in the range from 10 to 50%, a surface area of about 5 m2/g to about 100 m2/g and a Curie temperature above 650°C, and where the susceptor material has a spinel type structure, an inverse spinel type structure or a perovskite type structure. The method comprises the steps of:
(i) Generating an alternating magnetic field within the reactor unit upon energization by a power source supplying alternating current, said alternating magnetic field passing through the reactor unit, thereby heating catalyst material to a temperature within the given temperature range T by induction of a magnetic flux in the catalyst material;
(ii) bringing a reactant into contact with said catalyst material;
(iii) heating of said reactant by the catalyst material; and
(iv) letting the reactant react in order to provide a product to be outlet from the reactor.
By the process of the invention, the catalyst material is heated by induction. This provides the heat necessary for the endothermic catalytic chemical reaction. The heating of the reactant is provided by conduction when the reactant is brought into contact with the catalyst material, typically by being adsorbed onto the surface of the catalyst material, as well as by convection prior to the reactant contacting the surface of the catalyst material. The sequence of the steps (i) to (iv) is not meant to be limiting. Step (ii) and (iii) may happen simultaneously, or step (iii) may be initiated before step (ii) and/or take place at the same time as step (iv).
The ferromagnetic susceptor material is ferromagnetic at temperatures up to at least an upper limit of the given temperature range T, viz. also at temperatures above the upper limit of the given temperature range T. However, the Curie temperature of the ferromagnetic structured elements may substantially equal the upper limit of the tempera- ture range T. In this instance, it is ensured that the reaction temperature does not exceed the Curie temperature substantially and the chemical reaction is prevented from run-away. The method typically further comprises the step of recovering the product outlet from the reactor unit.
In an embodiment, the method furthermore comprises the step of pressurizing the reactor unit to a pressure of between 5 and 30 bar. The temperature range T is the range from between about 700 and about 950°C, preferably between about 400 and about 950°C.
According to yet another aspect, the invention relates to a process for manufacturing a susceptor material arranged for being part of a catalyst material, where the susceptor material is a ferromagnetic and porous material having a porosity in the range from about 10 to about 50%, a surface area of about 5 m2/g to about 100 m2/g and a Curie temperature above 650°C. The susceptor material has a spinel type structure, an inverse spinel type structure or a perovskite type structure. The process comprises the steps of:
- dissolving nitrate salts of a ferromagnetic element and a second, metallic element, and mixing with citric acid hydrate to form a gel precursor,
- optionally, adding a base in order to stabilize said gel precursor,
- performing a first calcination at a temperature of between 400°C and 500°C in order to obtain a first intermediate material,
- grinding said first intermediate material,
- performing a second calcination of the grinded first intermediate material at a temperature of between 850°C and 1 100°C in order to obtain a second intermediate material,
- grinding and tableting said second intermediate material in order to obtain a third intermediate material, and
- reducing said third intermediate material by means of a reducing agent, thereby obtaining said susceptor material.
The reducing agent may be hydrogen.
The final catalytic support is sufficiently porous to be well suited to be impregnated with a suitable catalytic active phase which is appropriate for the intended chemical reaction. Moreover, the support can also in some cases have an inherent catalytic functionality. In an embodiment, the susceptor material is an oxide comprising oxygen and a mixture between at least one ferromagnetic element and a second metallic element. The second metallic element is suitable for providing a structure to the susceptor material.
In an embodiment, the as least one ferromagnetic element is chosen from the list of: nickel, cobalt, iron and combinations thereof; and said second metallic element is chosen from the list of: aluminum, lanthanum, magnesium, chromium and combinations thereof.
BRIEF DESCRIPTION OF THE FIGURES
Figure 1 is a graph showing temperature profiles of a reactor unit heated by convec- tive/conductive and/or radiation heating, and induction heating, respectively;
Figures 2a-2e show schematic drawings of five embodiments of a reactor system;
Figures 3a and 3b show the magnetization and the size of the hysteresis curve for CoAI204; and
Figures 4a and 4b show the magnetization and the size of the hysteresis curve for a (Coo.5Nio.5MAI1.9Smo.1O4) .
