Investigation of Fischer-Tropsch synthesis performance and its intrinsic reaction behavior in a bench scale slurry bubble column reactor

A bench scale slurry bubble column reactor (SBCR) with active-Fe based catalyst was developed for the Fischer-Tropsch synthesis (FTS) reaction. Considering the highly exothermic reaction heat generated in the bench scale SBCR, an effective cooling system was devised consisting of a U-type dip tube submerged in the reactor. Also, the physical and chemical properties of the catalyst were controlled so as to achieve high activity for the CO conversion and liquid oil (C₅₊) production. Firstly, the FTS performance of the FeCuK/SiO₂ catalyst in the SBCR under reaction conditions of 265 °C, 2.5 MPa, and H₂/CO = 1 was investigated. The CO conversion and liquid oil (C₅₊) productivity in the reaction were 88.6% and 0.226 g/g_cat-h, respectively, corresponding to a liquid oil (C₅₊) production rate of 0.03 bbl/day. To investigate the FTS reaction behavior in the bench scale SBCR, the effects of the space velocity and superficial velocity of the synthesis gas and reaction temperature were also studied. The liquid oil production rate increased up to 0.057 bbl/day with increasing space velocity from 2.61 to 3.92 SL/h-g_Fe and it was confirmed that the SBCR bench system developed in this research precisely simulated the FTS reaction behavior reported in the small scale slurry reactor.     

Modeling and optimization of industrial Fischer–Tropsch synthesis with the slurry bubble column reactor and iron-based catalyst

To optimize industrial Fischer–Tropsch(FT) synthesis with the slurry bubble column reactor(SBCR) and ironbased catalyst, a comprehensive process model for FT synthesis that includes a detailed SBCR model, gas liquid separation model, simplified CO_2 removal model and tail gas cycle model was developed. An effective iteration algorithm was proposed to solve this process model, and the model was validated by industrial demonstration experiments data(SBCR with 5.8 m diameter and 30 m height), with a maximum relative error b 10% for predicting the SBCR performances. Subsequently, the proposed model was adopted to optimize the industrial SBCR performances simultaneously considering process and reactor parameters variations. The results show that C_(5+) yield increases as catalyst loading increases within 10–70 ton and syngas H_2/CO value decreases within1.3–1.6, but it doesn't increase obviously when the catalyst loading exceeds 45 ton(about 15 wt% concentration).Higher catalyst loading will result in higher difficulty for wax/catalyst separation and higher catalyst cost. Therefore, the catalyst loading(45 ton) is recommended for the industrial demonstration SBCR operation at syngas H_2/CO = 1.3, and the C_(5+) yield is about 402 ton" per day, which has an about 16% increase than the industrial demonstration run result.     

Performance of a slurry bubble column reactor for Fischer-Tropsch synthesis: Determination of optimum condition

The CO conversion and selectivity to C₁+ and C₁₁+ wax products over Co/Al₂O₃ as well as Ru/Co/Al₂O₃ Fischer-Tropsch (F-T)catalysts were investigated by varying reaction temperature (210-250 °C), system pressure (1.0-3.0 MPa), GHSV (1000-6000 L/kg/h), superficial gas velocity (1.7-13.6 cm/s) and slurry concentration (9.09-26.67 wt.%) in a slurry bubble column reactor (0.05 m diameter × 1.5 m height) to determine the optimum operating conditions. Squalane or paraffin wax was used as initial liquid media. The overall CO conversion increased with increasing reaction temperature, system pressure and catalyst concentration. However, the local maximum CO conversion was exhibited at GHSV of 1500-2000 L/kg/h and superficial gas velocity of 3.4-5.0 cm/s. The CO conversion in the case of Ru/Co/Al₂O₃ was much higher and stable than that in the case of Co/Al₂O₃. The selectivity to C₁₁+ wax products increased slightly with increasing GHSV; on the other hand, it decreased with increasing reaction temperature, system pressure, and solid concentration in a slurry bubble column reactor. It could be concluded that the optimum operating conditions based on the yield of hydrocarbons and wax products were; U_G = 6.8-10 cm/s, Cs = 15 wt.%, T = 220-230 °C, P = 2.0 MPa in a slurry bubble column reactor for F-T synthesis.     

