Simulation and Analysis of a Tubular Fixed‐Bed Fischer‐Tropsch Synthesis Reactor with Co‐Based Catalyst

A two‐dimensional pseudohomogeneous reactor model is proposed to simulate the performance of fixed‐bed Fischer‐Tropsch synthesis (FTS) reactors by lumped thought. A CO consumption kinetics equation and a carbon chain growth probability model were incorporated into the reactor model. The model equations discretized by a two‐dimensional orthogonal collocation method were solved by the Broyden method. Concentration and temperature profiles were obtained. The validity of the reactor model against the pilot plant test data was investigated. Satisfactory agreements between model prediction values and experiment results were obtained. Further simulations were carried out to investigate the effect of operating conditions on the reaction behavior of the fixed‐bed FTS reactor.     

Synthesis of butyl acrylate in a fixed‐bed adsorptive reactor over Amberlyst 15

The butyl acrylate synthesis from the esterification reaction of acrylic acid with 1‐butanol in a fixed‐bed adsorptive reactor packed with Amberlyst 15 ion exchange resin was evaluated. Adsorption experiments were carried out with nonreactive pairs at two temperatures (323 and 363 K). The experimental results were used to obtain multicomponent adsorption equilibrium isotherms of Langmuir type. Reactive adsorption experiments using different feed molar ratios and flow rates were performed, at 363 K, and used to validate a mathematical model developed to describe the dynamic behavior of the fixed‐bed adsorptive reactor for the butyl acrylate synthesis. Due to the simultaneous reaction and separation steps, it was possible to obtain a butyl acrylate maximum concentration 38% higher than the equilibrium concentration (for an equimolar reactants ratio solution as feed at a flow rate of 0.9 mL min^?1 and 363 K) showing that sorption‐enhanced reaction technologies are very promising for butyl acrylate synthesis. © 2014 American Institute of Chemical Engineers AIChE J, 61: 1263–1274, 2015     

Continuous‐Flow Di‐N‐Alkylation of 1H‐Benzimidazole in a Fixed‐Bed Reactor

A new process for a continuous‐flow di‐N‐alkylation of 1H‐benzimidazole to 1H‐benzimidazole‐3‐ium iodide by methylene iodide in the presence of potassium carbonate in a fixed‐bed reactor is presented. The synthesis was transferred from batch to continuous operation with similar yields and conversion rates. Moreover, the influence of temperature and residence time in the continuous flow setup was characterized; optimized conditions led to a doubling of yield. In addition, the continuous flow allowed for a better control of the two‐step reaction by adding an additional tube reactor after the fixed bed that further enhanced the overall performance. With this, the continuous‐flow system presented itself as superior due to higher available temperatures and a better controllability.     

Production of optically pure L‐valine in fluidized and packed bed reactors with immobilized L‐aminoacylase

A process to obtain L ‐valine has been developed using fluidized and packed bed reactors with L ‐aminoacylase (from hog kidney) immobilized by covalent binding. L ‐Valine production using the immobilized derivative of L ‐aminoacylase in fluidized and packed bed reactors was studied at three different substrate concentrations and two different flow rates. Higher productions were obtained in the packed bed reactor in all cases. The different solubilities of L ‐valine and acetyl‐D ‐valine in ethanol were used to purify L ‐amino acid from the reactor effluents. The amount of added ethanol did not influence the separation yields, although the purity of L ‐valine was strongly affected by this parameter. The last step involved was racemization of the unhydrolyzed acetyl‐D ‐valine, which was then used as substrate in a new reaction cycle. © 1999 Society of Chemical Industry     

CO2 methanation: Optimal start‐up control of a fixed‐bed reactor for power‐to‐gas applications