DETAILED DESCRIPTION OF THE FIGURES
Figure 1 is a graph showing temperature profiles of a reactor unit 10 heated by convec- tive/conductive and/or radiation heating, and induction heating, respectively, during an endothermic reaction within the reactor unit 10. The temperature profiles in figure 1 are indicated together with a schematic cross-section through a reactor unit 10 having walls 12 holding a catalyst bed 14 with catalyst material for endothermic reactions. The catalyst material in the catalyst bed 14 is susceptible to inductive heating. Means for heating the reactor unit 10 and/or the catalyst bed 14 are not shown. In the case of convective, conduction and/or radiation heating, the means for heating could e.g. be fired burners; means for induction heating would typically be an electromagnet, e.g. an induction coil. A temperature scale is indicated at the right side of Figure 1. The hori- zontal dotted line indicates a temperature of 850°C at the centre of the catalyst bed.
The dotted curve 16 indicates the temperatures outside the reactor unit, at the reactor unit walls as wells as within the catalyst bed 14 when heated by convective/conductive and/or radiation heating, whilst the solid curve 17 indicate the temperatures outside the reactor unit, at the reactor unit walls as well as within the catalyst bed 14 when heated by convective/conductive and/or radiation heating, and induction heating, respectively.
It is clear from Figure 1 , that in the case of convective/conductive and/or radiation heating, the temperature is higher outside the wall 12 than within the wall 12, and that the temperature within the catalyst bed 14 is lower than that at the wall 12. At the center of the catalyst bed, the temperature is at its lowest. This is because the temperature at the heat source must be higher than the reaction zone and due to the temperature loss through the walls and due to the endothermic nature of the reaction within the reactor unit 10. In contrast, the temperature profile as indicated by the curve 17 shows that for induction heating the temperature is higher at the wall 12 compared to outside the reactor unit, whilst the temperature inside the catalyst bed increases from the wall 12 to the center of the catalyst bed 14.
In general, performing endothermic reactions is limited by how efficient heat can be transferred to the reactive zone of the catalyst bed 14. Conventional heat transfer by convection/conduction/radiation can be slow and will often meet large resistance in many configurations. Moreover, heat losses within the walls of the reactor play a role. In contrast, when heat is deposited inside the catalyst bed 14 by the induction concept, the catalyst bed will be the hottest part of the reactor 10 in contrast to conventional heating where the exterior heat source has to be significantly hotter than the internal part to have a driving mechanism for the heat transfer. To make the catalyst bed susceptible for induction, different approaches may be applied. One approach is to heat the catalyst by induction by making the catalytically active particles of the catalyst ferromagnetic at reaction temperatures. In this approach it has been established that a reforming catalyst can be made with an active phase of a Ni-Co alloy, which is both active for steam reforming and ferromagnetic at temperatures above 700°C. However, it has been shown that having nanoparti- cles alone as the ferromagnetic phase typically will be inefficient for heating the catalyst bed. In another approach, being the approach of the invention, catalyst material comprises a ferromagnetic and porous susceptor material impregnated with the catalytically active phase. This approach offers a large versatility compared to the ferromagnetic nanoparticles in the catalyst, as the choice of catalytic active phase is not required to be ferromagnetic.
In addition to the possibility of delivering heat directly to the catalyst material, induction heating offers a fast heating mechanism, which potentially could make upstart of a reforming plant relative fast. Figures 2a - 2e show schematic drawings of five embodiments 100a, 100b, 100c,
100d, and 100e of a reactor system. In Figures 2a - 2e, similar features are denoted using similar reference numbers.
Figure 2a shows an embodiment of the reactor system 100a for carrying out an endo- thermic catalytic chemical reaction upon bringing a reactant into contact with a catalyst material 120. The reactor system 100a comprises a reactor unit 1 10 arranged to accommodate catalyst material 120 comprising catalyst material in the form of ferromagnetic and porous susceptor material impregnated with catalytically active particles; this material is susceptible for induction heating.
Reactant is introduced into the reactor unit 1 10 via an inlet 1 1 1 , and reaction products formed on the surface of the catalyst material 120 is outlet via an outlet 1 12. A pressure shell 130 surrounds the reactor unit 1 10 and is arranged for pressurizing the reactor unit 1 10. The inlet and outlet 1 1 1 , 1 12 as well as the pressure shell 130 have appro- priate gaskets, seals or the like (not shown in Figure 2a).
