Radiation-induced polymerization of ethylene in a pilot plant. II. Development of wet-wall process

Radiation-induced polymerization of ethylene using tert-butyl alcohol aqueous solution as a medium was carried out in a pilot plant with 10 liter reactor at pressures of 100 to 400 kg/cm², ethylene feed rates of 1.2 to 11.8 kg/hr, medium feed rates of 0 to 100 liter/hr, dose rates of 0.6 × 10⁵ to 1.4 × 10⁵ rad/hr, and at room temperature. The space-time yield and molecular weight of polymer were in the range of 1.2 to 16.7 g/liter hr and 6 × 10³ to 2 × 10⁵, respectively. The space-time yield and molecular weight increased with pressure and mean residence time. The space-time yield was the maximum at an ethylene molar fraction of 0.5. The produced polymer was continuously taken out from the high-pressure system as a slurry. The amount of deposited polymer to the reactor wall was markedly decreased, and five full days continuous operation was successfully performed with the space-time yield of 13.5 g/liter hr.     

Continuous Methanolysis of Palm Oil Using a Liquid–Liquid Film Reactor

A system for the continuous methanolysis of palm oil using a liquid–liquid film reactor (LLFR) was developed and characterized. This reactor is a co-current, constant diameter (0.01 m), custom-made packed column where the mass transfer area between the partially miscible methanol-rich and vegetable oil-rich phases is created in a non-dispersive way, without the intervention of mechanical stirrers or ultrasound devices. An increase in contact area between phases enhances reaction rate while the absence of small, dispersed droplets of one phase into the other diminishes the settling time at the end of the reaction. In this study variations on the concentration of catalyst (sodium hydroxide), flow rate of palm oil and normalized length of the reactor (L/L _max) were explored, keeping constant both the methanol to oil molar ratio and the temperature of the reaction (6:1 and 60 °C). The best experimental results with a reactor of 1.26 m (L/L _max = 1.0) showed a conversion of palm oil of 97.5% and a yield of methyl esters of 92.2% of the theoretical yield, when the mass flow rate and the residence time of the palm oil were 9.0 g min⁻¹ and 5.0 min, respectively. To determine the mean residence time and the degree of axial mixing in the reactor, a residence time distribution (RTD) study was performed using a step-function input. The dispersion model appears to fit well the RTD experimental data.     

Continuous‐Flow Asymmetric Hydrogenation of the β‐Keto Ester Methyl Propionylacetate in Ionic Liquid–Supercritical Carbon Dioxide Biphasic Systems

A continuous‐flow process for the asymmetric hydrogenation of methyl propionylacetate as a prototypical β‐keto ester in a biphasic system of ionic liquid and supercritical carbon dioxide (scCO₂) is presented. An established ruthenium/2,2′‐bis(diphenylphosphino)‐1,1′‐binaphthyl (BINAP) catalyst was immobilised in an imidazolium‐based ionic liquid while scCO₂ was used as mobile phase transporting reactants in and products out of the reactor. The use of acidic additives led to significantly higher reaction rates and enhanced catalyst stability albeit at slightly reduced enantioselectivity. High single pass conversions (>90%) and good enantioselectivity (80–82% ee) were achieved in the first 80 h. The initial catalyst activity was retained to 91% after 100 h and to 69% after 150 h time‐on‐stream, whereas the enantioselectivity remained practically constant during the entire process. A total turnover number of ∼21,000 and an averaged space‐time yield (STY_av) of 149 g L⁻¹ h⁻¹ were reached in a long‐term experiment. No ruthenium and phosphorus contaminants could be detected via inductively coupled plasma optical emission spectrometry (ICP‐OES) in the product stream and almost quantitative retention by the analysis of the stationary phase was confirmed. A comparison between batch‐wise and continuous‐flow operation on the basis of these data is provided.     