Utilizing volatile renewable energy sources (e.g., solar, wind) for chemical production systems requires a deeper understanding of their dynamic operation modes. Taking the example of a methanation reactor in the context of power‐to‐gas applications, a dynamic optimization approach is used to identify control trajectories for a time optimal reactor start‐up avoiding distinct hot spot formation. For the optimization, we develop a dynamic, two‐dimensional model of a fixed‐bed tube reactor for carbon dioxide methanation which is based on the reaction scheme of the underlying exothermic Sabatier reaction mechanism. While controlling dynamic hot spot formation inside the catalyst bed, we prove the applicability of our methodology and investigate the feasibility of dynamic carbon dioxide methanation. © 2016 American Institute of Chemical Engineers AIChE J, 63: 23–31, 2017     

吸附反应器的动态特性—非瞬时竞争吸附的影响

针对可逆催化反应Ａ－Ｂ＋Ｃ、各组分非瞬时Ｌａｎｇｍｕｉｒ吸附的情况，研究了固定床吸附反应器的动态特性，着重分析多组分非时竞争吸附的影响。对反应物阶跃输入时，吸附反应器的出口浓度响应进行了模拟分析，模拟结果预示，在一定的参数条件下，动态操作的吸附反应器有较高的反应转化率、高的产物和反应物分离度、而且产物Ｂ和Ｃ之间也能同时得到高度分离。另外，给出了Ｂ和Ｃ分离的条件及定性评价其分离程度的判据。     

Modeling of Multi‐Tubular Reactors for Fischer‐Tropsch Synthesis

The results of the simulation of multi‐tubular Fischer‐Tropsch reactors based on a two‐dimensional pseudo‐homogeneous model are presented. The model takes into account the intrinsic kinetics of two commercial iron and cobalt catalysts, intraparticle mass transfer limitations, and the radial heat transfer within the fixed bed and to the cooling medium (boiling water). The effective rate with Co is slightly higher than with Fe. Hence, a temperature level can be used for Co that is 20 °C lower compared to Fe. The conversion and product selectivies are then almost the same and the reactor can be operated safely without a temperature runaway. The results of the simulations are consistent with literature data and show that there is still room for improvement of fixed bed FT reactors, e.g., by an enhanced heat transfer.     

Fischer‐Tropsch Synthesis: Modeling and Performance Study for Fe‐HZSM5 Bifunctional Catalyst

A water‐cooled fixed bed Fischer‐Tropsch reactor packed with Fe‐HZSM5 catalyst has been modeled in two dimensions (radial and axial) using the intrinsic reaction rates previously developed at RIPI. The reactor is used for production of high‐octane gasoline from synthesis gas. The Fischer‐Tropsch synthesis reactor was a shell and tube type with high pressure boiling water circulating on the shell side. By the use of a two‐dimensional model, the effects of some important operating parameters such as cooling temperature, H₂/CO ratio in syngas and reactor tube diameter on the performance capability of the reactor were investigated. Based on these results, the optimum operating conditions and the tube specification were determined. The model has been used to estimate the optimum operating conditions for the pilot plant to be operated in RIPI.     

Acetaldehyde dimethylacetal synthesis with Smopex 101 fibres as catalyst/adsorbent

The synthesis of dimethylacetal using acetaldehyde and methanol as raw material in the presence of Smopex 101 fibres as catalyst and adsorbent in batch reactor and in a fixed bed adsorptive reactor, respectively, was studied. In the batch reactor the determination of thermodynamic and reaction kinetics data for acetalization reaction was presented. A kinetic model based on a pseudo-homogeneous rate expression using activities was proposed to describe the experimental kinetic results. The dynamic binary adsorption experiments were carried out in the absence of reaction at 293.15 K in a laboratory scale column. The experimental results of the adsorption of binary non-reactive mixtures are reported and used to obtain multi-component adsorption equilibrium isotherms of Langmuir type. The mathematical model was proposed to describe the adsorptive reactor dynamic behaviour. The experimental results obtained for the reaction and regeneration experiments were compared with the model proposed. Model equations were solved by orthogonal collocation on finite elements (OCFE) implemented by the PDECOL package, using the measured model parameters and was validated for both reaction and regeneration steps.     