The reactor system 100a further comprises an induction coil 150a arranged to be powered by a power source 140 supplying alternating current. The induction coil 150a is connected to the power source 140 by conductors 152. The induction coil 150a is positioned so as to generate an alternating magnetic field within the reactor unit 1 10 upon energization by the power source 140. Hereby the catalyst material 120 is heated to a temperature within a given temperature range T relevant for carrying out the chemical reaction, by means of the alternating magnetic field. In the embodiment of Figure 2a, the induction coil 150a is position on the outside of the pressure shell 130.
Figures 2b-2e show other embodiments 100b, 100c, 10Od and 10Oe of the reactor system for carrying out an endothermic catalytic chemical reaction. The reactor unit 1 10 and its inlet and outlet 1 1 1 , 1 12, the catalyst material 120, the pressure shell 130 (in Figures 2b and 2c), the power source 140 and its connecting conductors 152 are similar to those of the embodiment shown in Figure 2a.
In the embodiment of Figure 2b, an induction coil 150b is wound or positioned around the outside of the reactor unit 1 10, within the pressure shell 130. The conductors 152 connecting the induction coil 150b and the power source 140 are led through the pressure shell 130 at openings (not shown) arranged to let the conductors 152 pass through a wall of the pressure shell 130 without depriving the pressure shell 130 of its pressurizing ability.
In the embodiment of Figure 2c, an induction coil 150c is positioned within the reactor unit 1 10, and thus also within the pressure shell 130. The induction coil 150c of Figure 2c is placed substantially adjacent to the inner surface of the reactor unit 1 10 in order to enclose as much of the reactor volume as possible. The induction coil 150c is typi- cally also in physical contact with the catalyst material 120. In this case, in addition to the induction heating provided by the magnetic field, the catalyst material 120 adjacent the induction coil 150c is additionally heated directly by ohmic/resistive heating due to the passage of electric current through the windings of the induction coil 150c. The conductors 152 connecting the induction coil 150c and the power source 140 or parts of the induction coil 150c are led through the pressure shell 130 at openings (not shown) arranged to let the conductors 152 or parts of the induction coil 150c pass through a wall of the pressure shell 130 without depriving the pressure shell 130 of its pressurizing ability. In the embodiment of Figure 2d, an induction coil 150d is positioned within the reactor unit 1 10; however, in the embodiment of Figure 2d no pressure shell is present in the reactor system. In one embodiment of the reactor system 100d shown in Figure 2d, the reactor unit 1 10 is able to pressurize its content. In another embodiment of the reactor system 100d, the reactor unit 1 10 is not able put its content to a substantially elevated pressure; this may be the case for reactor units for e.g. tar reforming or reverse water- gas shift reactions. However, the reactor unit 1 10 should be arranged to provide a small excess pressure within the reactor unit in order to ensure sufficient flow of the re- actant and product streams.
The induction coil 150d of Figure 2d is placed substantially adjacent to the inner surface of the reactor unit 1 10 and in physical contact with the catalyst material 120. In this case, in addition to the induction heating provided by the magnetic field, the catalyst material 120 adjacent the induction coil 150d is additionally heated directly by ohmic/resistive heating due to the passage of electric current through the windings of the induction coil 150c.
In the embodiment of Figure 2e, an induction coil 150e is wound or positioned around the outside of the reactor unit 1 10; however, in the embodiment of Figure 2d no pres- sure shell is present in the reactor system.
In one embodiment of the reactor system 100d shown in Figure 2d, the reactor unit 1 10 is able to pressurize its content. In another embodiment of the reactor system 100d, the reactor unit 1 10 is not able to put its content to a substantially elevated pressure; this may be the case for reactor units for e.g. tar reforming or reverse water-gas shift reactions. However, the reactor unit 1 10 should be arranged to provide a small excess pressure within the reactor unit in order to ensure sufficient flow of the reactant and product streams. The conductors 152 connecting the induction coil 150c and the power source 140 or parts of the induction coil 150c are led through the pressure shell 130 at openings (not shown) arranged to let the conductors 152 or parts of the induction coil 150c pass through a wall of the pressure shell 130 without depriving the pressure shell 130 of its pressurizing ability. In all five embodiments shown in Figures 2a-2e, the catalyst material can be any catalyst material according to the invention. Thus, the catalyst material is not limited to catalyst material having relative size as compared to the reactor system as shown in the Figures. Furthermore, in all five embodiments shown in Figures 2a-2e, the reactor unit 1 10 and the pressure shell 130 (only relevant for the embodiments of Figures 2a-2c) are made of non-ferromagnetic material. In all five embodiments of Figures 2a-2e, the power source 140 is an electronic oscillator arranged to pass a high-frequency alternating current (AC) through the coil surrounding at least part of the catalyst material within the reactor system.