Machine learning-assisted multiscale modeling of an autothermal fixed-bed reactor for methanol to propylene process

The current commercial multistage reactor for methanol to propylene (MTP) process suffers from poor propylene selectivity and catalyst efficiency, mainly because of the low inlet methanol concentration and long residence time. In this work, we proposed an autothermal co-current flow reactor for MTP process, where the reaction heat is continuously removed through heat exchange with cold reactants, thus single-stage reactor can be used with higher methanol inlet concentration. The reactor feasibility was investigated by a three-dimensional multiscale model, in which the diffusion–reaction interaction inside catalyst particle was described by a neural network model trained by machine learning. With the feeding methanol fraction increasing to 30%, propylene selectivity reaches 82.27% while the space velocity approaches 2.68 g_MeOH g_cat⁻¹ h⁻¹ at 99.97% methanol conversion, about 1.4 and 3.8 times those of a commercial multibed reactor, respectively. With proper catalyst bed dilution, the reaction temperature is well controlled between 700 and 754 K.     

Performance of an internally circulating fluidized-bed reactor for the catalytic oxidative coupling of methane

The oxidative coupling of methane to C₂-hydrocarbons (OCM) over a La₂O₃/CaO catalyst (27 at.%) was investigated in an internally circulating fluidized-bed (ICFB) reactor (ID_eff = 1.9 cm, H_riser = 20.5 cm). The experiments were performed in the following range of conditions: T = 800?900°C, p_CH4:p_O2p_N2 = 57.1–64:16–22.9:20 kPa. The obtained C₂ selectivities and C₂ yields were compared with the corresponding data from a spouted-fluid-bed reactor (ID = 5 cm) and a bubbling fluidized-bed (FIB) reactor (ID = 5 cm). The maximum C₂ yield in the internally circulating fluidized-bed (ICFB) reactor amounted to 12.2% (T = 860°C, 38.7% C₂ selectivity, 31.5% methane conversion), whereas in the FIB reactor a maximum C₂ yield of 13.8% (T = 840°C, 40.4% C₂ selectivity, 34.2% methane conversion) was obtained. The lowest C₂ yield was achieved in the spouted-bed (SFB) reactor (Y = 11.6%, T = 840°C, 36.2% C₂ selectivity, 32.0% methane conversion). The highest space-time yield of 24.0 mol/kg_cat.h was obtained in the ICFB reactor, whereas in a FIB reactor only a space-time yield of 9.6 mol/kg_catcould be obtained. The performance of the ICFB reactor was strongly influenced by gas-phase reactions. Furthermore, stable reactor operation was possible only over a narrow range of gas velocities.     

Radiation-induced polymerization of ethylene in a pilot plant. I. Bulk process

Radiation-induced bulk polymerization of ethylene was carried out with use of a pilot plant with a 10 liter reactor at pressures of 225–400 kg/cm², temperatures of 30–95°C, ethylene feed rates of 5–28 kg/hr, and dose rate of 3.8 × 10⁵ rad/hr. Characteristics of the process are mild polymerization conditions and capability of producing medium density polyethylene in powder form. The spacetime yield and molecular weight of polymer were in the range of 3.5 to 13.1 g/liter hr and 2.2 × 10⁴ to 14 × 10⁴, respectively. The space-time yield increased with mean residence time and 2.4 powders of pressure, and decreased with temperature. Molecular weight changed similarly with the reaction conditions. These results were consistent with those of the bench plant experiment and the scale effect was small. Polymer deposit to the reactor wall limited a period of continuous operation of the plant. The amount of deposited polymer was increased with the square of reaction time. The rate of polymer deposit was proportional to polymer concentration and to the cube of pressure. The polymer deposit cannot be solved in the bulk process.     

Determination of agitation and aeration conditions for scale-up of cellulolytic enzymes production by <Emphasis Type="Italic">Trichoderma inhamatum</Emphasis> KSJ1