Three‐stage well‐mixed reactor model for a pressurized coal gasifier

Three Canadian coals of different rank were gasified with air‐steam mixtures in a 0.1 m diameter spouted bed reactor at pressures to 292 kPa, average bed temperatures varying between 840 and 960°C, and steam‐to‐coal feed ratios between 0.0 and 2.88. In order to analyze gasifier performance and correlate data, a three‐stage model has been developed incorporating instantaneous devolatilization of coal, instantaneous combustion of carbon at the bottom of the bed, and steam/carbon gasification and water gas shift reaction in a single well mixed isothermal stage. The capture of H₂S by limestone sorbent injection is also treated. The effects of various assumptions and model parameters on the predictions were investigated. The present model indicates that gasifier performance is mainly controlled by the fast coal devolatilization and char combustion reactions, and the contribution to carbon conversion of the slow char gasification reactions is comparatively small. The incorporation of tar decomposition into the model provides significantly closer predictions of experimental gas composition than is obtained otherwise.     

Corrosion‐Resistant Parallel Fixed‐Bed Reactors for High‐Throughput Screening of New Deacon Reaction Catalysts

Two ten‐channel fixed‐bed reactor systems were developed for high‐throughput screening of new Deacon catalysts. The sequential ten‐channel reactor allows the determination of the activity of up to ten catalysts per day. With a ten‐channel ageing reactor the long‐time stability of catalytic activity can be tested in parallel. Both systems are robust, quite resistant against corrosion, and use the identical reaction tubes which enable the direct transfer of a catalyst from one to the other system. A mass‐spectrometric pulse method has been developed and applied successfully for the analysis of the corrosive product gas mixture of the Deacon reaction.     

Transient Effects during Dynamic Operation of a Wall‐Cooled Fixed‐Bed Reactor for CO2 Methanation

The power‐to‐gas process is an option to transform fluctuating renewable electric energy into methane via water electrolysis and subsequent conversion of H₂ by methanation with CO₂. The dynamic behavior of the methanation reactor may then be a critical aspect. The kinetics of CO₂ methanation on a Ni‐catalyst were determined under isothermal and stationary conditions. Transient isothermal kinetic experiments showed a fast response of the rate on step changes of the concentrations of H₂, CO₂; in case of H₂O, the response was delayed. Non‐isothermal experiments were conducted in a wall‐cooled fixed‐bed reactor. Temperature profiles were measured and the effect of a changing volumetric flow was studied. The experimental data were compared with simulations by a transient reactor model.     

Experimental and Theoretical Studies on Hydrogenation in Multiphase Fixed‐Bed Reactors

Multiphase fixed‐bed reactors have complex hydrodynamic and mass transfer characteristics. The modeling and scale‐up are therefore difficult. The present work focuses on the role of mass transfer on the effective reaction rate. The catalytic 1‐octene hydrogenation was taken as a model reaction. The reaction rate in the trickle‐bed reactor is by a factor of 20 smaller than (theoretically) in the absence of any mass transfer limitations. For high octene concentrations (> 10 %), the effective reaction rate is limited by the H₂ consumption, above all by the gas/liquid and liquid/solid mass transfer. For lower octene concentrations the reaction is zero order with respect to H₂ and only depends on the octene consumption, i.e., on the interplay of chemical reaction, L/S and intraparticle mass transfer of octene.     

A two‐phase model for variable‐density fluidized bed reactors with generalized nonlinear kinetics

A model based on the classical two‐phase concept is developed for the simulation of variable‐density reaction with generalized nonlinear kinetics in a bubbling fluidized bed. The influence of reaction density parameter on the fluidodynamics and performance of the reactor for four general types of reactions was explored. The results show that the expansion factor has a significant effect on both fluidodynamic characteristics and reaction conversion. In all types of reactions, higher values of hydro‐dynamic variables were obtained when ? ≥ 0. Reaction conversion, however, dropped as the expansion factor increased. This trend was more pronounced for reaction orders higher than unity. This suggests that bubbling fluidized operations are probably not optimal and applicable for certain types of reactions. Comparative analysis between reaction type and implications for optimum fluidized bed reactor are discussed.     