Figures 3a and 3b show the magnetization and the size of the hysteresis curve for (Coo.5,Nio.5)Al2C>4. (Coo.5,Nio.5)Al2C>4 is a susceptor material having spinel type structure and comprising oxygen, two ferromagnetic element, viz. Co and Ni, and a second me- tallic element, viz. Al.
From Figure 3a it is clear that the magnetization drops as a function of temperature increase, ant that the magnetization drops relatively suddenly between 850 and 900°C. This indicates that the Curie temperature is close to 900°C.
Complementary to Figure 3a, the size of the hysteresis curve (Q) of (Coo.s.Nio^A C was evaluated as a function of temperature and maximum magnetic field (Bmax) as shown in Figure 3b. The plot shows that at a temperature of 200°C, the size of the hysteresis curve is almost 2 J/kg for a maximum magnetic field of Bmax= 0.1 T. The plot also shows that the size of the hysteresis curve decreases with increasing temperature, and that a significant hysteresis curves is present even at 850°C.
Figures 4a and 4b show the magnetization and the size of the hysteresis curve for a (Coo.sNio.s)(Ali.9Smo.i04). (Coo.sNio.s)(Ali.9Smo.i04). is a susceptor material having spinel type structure and comprising oxygen, two ferromagnetic elements, viz. Co and Ni, and two metallic element, viz. Sm and Al.
Figure 4a shows the magnetization of (Coo.sNio.sMAIi.gSmo.iC ) as a function of tempera- ture. From Figure 4a it is clear that the magnetization drops as a function of temperature increase, ant that the magnetization drops relatively suddenly between 850 and 900°C. This indicates that the Curie temperature is close to 900°C also for
(Coo.5Nio.5)(Ali.9Smo.i04).
Complementary to Figure 4a, the size of the hysteresis curve (Q) was evaluated as a function of temperature and maximum magnetic field (Bmax) as shown in Figure 4b. The plot shows that at a temperature of 25°C and 200 °C, respectively, the size of the hysteresis curve is almost 1 J/kg and about 0.75 J/kg, respectively, for a maximum mag- netic field of Bmax= 0.1 T. The plot also shows that the size of the hysteresis curve decreases with increasing temperature, and that a significant hysteresis curves is present even at 850°C.
EXAMPLARY PROCESSES FOR MANUFACTURING OF A SUSCEPTOR MATE- RIAL:
Synthesis of C0AI2O4:
An equimolar amount of Co(N03)2*6H20 and AI(N03)3*9H20 is mixed together in 40 ml of demineralized water using magnetic stirring. After complete dissolution, citric acid monohydrate is added so that the metal to citrate ratio is 1 :1 or 1 :2 and stirring is continued until complete dissolution. In some cases, a bit of heat is needed to get everything into solution. The temperature is then raised in increments to 90°C and heating is maintained until the solution becomes a gel. Subsequently, the reaction mixture is transferred into a calcination vessel.
The gel is calcined at 450°C for 2 hours, resulting in a dark green/black powder, which is then crushed and calcined again at 1000°C for 4 hours to obtain a blue powder. Optionally, the final powder is reduced in a reducing gas of e.g. hydrogen at 850°C.
Using the above-mentioned synthetic route, the following phase-pure samples have been synthesized:
Compounds with perovskite-type structure include (but are not limited to):
SmCoOs
Figure imgf000022_0001
LaFeOs
LaCoOs Compounds with spinel-type structure include (but are not limited to):
Figure imgf000022_0002
(Coo.5Mgo.5)(Cr0.8,Ali.2)04
CU0.01C00.495N10.495AI2O4
Mno.Ol COo.495Nio.495Al204
Feo.01 C00.495N 10.495AI2O4
Cro.OlCOo.495Nio.495Al204
coo.5Nio.5AI1.9smo.104
These materials are candidates as ferromagnetic susceptor material with a sufficient surface area to facilitate support of an active phase in the form of impregnated nano- particles.