10 to 35 L jar fermentation scale-up cultures were performed to determine the optimum agitation and aeration rates in the cellulolytic enzymes production culture by Trichoderma inhamatum KSJ1. The optimum agitation rate in the 35 L jar fermenter was provisionally determined to be 150 rpm by using a geometrically resembled scale up method from the 10 L jar fermenter. The optimum aeration rate was determined to be 0.5 vvm by applying the mean values of superficial velocity and vvm. The DO (Dissolved Oxygen) concentration of the culture liquid was maintained below the critical DO concentration (2.336 mg/L) at 150 rpm in the 35 L jar fermenter. To increase the DO above the critical DO concentration, the agitation rate was increased from 150 to 200 rpm, with the aeration rate maintained at 0.5 vvm. As a result, the DO was maintained above critical DO concentration. The OUR (Oxygen Uptake Rate) and k _L a values were 0.91 mg-DO/L·min and 11.1 hr⁻¹, respectively. The amylase and FPase (filter paper activity) activities were 4.48 and 0.74 U/mL, respectively, in the 35 L jar fermenter, which was comparable to that in the 10 L fermenter (4.2 and 0.5 U/mL, respectively). Therefore, the scale-up conditions, 0.5 vvm and 200 rpm, were concluded to be the optimum aeration and agitation rates in the 35 L jar fermenter.     

Development of solid base catalyst X/Y/MgO/γ-Al2O3 for optimization of preparation of biodiesel from Jatropha curcas L.seed oil

The preparation and regeneration conditions of the identified catalyst X/Y/MgO/γ-Al₂O₃ with high catalytic activity were studied and optimized. The biodiesel was prepared by transesterification of Jatropha curcas seed oil produced in Guizhou with methanol at its reflux temoerature in the presence of X/Y/MgO/γ-Al₂O₃. The pilot plant tests were carried out in a 100 L reaction vessel. Both average yield and fatty acid methyl esters (FAME) content reached more than 96.50% under the optimum reaction conditions of the pilot plant tests designed withan oil/methanol molar ratio of 1: 10, catalyst concentration of 1.00%, and reaction time of 3 h at reflux temperature. In addition, analysis shows that the quality of biodiesel meets the standard EN 14214. __________ Translated from Modern Chemical Industry, 2007, 27(Suppl. 2): 452–455 [译自: 现代化工]     

A comparison between a conventional submerged culture fermenter and a new concept gas/solid fluid bed bioreactor for glutathione production

Glutathione is produced conventionally by submerged culture fermentation with yeast S. cerevisiae using L-cysteine, L-glutamate, and glycine as precursors. To obtain high glutathione concentrations, as well as high reaction rates, optimum temperature and high precursor concentrations have to be applied. Therefore, due to dilution in submerged culture, large quantities of precursor are needed. On the other hand, in solid state fermentation, increased precursor concentration is reached by the reduction of the water holdup in the fermenter. Experiments were performed to compare submerged culture fermentation in a stirred tank reactor with solid state fermentation in a gas/solid fluid bed bioreactor. In a 1.5 L stirred tank reactor the influence of temperature, substrate composition, and precursor concentration on reaction rate and maximum glutathione accumulation in the yeast cells was evaluated. A laboratory scale fluid bed fermenter of 0.15 m diameter and a pilot scale fermenter of 1.0 m diameter with 42 kg of yeast load were used to evaluate the optimum feed strategy to optimize glutathione yield with respect to precursor feed and glutathione accumulation in the yeast cells. In submerged culture, the maximum glutathione yield with respect to the precursor cysteine at maximum glutathione accumulation ranged from 4 to 8 mole %, whereas, with the gas/solid fermentation, yields of up to 40 mole % were obtained.     

Olefin production by cofeeding methanol and n‐butane: Kinetic modeling considering the deactivation of HZSM‐5 zeolite

The joint transformation of methanol and n‐butane fed into a fixed‐bed reactor on a HZSM‐5 zeolite catalyst has been studied under energy neutral conditions (methanol/n‐butane molar ratio of 3/1). The kinetic scheme of lumps proposed integrates the reaction steps corresponding to the individual reactions (cracking of n‐butane and MTO process at high‐temperature) and takes into account the synergies between the steps of both reactions. The deactivation by coke deposition has been quantified by an expression dependent on the concentration of the components in the reaction medium, which is evidence that oxygenates are the main coke precursors. The concentration of the components in the reaction medium (methanol, dimethyl ether, n‐butane, C₂? C₄ paraffins, C₂? C₄ olefins, C₅? C₁₀ lump, and methane) is satisfactorily calculated in a wide range of conditions (between 400 and 550°C, up to 9.5 (g of catalyst) h (mol CH₂)^?1 and with a time on stream of 5 h) by combining the equation of deactivation with the kinetic model of the main integrated process. © 2010 American Institute of Chemical Engineers AIChE J, 2011     