Low Temperature Liquid State Synthesis of Lithium Zirconate and its Characteristics as a CO2 Sorbent

Abstract

In this study, a new preparation method providing greatly improved CO₂ sorption is introduced. Li₂ZrO₃ sorbent was prepared by low temperature co‐precipitation and compared in CO₂ sorption performance with a sorbent prepared by the conventional high temperature solid‐state reaction method. The two sorbents were characterized using scanning electron microscopy, X‐ray diffraction and thermo‐gravimetric analysis. The Li₂ZrO₃ powder prepared by the relatively simple co‐precipitation method showed significantly better performance than the one prepared by solid‐state reaction with respect to both kinetics and CO₂ sorption capacity. Extensive study of the powder prepared by co‐precipitation has been performed at various conditions.     

Investigation of low-temperature methanol synthesis in a bubble column slurry reactor with a flash column

Reaction performance of a CuCr/CH₃ONa catalyst for the low-temperature methanol synthesis was examined in a bubble column slurry reactor with a flash column (BCSR/FC). The BCSR/FC was operated at 4.5 ± 0.2 MPa/110–120 °C for BCSR and 0.4 ± 0.1 MPa/80–90 °C for FC, although fluctuation of operation parameters was larger. Syngas conversion decreased from 71.0% to 19.8% during the operation test in 100 h, which was attributed to consumption of CH₃ONa and a negative effect of the emulsifier OP-10 used.     

CO2 Capture/Separation Control by SiO2 Nanoparticles and Surfactants

In this study, the performance enhancement of CO₂ capture and separation by the SiO₂ nanoparticles and surfactants is evaluated. The main objectives are to test the dispersion stability of nanofluids (DI water with nanoparticles and surfactants), to quantify the effect of the nanoparticles and surfactants on the CO₂ capture and separation performance, and to find the optimum conditions of the nanoparticles and surfactants. It is found that the CO₂ capture and separation performances are enhanced up to 13.1% and 7.8% at the nanoparticle concentration of 0.01 vol%, respectively. It is concluded that nanoparticles enhance both CO₂ capture and separation rates, while the surfactants enhance the CO₂ capture rate but they interrupt the CO₂ separation rate.     

Behaviors and kinetic models analysis of Li4SiO4 under various CO2 partial pressures

The absorption behaviors of Li₄SiO₄ sorbent under various CO₂ partial pressures and temperatures were investigated through numerical and experimental methods. It was found that Li₄SiO₄ showed poor absorption capacity at high temperatures (>525°C) under CO₂ partial pressure of 5066 Pa. This phenomenon was explained by the thermodynamic results from FactSage5.5 software. Meanwhile, a modified Jander‐Zhang model based on the double‐shell structure of the Li₄SiO₄ sorbent was developed to describe the absorption kinetic behaviors of CO₂ on Li₄SiO₄. The results showed that the modified Jander‐Zhang model could fit the kinetic experimental data well. Furthermore, the influence of steam on CO₂ absorption was also analyzed by the modified Jander‐Zhang model. The results showed that the activation energy in the absorption process with steam was smaller than that without steam, which indicated that the presence of steam could promote the CO₂ diffusion in product layer, therefore, improving the sorption capacity. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2153–2164, 2017     

Investigation of CO2 Reaction with CaO and an Acid Washed Lime in a Packed-Bed Reactor

In this work, a mathematical model was developed for the prediction of packed-bed reactor behavior for CaO+CO₂ reaction based on the random pore model. A natural limestone and a modified sorbent using acetic acid washing were used for the experiments. The performances of these sorbents were initially determined using a thermogravimeter analyzer. Then, the reaction was accomplished in a packed-bed reactor for obtaining CO₂ breakthrough curves and investigation of model predictions. This model was able to successfully predict the effect of process conditions and solid texture on the breakthrough curves of the packed-bed reactor.     