EXEMPLARY SUSCEPTOR MATERIALS
Example 1 :
C0AI204 - spinel
Aluminum 31.9 wt%
Cobalt 32.1 wt%
Single point surface area 9.97 m2/g
Example 2:
Mgo.8Coo.2AI204 - spinel calc. at 1000°C
Aluminum 37.0 wt%
Cobalt 8.01 wt%
Carbon 690 wt ppm
Magnesium 13.1 wt%
Single point surface area 7.45 m2/g
Example 3:
C00.5N10.5AI2O4 - spinel calc. at 1000°C
Aluminum 30.3 wt%
Cobalt 16.5 wt%
Nickel 16.0 wt%
Single point surface area 15.3 m2/g Example 4:
Figure imgf000023_0001
Example 9:
Cr0.oiCoo.495Nio.495AI204 - spinel calc. At 1000°C
Aluminium 30.1 %
Cobalt 16.1 %
Nickel 16.3 %
Chromium 0.38% Example 10:
Figure imgf000024_0001
EXAMPLARY REACTIONS:
In the following some examples are given in relation to the invention. In the reactor system used for the reactions, the induction coil may be placed within the reactor unit, around the reactor unit or around a pressure shell holding the reactor unit, as appropri- ate.
As noted above, a general advantage of using induction heating as compared to side fired reformers or top fired reformers, is that such fired reformers are limited in the hot part by the heat transfer rate to the catalytic zone. By use of induction, this heat trans- fer limitation can be circumvented since the catalyst material itself is heated directly by the magnetic flux from an induction coil positioned so as to generate an alternating magnetic field within the reactor unit holding the catalyst material.
Steam reforming
A first example of an endothermic chemical reaction for which the invention is suitable is steam reforming, generating i.a. hydrogen. Today, the decentralized market for hydrogen is often dependent on expensive distribution and storage of hydrogen. As an alternative to this, induction heated reforming could be envisioned as a small scale hy- drogen production technology potentially with fast startup for ad hoc hydrogen production and a heating system based on electricity instead of a fired hot box.
The catalyst material for the steam reforming reaction, CH4 + H2O ^ CO + 3H2, at a temperature within the temperature range from about 800 to about 950°C is for exam- pie a catalytic and ferromagnetic support of CoyNixAl204, where x + y = 1 , impregnated with Ni and as active phase. A typical example of the catalyst material is
Ni Coo.5Nio.5Al204. Another example is a catalyst material where the susceptor material is C0AI2O4 impregnated with Ni as catalytically active particles. Hydrogen production can be facilitated at 860°C and 5 bar with a steam to hydrocarbon carbon ratio of 2 using this catalyst material for the reaction. The heat for the reaction is supplied by a magnetic field which is supplied by an induction coil.
The concept is well suited for small scale hydrogen production. When performing the reaction at low pressure (5 bar), in comparison to 30 bar in large scale industry plants, the required maximum temperature would be 800-850°C, making induction heating possible.
Tar reforming
A further example of an endothermic chemical reaction for which the invention is suitable is the tar reforming reaction CnHm + nH2<D nCO + (m/2+n)H2, which may take place at a temperature within the range from about 750 to about 950°C.
A suitable catalyst material is for example a ferromagnetic and porous susceptor material of CoyNixA CU, where x + y = 1 , impregnated with Ni. A typical example of the catalyst material is Ni/Coo.sNio.sA CU. Thus, the susceptor material may be C0AI2O4 im- pregnated with Ni as catalytically active particles
Reverse water gas shift
Yet a further example of an endothermic chemical reaction for which the invention is suitable is the reverse water gas shift CO2 + H2 ^ CO + H2O, typically taking place at a temperature within the range from about 400 to about 750°C.