Thermal‐Enzymatic Hydrolysis of Wheat Straw in a Single High Pressure Fixed Bed

An integrated flow‐through fixed‐bed reactor concept for lignocellulose separation at 3 L scale is presented. Wheat straw is degraded using sequential liquid hot water treatment and enzymatic hydrolysis in a single‐pot reactor setup. System responses on process parameters are modeled and optimized using response surface methodology. Accurate empiric models and significant factor influences could be identified for both treatment steps. With optimal factor settings, 23.9 and 49.2 wt % hot‐water‐soluble lignin and C5 oligomers could be recovered, respectively. 70.0 wt % cellulose solubilization could be achieved in the fixed‐bed enzymatic hydrolysis after 72 hours.     

Liquid‐Solid Mass Transfer Behavior of a Stirred‐Tank Reactor with a Fixed Bed at Its Bottom

The mass transfer behavior of a new batch stirred tank with a fixed bed of Raschig rings at the bottom was studied using diffusion‐controlled dissolution of copper in acidified dichromate. Variables studied, amongst others, were the impeller rotation speed, Raschig ring diameter, fixed‐bed height, and impeller geometry. The rate of mass transfer from the fixed bed to the solution increased with increasing impeller rotation speed, decreasing particle size, and decreasing bed height. The axial‐flow turbine is more efficient in increasing the rate of mass transfer than the radial‐flow turbine. The presented reactor is especially useful for conducting diffusion‐controlled liquid‐solid catalytic reactions involving reactants that need to be dispersed first, such as sparingly soluble solid particles.     

Catalytic Steam Reforming of Fast Pyrolysis Bio‐Oil in Fixed Bed and Fluidized Bed Reactors

Catalytic steam reforming of bio‐oil is an economically‐feasible route which produces renewable hydrogen. The Ni/MgO‐La₂O₃‐Al₂O₃ catalyst was prepared with Ni as active agent, Al₂O₃ as support, and MgO and La₂O₃ as promoters. The experiments were conducted in fixed bed and fluidized bed reactors, respectively. Temperature, steam‐to‐carbon mole ratio (S/C), and liquid hourly space velocity (LHSV) were investigated with hydrogen yield as index. For the fluidized bed reactor, maximum hydrogen yield was obtained under temperatures 700–800 °C, S/C 15–20, LHSV 0.5–1.0 h^–1, and the maximum H₂ yield was 75.88 %. The carbon deposition content obtained from the fluidized bed was lower than that from the fixed bed. The maximum H₂ yield obtained in the fluidized bed was 7 % higher than that of the fixed bed. The carbon deposition contents obtained from the fluidized bed was lower than that of the fixed bed at the same reaction temperature.     

SOME ASPECTS OF THEORETICAL COMPARISON OF FISCHER-TROPSCH REACTORS

The reactor systems used for the Fischer-Tropsch synthesis, fixed bed, fluidized bed and slurry bed, are compared on the basis of space time yield (STY) and level of conversion obtainable under the same set of feed and operating conditions. The slurry bed and fluidized bed reactor were compared on the basis of a first order reaction model. The performance of these two reactors was found to be comparable at low values of WHSV, but at higher values of WHSV, the fluidized bed reactor gave higher conversions and STY. A power law kinetic expression was used to compare the performance of the slurry bed and fixed bed reactors. Higher conversions and STY were obtained from the fixed bed with varying WHSV. This may be due to the omission of the intra and inter phase mass transfer resistances in the modelling of the fixed bed reactor.     

High‐Pressure High‐Temperature Transparent Fixed‐Bed Reactor for Operando Gas‐Liquid Reaction Follow‐up

A 3‐MPa, 350 °C fixed‐bed reactor was designed to follow‐up gas‐liquid‐solid reactions on a millimetric size heterogeneous catalyst with Raman spectroscopy. The transparent reactor is a quartz cylinder enclosed in a Joule effect heated stainless‐steel tube. A methodology to determine how to focus the microscope for liquid and solid phase characterization is presented. The setup was validated by performing diesel hydrodesulfurization on a CoMo/alumina extrudate catalyst with a conversion very close to expected values along with the acquisition of Raman spectra of the solid catalyst showing an evolution of the catalyst phase during sulfidation.