Analysis of CO2 sorption/desorption kinetic behaviors and reaction mechanisms on Li4SiO4

The CO₂ sorption/desorption kinetic behaviors on Li₄SiO₄ were analyzed. The theoretical compositions of the sorption/desorption reactions were calculated using FactSage. The sorption/desorption process on Li₄SiO₄ was investigated by comparing the shrinking core, double exponential, and Avrami–Erofeev models. The Avrami–Erofeev model fits the kinetic thermogravimetric experimental data well and, together with the double‐shell mechanism, clearly explains the sorption/desorption mechanism. The sorption process is limited by the rate of the formation and growth of the crystals with double‐shell structure consisting of Li₂CO₃ and Li₂SiO₃. The whole desorption process is found to be controlled by the rate of the formation and growth of the Li₄SiO₄ crystals. Furthermore, the influence of steam on the CO₂ sorption process was analyzed. It has been observed that the presence of steam enhance the mobility of Li⁺ and, therefore, the rate of diffusion control stage. © 2012 American Institute of Chemical Engineers AIChE J, 59: 901–911, 2013     

Tackling increased CO2 concentration in feeds for existing acid gas removal units: A simulation study based on a customized CO2 kinetics model

A Middle East-based amine sweetening unit, with an overall capacity of about 2.2 BSCFD of gas, is among the world’s largest process plants and currently processes sour gas with 10 mol% of hydrogen sulfide (H₂S) and carbon dioxide (CO₂) put together. Current expectation is that acid gas contents in the feed may increase beyond the design limit of the plant. The present work is an effort to quantify the effects of the feed gas CO₂ increase on the plant and to proffer solutions to handle these effects efficiently. We revised the kinetics of amine-based CO₂ absorption correlation of an existing model using real-data-driven parameters re-estimation. Evolutionary technique that employs particle swarm optimization algorithm is used for this purpose. The new CO₂ kinetic model is inserted in a first-principle process simulator, ProMax® V4.0, in order to analyze various solutions necessary to mitigate the operational challenges due to increased feed CO₂. The process plant with present design and operating conditions is determined to handle up to 8.45 mol% CO₂ contents in the sour gas feed. Further results revealed that methyldiethanolamine, diethanolamine, and dimethyl ether propylene glycol (DEPG) could not handle this high feed CO₂ challenge, even at maximum (design) steam and solvent usage. However, diglycolamine exclusively renders the solution as it treats high CO₂ feed gas efficiently with allowable utility consumption, while satisfying the constraints imposed by product gas specifications.     

Experimental study on CO2 hydrate formation in the presence of TiO2, SiO2, MWNTs nanoparticles

ABSTRACT

A series of experiments on CO₂ hydrate formation were carried out in the presence of titanium dioxide (TiO₂), silicon dioxide (SiO₂), multi-walled carbon nanotubes (MWNTs) nanoparticles. The effects of these nanoparticles on induction time, final gas consumption, and gas storage capacity have been investigated at the temperature of 274.15 K and the initial pressure of 5.0 MPa.g. The induction time of CO₂ hydrate formation was remarkably shortened to 12.5 min in the presence of 0.005 wt% MWNTs nanoparticles. The high thermal conductivity and heat capacity of MWNTs nanoparticles presented better heat transfer, and large surface area provided more suitable sites for heterogeneous nucleation of CO₂ hydrate.     

Experimental study of a cocurrent upflow packed bed bubble column reactor: pressure drop, holdup and interfacial area

Gas–liquid interfacial areas have been determined by means of chemically enhanced absorption of CO₂ into DEA in a packed bed bubble column reactor with an inner diameter of 156 mm. The influence of the gas velocity and particle diameter on the interfacial areas, pressure drops and liquid holdups has been investigated. For both packings the limiting values of the gas velocities have been determined above which the interfacial areas and liquid holdups stabilize. In particular gas channelling has been found, which is less pronounced in the bed of larger particles.     

Experimental study on CO2 capture conditions of a fluidized bed limestone decomposition reactor

In this study, the decomposition conditions of limestone particles (0.25-0.50 mm) for CO₂ capture in a steam dilution atmosphere (20-100% steam in CO₂) were investigated by using a continuously operating fluidized bed reactor. The results show that the decomposition conversion of limestone increased with the steam dilution percentage in the CO₂ supply gas. At a bed temperature of 920 °C, the conversions were 72% without steam dilution and 98% with 60% steam dilution. The conversion was 99% with 100% steam dilution at 850 °C of the bed temperature. Steam dilution can decrease not only the decomposition temperature of limestone, but also the residence time required for nearly complete decomposition of CaCO₃. The hydration and carbonation reactivities of the CaO produced were also tested and the results show that both the reactivities increased with the steam dilution percentage for decomposing limestone.     