Optimization of fermentation medium composition in substrate-controlled continuous stirred tank reactors

A ‘carbon source controlled shift technique’ was developed for fermentation medium optimization in continuous culture with the objective to maximize growth rate and growth-linked product formation of a biological system. An automatic culture medium preparation system was operated together with 2 parallel stirred tank reactors and a HPLC system for on-line analysis of the carbon source concentration in the reactors. A genetic algorithm was applied for experimental design. The concentrations of 7 medium components (mineral salts and vitamins) were optimized automatically within 40 continuous experiments to result in a maximum growth rate of the methylotrophic yeast Candida boidinii and growth-linked production of the formate dehydrogenase enzyme (FDH). The specific growth rate of Candida boidinii and the specific activity of the FDH enzyme at a set-point of 420 mM methanol in the reactor were, thus, improved by 19% to 0.16 h^?1 and 26% to 164 U g^?1, respectively, compared to the previously used medium, which has already been previously optimized in shake flask experiments. The results of the continuous medium optimization were evaluated with a full second order seven-dimensional polynomial model (regression coefficient 96.8%).     

Radiation-induced polymerization of ethylene in pilot plant. IV. Kinetic analysis

The kinetics of the radiation-induced polymerization of ethylene in a flow system using tert-butyl alcohol aqueous solution as a medium were studied. The polymerization was carried out in a large-scale pilot plant with a 50-liter central source-type reactor at various mean residence times and does rates under constant pressure of 300 kg/cm², temperature of 30°C, and ethylene molar fraction of ca. 0.4. The reaction mixture in the reactor was back-mixed flow from the residual polymer concentration in the reactor. The results of the polymerization were analyzed by kinetic treatment based on a reaction mechanism with both first-and second-order terminations for the propagating radical. The apparent rate constants, except for that of second-order termination (k_t2), were consistent with those determined by small-scale batch experiments. The k_t2 is 20 to 40 times larger than that in the batch experiments. The k_t2 increases with decrease in mean residence time and with agitation, probably because of mobility of the propagating radical.     

Improved methanol yield from methane oxidation in a non-isothermal reactor

Partial oxidation of methane to methanol was carried out homogeneously in a non-isothermal reactor that contained a non-permselective membrane. A tubular reactor was used with a smaller-diameter tubular membrane of 5 nm pore diameter alumina or 0.5 μm pore diameter metal. The membrane provided a uniform flow distribution and separated the hot reactor wall from a cooling tube located in the centre of the reactor. The cold region in the reactor rapidly quenched further reaction. The selectivity for CH₃OH formation at 4.6% conversion increased from 34 to 52% when quenching was used. The highest yield (selectivity times conversion) obtained was 3.8% at 55 MPa and 800 K. Methanol selectivity increased with increasing pressure and decreased with increasing temperature, residence time and O₂ concentration. The combined selectivity to partial oxidation products (CO, CH₃OH, CH₂O) was almost constant at 86%.     

Selective Oxidation of Methanol to Formaldehyde Using Modified Iron-Molybdate Catalysts

Methanol selective oxidation to formaldehyde over a modified Fe-Mo catalyst with two different stoichiometric (Mo/Fe atomic ratio = 1.5 and 3.0) was studied experimentally in a fixed bed reactor over a wide range of reaction conditions. The physicochemical characterization of the prepared catalysts provides evidence that Fe₂(MoO₄)₃ is in fact the active phase of the catalyst. The experimental results of conversion of methanol and selectivity towards formaldehyde for various residence times were studied. The results showed that as the residence time increases the yield of formaldehyde decreases. Selectivity of formaldehyde decreases with increase in residence time. This result is attributable to subsequent oxidation of formaldehyde to carbon monoxide due to longer residence time.     