A suitable catalyst material is for example a ferromagnetic and porous susceptor material support of CoyNixA C , where x + y = 1 , impregnated with oxides of manganese and zirconium as the catalytically active particles. Suitable catalytically active particles of oxides of manganese and zirconium are described in EP1445235. Again, a typical example of the susceptor material is Coo.sNio.sA C .
When the oxide coating is an oxide made of a combination of Al, Zr, Ce, an example of the amounts of these elements would be 70±30 wt% Zr, 10±5 wt% Ce and 10±5 wt% Al. sed herein, the understanding of magnetic material classification is as follows:
• Paramagnetic materials: A magnetic moment only exists when the material is exerted to an external magnet field; otherwise the dipoles within the material are scrambled. Such a material is often also referred to as nonmagnetic.
• Ferromagnetic materials: This type of material can maintain a magnetic moment in the absence of an external magnetic field.
• Ferrimagnetic materials: Materials having populations or combinations of atoms/ions which have different magnetic moments, where the different moments are unequal or equal, but not aligned parallel to each other (such as in canted antiferromagnets). This group of materials has a net magnetic moment.
• Antiferromagnetic materials: Materials having populations or combinations of atoms/ions which have different orientation on the magnetic spin of the same size. The net magnetic moment on this type of material is zero as it is cancelled out by the opposing magnetic moments.

Claims

1 . A susceptor material arranged for supporting catalytically active particles, said susceptor material being a ferromagnetic and porous material having a porosity in the range from about 10 to about 50%, a surface area of about 5 m2/g to about 100 m2/g and a Curie temperature above 650°C, where said susceptor material has a spinel type structure, an inverse spinel type structure or a perovskite type structure.
2. A susceptor material according to claim 1 , wherein said susceptor material is an ox- ide comprising oxygen and a mixture between at least one ferromagnetic element and a second, metallic element.
3. A susceptor material according to claim 1 or 2, wherein said at least one ferromagnetic element is chosen from the list of: nickel, cobalt, iron and combinations thereof; and said second, metallic element is chosen from the list of: aluminum, lanthanum, magnesium, chromium, and combinations thereof.
4. A susceptor material according to any of the claims 1 to 3, wherein said susceptor material further comprises a third element, said third element being an element chosen between the list of: samarium, copper, manganese and combinations thereof.
5. A catalyst material for catalyzing an endothermic chemical reaction in a reactor in a given temperature range T upon bringing a reactant into contact with the catalyst material, said catalyst material comprising a ferromagnetic and porous susceptor material and catalytically active particles impregnated on the ferromagnetic and porous susceptor material, where said ferromagnetic and porous susceptor material has a porosity in the range from 10 to 50%, a surface area of about 5 m2/g to about 100 m2/g and a Curie temperature above 650°C, and where said susceptor material has a spinel type structure, an inverse spinel type structure or a perovskite type structure.
6. A catalyst material according to claim 5, wherein said ferromagnetic and porous susceptor material is an oxide comprising oxygen and a mixture between at least one ferromagnetic element and a second, metallic element.
7. A catalyst material according to claim 5 or 6, wherein said at least one ferromagnetic element is chosen from the list of: nickel, cobalt, iron and combinations thereof; and said second metallic element is chosen from the list of: aluminum, lanthanum, magnesium, chromium, and combinations thereof.
8. A catalyst material according to any of the claims 5 to 7, wherein said susceptor material further comprises a third element, said third element being an element chosen between the list of: samarium, copper, manganese and combinations thereof.
9. A catalyst material according to any of the claims 5 to 8, wherein catalytically active particles comprise nickel, ruthenium, rhodium, a combination of nickel and cobalt or a combination of manganese and zirconium.
10. A catalyst material according to any of the claims 5 to 9, wherein the Curie temper- ature of the ferromagnetic and porous material equals an operating temperature at substantially the upper limit of the given temperature range T of the endothermic reaction.