A Fourier-transform infrared study of CO2 and CO2/H2 interactions with caesium-doped copper catalysts

FTIR spectra are reported of CO₂ and CO₂/H₂ on a silica-supported caesium-doped copper catalyst. Adsorption of CO₂ on a “caesium”/silica surface resulted in the formation of CO₂ ⁻ and complexed CO species. Exposure of CO₂ to a caesium-doped reduced copper catalyst produced not only these species but also two forms of adsorbed carboxylate giving bands at 1550, 1510, 1365 and 1345 cm⁻¹. Reaction of carboxylate species with hydrogen at 388 K gave formate species on copper and caesium oxide in addition to methoxy groups associated with caesium oxide. Methoxy species were not detected on undoped copper catalyst suggesting that caesium may be a promoter for the methanol synthesis reaction. Methanol decomposition on a caesium-doped copper catalyst produced a small number of formate species on copper and caesium oxide. Methoxy groups on caesium oxide decomposed to CO and H₂, and subsequent reaction between CO and adsorbed oxygen resulted in carboxylate formation. Methoxy species located at interfacial sites appeared to exhibit unusual adsorption properties.     

Role of support in reforming of CH4 with CO2 over Rh catalysts

The reforming of CH₄ with CO₂ over supported Rh catalysts has been studied over a range of temperatures (550–1000 K). A significant effect of the support on the catalytic activity was observed, where the order was Rh/Al₂O₃>Rh/TiO₂>Rh/SiO₂. The catalytic activity of Rh/SiO₂ was promoted markedly by physical mixing of Rh/SiO₂ with metal oxides such as Al₂O₃, TiO₂, and MgO, indicating a synergetic effect. The role of the metal oxides used as the support and the physical mixture may be ascribed to the promotion in dissociation of CO₂ on the surface of Rh, since the CH₄ + CO₂ reaction is first order in the pressure of CO₂, suggesting that CO₂ dissociation is the rate-determining step. The possible model of the synergetic effect was proposed.     

Effects of Synthesis Temperature and Support Material on CO2 and CH4 Permeation through SAPO-34 Membranes

In this research, continuous SAPO-34 membranes were synthesized via secondary growth method onto both α-Al₂O₃ and mullite supports at three levels of synthesis temperature: 185, 195, and 220°C for 24 h. The synthesized membranes were characterized using XRD and SEM analysis and single gas permeation experiments. It was found out that support material and synthesis temperature both have significant effects on the membrane performance. At higher synthesis temperature, SAPO-34 crystals grown over the mullite support become more uniform and smaller in size but those grown on the α-Al₂O₃ support become larger. Effect of synthesis temperature on single gas permeation properties of the synthesized SAPO-34 membranes was also studied. For the mullite supported membranes, the CH₄ and CO₂ permeances decrease as synthesis temperature increases; but in the case of the alumina supported membranes, by increasing synthesis temperature, CH₄ and CO₂ permeances first decrease up to 195°C and then increase up to 220°C. Even in equal membrane thicknesses, the mullite supported membrane shows lower gas permenaces. Increasing synthesis temperature decreases CO₂/CH₄ ideal selectivity for the α-Al₂O₃ supported membranes, while increases for the mullite supported membranes. Under optimum synthesis conditions, at room temperature and 2 bar feed pressure, the CO₂ permeance through the α-Al₂O₃ and the mullite supported SAPO-34 membranes are 8.2 × 10^?7 and 8.5 × 10^?8 (mol/m² · s · Pa), respectively, and CO₂/CH₄ ideal selectivities are 51 and 61, respectively.     

Pressure-Swing Adsorption Separation of H2S from CO2 with Molecular Sieves 4A, 5A,and 13X

The separation of bulk quantities of H₂S from CO₂ was investigated through a series of pressure-swing adsorption experiments utilizing 4A, 5A, and 13X molecular sieves. High selectivity of H₂S over CO₂ was encountered for all sieves, particularly for the 13X and 5A. Practically pure CO₂ was produced in the adsorption stage with fresh 5A and 13X sieves, at high product recovery rates. Efficient H₂S purification was obtained with fresh 5A and regenerated 4A zeolites. The experimental results were in line with theoretical predictions of the literature.