Comparison of lipase production by Geotrichum candidum in stirring and airlift fermenters

The production of lipase by Geotrichum candidum in both, stirred tank and airlift bioreactors were compared. G candidum an imperfect filamentous fungus, grows well in liquid medium, and produces a lipase with specific affinity for long‐chain fatty acids with cis‐9 double bonds but, lipase production is generally not efficient because the optimum medium composition and fermentation conditions are not known. Response surface methodology was used to optimize the agitation speed (100–500 rpm) and aeration (0.2–1.8 vvm) for production of lipase by G candidum in a bench‐scale stirred fermenter. A Central Composite Rotatable Design (CCRD) was used to optimize lipase activity and productivity. Lipase production in an airlift fermenter was also studied with aeration ranging from 1 to 3 vvm. A previously optimized culture medium containing 3.58% of peptone, 0.64% of soy oil and an initial pH of 7.0, was used in the experiments, incubating at 30°C. In the stirred reactor the optimum conditions of agitation and aeration for lipase production and productivity were 300 rpm and 1 vvm, leading to an activity of 20 U cm^?3 in 54 h of fermentation and 0.3900 (U cm^?3 h^?1) of productivity. The best aeration condition in the airlift fermenter was 2.5 vvm, which yielded similar lipase activity after 30 h of fermentation, resulting in a productivity of 0.6423 (U cm^?3 h^?1). In the absence of mechanical agitation similar lipase yields were achieved but in less time, resulting in productivity, about 60% greater than in a stirred fermenter; the lower energy demand for the same lipase yield offers economic advantages. Copyright © 2004 Society of Chemical Industry     

Simulation of CO2 hydrogenation with CH3OH removal in a zeolite membrane reactor

A thermodynamic analysis of the CO₂ hydrogenation to methanol where competitive reactions take place is presented for a membrane reactor (MR) where methanol was selectively removed. A non-isothermal mathematical model was written to simulate a micro-porous MR. Zeolite membranes with different values of the CH₃OH and H₂O permeances were considered in the MR modelling. The effect of temperature, pressure and species permeation on the conversion, selectivity and yield was analysed. A higher CO₂ conversion and CH₃OH selectivity can be reached by the use of an MR. An increased CH₃OH yield allows to reduce the consumption of reactant and also to operate at lower pressures and higher temperatures, a fact, which favours the kinetics reducing the residence time and the reactor volume. The MR with the highest CH₃OH/H₂O permeance ratio resulted in better selectivity and yield of CH₃OH with respect to the other MR characterised by a higher conversion.     

Performance evaluation of batch and unsteady state fed‐batch reactor operations for the production of a marine microbial surfactant

BACKGROUND: Biosurfactants are microbially derived surface‐active and amphipathic molecules produced by various microorganisms. These versatile biomolecules can find potential applications in food, cosmetics, petroleum recovery and biopharmaceutical industries. However, their commercial use is impeded by low yields and productivities in fermentation processes. Thus, an attempt was made to enhance product yield and process productivity by designing a fed‐batch mode reactor strategy. RESULTS: Biosurfactant (BS) production by a marine bacterium was performed in batch and fed‐batch modes of reactor operation in a 3.7 L fermenter. BS concentration of 4.61 ± 0.07 g L^?1 was achieved in batch mode after 22 h with minimum power input of 33.87 × 10³ W, resulting in maximum mixing efficiency. The volumetric oxygen flow rate (K_La) of the marine culture was about 0.08 s^?1. BS production was growth‐associated, as evident from fitting growth kinetics data into the Luedeking‐Piret model. An unsteady state fed batch (USFB) strategy was employed to enhance BS production. Glucose feeding was done at different flow rates ranging from 3.7 mL min^?1 (USFB‐I) to 10 mL min^?1 (USFB‐II). USFB‐I strategy resulted in a maximum biosurfactant yield of 6.2 g l^?1 with an increment of 35% of batch data. The kinetic parameters of USFB‐I were better than those from batch and USFB‐II. CONCLUSION: Comparative performance evaluation of batch and semi‐continuous reactor operations was accomplished. USFB‐I operation improved biosurfactant production by about 35% over batch mode. USFB‐I strategy was more kinetically favorable than batch and USFB‐II. © 2012 Society of Chemical Industry     

Catalytic depolymerisation and conversion of Kraft lignin into liquid products using near-critical water

