Fabrication of Micro-Reactors Using Tape-Casting Methods

We have developed a simple, rapid, and inexpensive method for the fabrication of micro-channel reactors using tape-casting methods. Rectangular channels, with self-contained heaters, were fabricated with cross-sectional dimensions of 500 μm×800 μm and 1000 μm×800 μm. The conduits were loaded with Pd and Pd/alumina catalysts using a syringe. To demonstrate the capabilities of this methodology, n-butane oxidation rates were measured between 300 and 700 K. Because free-radical reactions are suppressed by the small channel size, it was possible to measure catalytic rates within the flammability limits. Based on the results, it appears that micro-reactors formed using tape-casting methods may be useful for initial catalyst screening.