1 1 . A reactor system for carrying out an endothermic catalytic chemical reaction in a given temperature range T upon bringing a reactant into contact with a catalyst material within said reactor system, said reactor system comprising:
- a reactor unit arranged to accommodate catalyst material for catalyzing an endothermic chemical reaction in a given temperature range T upon bringing a reactant into contact with the catalyst material, said catalyst material comprising a ferromagnetic and porous susceptor material and catalytically active particles impregnated on the ferro- magnetic and porous susceptor material, where said ferromagnetic and porous susceptor material has a porosity in the range from about 10 to about 50%, a surface area of about 2 m2/g to about 40 m2/g and a Curie temperature above 650°C, and where said susceptor material has a spinel type structure, an inverse spinel type structure or a per- ovskite type structure, wherein said ferromagnetic and porous susceptor material is susceptible for induction heating when subject to an alternating magnetic field and wherein said ferromagnetic and porous susceptor material is ferromagnetic at temperatures up to an upper limit of the given temperature range T,
- an induction coil arranged to be powered by a power source supplying alternating cur- rent and being positioned so as to generate an alternating magnetic field within the reactor unit upon energization by the power source.
12. A reactor system according to claim 1 1 , wherein the reactor system comprises a pressure shell arranged to pressurize the reactor unit in order to obtain a pressure within the reactor unit of between about 5 bar and about 30 bar.
13. A reactor system according to claim 1 1 or 12, wherein the induction coil is placed within the reactor unit, around the reactor unit or around a pressure shell enclosing the reactor unit.
14. A reactor system according to any of the claims 1 1 to13, wherein the distance between windings of said induction coil is varied along a length of the reactor unit.
15. A reactor system according to any of the claims 1 1 to 13, wherein the catalyst material comprises two or more types of catalyst materials along the catalyst bed, said two or more types of catalyst material having different Curie temperatures.
16. A method for carrying out an endothermic catalytic chemical reaction in a given temperature range T in a reactor system, said reactor system comprising a reactor unit arranged to accommodate catalyst material for catalyzing an endothermic chemical reaction in a given temperature range T upon bringing a reactant into contact with the catalyst material, said catalyst material comprising a ferromagnetic and porous susceptor material and catalytically active particles impregnated on the ferromagnetic and porous susceptor material, where said ferromagnetic and porous susceptor material has a porosity in the range from 10 to 50%, a surface area of about 5 m2/g to about 100 m2/g and a Curie temperature above 650°C, and where said susceptor material has a spinel type structure, an inverse spinel type structure or a perovskite type structure, said method comprising the steps of:
i. Generating an alternating magnetic field within the reactor unit upon energization by a power source supplying alternating current, said alternating magnetic field passing through the reactor unit, thereby heating catalyst material to a temperature within the given temperature range T by induction of a magnetic flux in the catalyst material; ii. bringing a reactant into contact with said catalyst material;
iii. heating of said reactant by the catalyst material; and
iv. letting the reactant react in order to provide a product to be outlet from the reactor.
17. A method according to claim 16, wherein the method furthermore comprises the step of pressurizing the reactor unit to a pressure of between 5 and 30 bar.
18. A method according to claim 16 or 17, wherein the temperature range T is the range from between about 400°C and about 950°C, preferably between about 700°C and about 950°C.
19. A process for manufacturing a susceptor material arranged for being part of a catalyst material, said susceptor material being a ferromagnetic and porous material having a porosity in the range from about 10 to about 50%, a surface area of about 5 m2/g to about 100 m2/g and a Curie temperature above 650°C, where said susceptor material has a spinel type structure, an inverse spinel type structure or a perovskite type structure, said process comprising the steps of:
- dissolving nitrate salts of a ferromagnetic element and a second, metallic element, and mixing with citric acid hydrate to form a gel precursor,
- optionally, adding a base in order to stabilize said gel precursor,
- performing a first calcination at a temperature of between 400°C and 500°C in order to obtain a first intermediate material,
- grinding said first intermediate material,
- performing a second calcination of the grinded first intermediate material at a temperature of between 850°C and 1 100°C in order to obtain a second intermediate material,
- grinding and tableting said second intermediate material in order to obtain a third intermediate material, and
- reducing said third intermediate material by means of a reducing agent, thereby ob- taining said susceptor material.
20. A process according to claim 19, wherein said susceptor material is an oxide comprising oxygen and a mixture between at least one ferromagnetic element and a second metallic element.
21 . A process according to claim 19 or 20, wherein said as least one ferromagnetic element is chosen from the list of: nickel, cobalt, iron and combinations thereof; and said second metallic element is chosen from the list of: aluminum, lanthanum, magnesium, chromium and combinations thereof.
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