A high-pressure pilot plant was developed to study the conversion of LignoBoost Kraft lignin into bio-oil and chemicals in near-critical water (350 °C, 25 MPa). The conversion takes place in a continuous fixed-bed catalytic reactor (500 cm³) filled with ZrO₂ pellets. Lignin (mass fraction of approximately 5.5%) is dispersed in an aqueous solution containing K₂CO₃ (from 0.4% to 2.2%) and phenol (approximately 4.1%). The feed flow rate is 1 kg/h (reactor residence time 11 min) and the reaction mixture is recirculated internally at a rate of approximately 10 kg/h. The products consist of an aqueous phase, containing phenolic chemicals, and a bio-oil, showing an increased heat value (32 MJ/kg) with respect to the lignin feed. The 1-ring aromatic compounds produced in the process are mainly anisoles, alkylphenols, guaiacols and catechols: their overall yield increases from 17% to 27% (dry lignin basis) as K₂CO₃ is increased.     

Liquid phase methanol and dimethyl ether synthesis from syngas

The Liquid Phase Methanol Synthesis (LPMeOH^TM) process has been investigated in our laboratories since 1982The reaction chemistry of liquid phase methanol synthesis over commercial Cu/ZnO/Al₂O₃ catalysts, established for diverse feed gas conditions including H₂-rich, CO-rich, CO₂-rich, and CO-free environments, is predominantly based on the CO₂ hydrogenation reaction and the forward water-gas shift reactionImportant aspects of the liquid phase methanol synthesis investigated in this in-depth study include global kinetic rate expressions, external mass transfer mechanisms and rates, correlation for the overall gas-to-liquid mass transfer rate coefficient, computation of the multicomponent phase equilibrium and prediction of the ultimate and isolated chemical equilibrium compositions, thermal stability analysis of the liquid phase methanol synthesis reactor, investigation of pore diffusion in the methanol catalyst, and elucidation of catalyst deactivation/regenerationThese studies were conducted in a mechanically agitated slurry reactor as well as in a liquid entrained reactorA novel liquid phase process for co-production of dimethyl ether (DME) and methanol has also been developedThe process is based on dual-catalytic synthesis in a single reactor stage, where the methanol synthesis and water gas shift reactions takes place over Cu/ZnO/Al₂O₃ catalysts and the in-situ methanol dehydration reaction takes place over -Al₂O₃ catalystCo-production of DME and methanol can increase the single-stage reactor productivity by as much as 80%. By varying the mass ratios of methanol synthesis catalyst to methanol dehydration catalyst, it is possible to co-produce DME and methanol in any fixed proportion, from 5% DME to 95% DMEAlso, dual catalysts exhibit higher activity, and more importantly these activities are sustained for a longer catalyst on-stream life by alleviating catalyst deactivation.     

Biodiesel production from waste cooking palm oil using calcium oxide supported on activated carbon as catalyst in a fixed bed reactor

A reactor has been developed to produce high quality fatty acid methyl esters (FAME) from waste cooking palm oil (WCO). Continuous transesterification of free fatty acids (FFA) from acidified oil with methanol was carried out using a calcium oxide supported on activated carbon (CaO/AC) as a heterogeneous solid-base catalyst. CaO/AC was prepared according to the conventional incipient-wetness impregnation of aqueous solutions of calcium nitrate (Ca(NO₃)₂·4H₂O) precursors on an activated carbon support from palm shell in a fixed bed reactor with an external diameter of 60 mm and a height of 345 mm. Methanol/oil molar ratio, feed flow rate, catalyst bed height and reaction temperature were evaluated to obtain optimum reaction conditions. The results showed that the FFA conversion increased with increases in alcohol/oil molar ratio, catalyst bed height and temperature, whereas decreased with flow rate and initial water content in feedstock increase. The yield of FAME achieved 94% at the reaction temperature 60 °C, methanol/oil molar ratio of 25: 1 and residence time of 8 h. The physical and chemical properties of the produced methyl ester were determined and compared with the standard specifications. The characteristics of the product under the optimum condition were within the ASTM standard. High quality waste cooking palm oil methyl ester was produced by combination of heterogeneous alkali transesterification and separation processes in a fixed bed reactor. In sum, activated carbon shows potential for transesterification of FFA.