Microstructured Fischer‐Tropsch Reactor Scale‐up and Opportunities for Decentralized Application

Current projects focusing on the energy transition in traffic will rely on a high‐level technology mix for their commissioning. One of those technologies is the Fischer‐Tropsch synthesis (FTS) that converts synthesis gas into hydrocarbons of different chain lengths. A microstructured packed‐bed reactor for low‐temperature FTS is tested towards its versatility for biomass‐based syngas with a high inert gas dilution. Investigations include overall productivity, conversion, and product selectivity. A 60‐times larger pilot‐scale reactor is further tested. Evaporation cooling is introduced which allows to increase the available energy extraction from the system. From that scale on, an autothermal operation at elevated conversion levels is applicable.     

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.     

Importance of proper hydrodynamics modelling in fixed‐bed reactors: Fischer‐Tropsch synthesis study case

The importance of hydrodynamics, particularly gas density, superficial gas velocity, and total pressure in axial and radial directions, was analyzed for the modelling of a catalytic reactor using a non‐isothermal pseudo‐homogeneous approach. The modelling of a fixed‐bed reactor in one and two stages for CO conversion by Fischer‐Tropsch synthesis was taken as a study case. For the validation of the proposed model, the results of the simulations for the CO conversion and temperature profiles were compared with experimental data reported in the literature. Simulations for CO conversion and reactor temperature profiles confirmed the model's ability to predict the selectivity of the liquid products in the Fischer‐Tropsch synthesis reactor in one and two stages. The proposed model predicts more suitable profiles of CO conversion and temperature along the reactor, which makes it a more robust and efficient tool for design, optimization, and control purposes.     

Optimization of Fischer‐Tropsch Process in a Fixed‐Bed Reactor Using Non‐uniform Catalysts

Optimization of Fischer‐Tropsch (FT) process in a fixed‐bed reactor is carried out using non‐uniform catalysts. The C₅⁺ yield of the reactions is maximized utilizing a combination of non‐uniform catalysts across the bed. A 1D heterogeneous model is developed to simulate the bed containing uniform and non‐uniform catalysts. It is found that the egg‐shell and surface‐layered catalysts result in higher C₅⁺ yield. Moreover, effects of cooling temperature are studied. Genetic Algorithm (GA) and Successive Quadratic Programming (SQP) methods are applied. Feed and cooling temperature are selected as decision variables together with distribution of non‐uniform catalysts along the bed. The optimization result shows 14.47 % increase in the C₅⁺ yield with respect to the base condition.     

Comprehensive Polymerization Model for Fischer‐Tropsch Synthesis

The polymerization kinetics of Fischer‐Tropsch reactions on a cobalt‐based catalyst was studied. A kinetic model was developed based on the alkyl and alkenyl mechanisms for hydrocarbon chain propagation that may occur simultaneously in the Fischer‐Tropsch synthesis. The kinetic model comprised initiation of hydrocarbon chains, propagation, termination to paraffin and olefin and readsorption of olefin. The proposed model was validated by F‐test and proved valid at a confidence level of 95 %.     

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.     

Influence of Particle Size and Single‐Tube Diameter on Thermal Behavior of Fischer‐Tropsch Reactors. Part I. Particle Size Variation for Constant Tube Size and Vice Versa

Simulation of a single tube of a wall‐cooled multitubular Fischer‐Tropsch (FT) reactor with a cobalt catalyst indicates that the reactor performance is improved by enlarging the catalyst particle diameter. This aspect is studied for variation of the particle size for a fixed tube diameter and vice versa. For a syngas conversion per pass of about 30 % as target and a typical industrially used single‐tube diameter of 40 mm, a particle size of > 3 mm is appropriate with regard to a high production rate of higher hydrocarbons. For a particle diameter of < 3 mm, a temperature runaway can only be avoided by rather low cooling temperatures, and the target conversion cannot be reached. In addition, the pressure drop then gets rather high. The reasons for this behavior are: (i) the heat transfer to the cooled tube wall for a given tube size is considerably enhanced by increasing the particle size; (ii) the influence of pore diffusion on the effective rate gets stronger with rising particle size which decreases the danger of temperature runaway.     

Influence of Particle Size and Single‐Tube Diameter on Thermal Behavior of Fischer‐Tropsch Reactors. Part II. Eggshell Catalysts and Optimal Reactor Performance

The optimal combination of particle and tube size for simulation of a single tube of a wall‐cooled multitubular Fischer‐Tropsch (FT) reactor with cobalt as catalyst was determined. The maximum size of the tubes, realized without temperature runaway, enhances with increasing particle size until an optimal value is reached, thereby improving the production rate of liquid fuels per tube. Reasons for this are that heat transfer to the cooled tube wall for a given tube size is considerably enhanced by increasing the particle size and that the influence of pore diffusion on the effective rate of FT synthesis gets stronger with rising particle size, which reduces the temperature sensitivity of the reactor and decreases the danger of a temperature runaway. The simulations indicate that the use of FT eggshell catalysts is not an option for fixed‐bed reactors. The temperature sensitivity of the reactor is strongly enhanced, which decreases the maximum tube size and with that the productivity per tube. All these effects are valid in general for wall‐cooled fixed‐bed reactors. Respective criteria are presented.     

Staging of the Fischer‐Tropsch Reactor with a Cobalt‐Based Catalyst

A method for systematic reactor design, described by Hillestad [1], is applied to the Fischer‐Tropsch synthesis. The reactor path is sectioned into stages and design functions are optimized to maximize an objective function. Two different objective functions are considered: the yield of wax and a measure of the profitability. With the chosen kinetic model [2] and the path temperature constrained by 240 °C, staging of the Fischer‐Tropsch synthesis based on the first criteria will increase the yield of wax. By introducing the cost of heat transfer area in the objective function, the total heat transfer area requirement of a two‐stage reactor is significantly less than of a single‐stage reactor.     

Optimal Design of a Gas‐to‐Liquids Process with a Staged Fischer‐Tropsch Reactor

The optimal design of a natural gas‐to‐liquid hydrocarbons (GTL) process with a multistage cobalt‐based Fischer‐Tropsch reactor and interstage product separation is considered. The objective function is to maximize the wax (C₂₁₊) production rate at the end of the reactor path. Sectioning of the Fischer‐Tropsch reactor increases the chain growth probability inside the reactor which results in a higher production of wax. The carbon efficiency of the two‐stage reactor is distinctly higher than that of the single‐stage reactor.     

Unpromoted and Mn‐Promoted Cobalt Catalyst Supported on Carbon Nanotubes for Fischer‐Tropsch Synthesis

Langmuir‐Hinselwood (LH) and power rate equations were applied to describe the kinetics of the Fischer‐Tropsch reaction on cobalt catalysts and manganese‐doped cobalt catalysts supported on carbon nanotubes (CNTs). LH‐based kinetics characterize the activity behavior of the unpromoted Co/CNT system satisfactorily, but fail with respect to the manganese‐promoted Co/CNT catalyst. An alternative LH equation is able to fit the experimental data, but the fitting parameters are out of the range of usual values and underrate the activity at ambient pressure regardless of manganese promotion. Application of power law rate expressions results in satisfying characterization of the kinetics in the whole CO pressure range in the promoted case and within a defined range of CO pressure in the unpromoted case.     

Parametric analysis of Fischer‐tropsch synthesis in a catalytic microchannel reactor

Fischer‐Tropsch synthesis (FTS) involves highly exothermic conversion of syngas to a wide range of hydrocarbons, but demands isothermal conditions due to the strong dependence of product distribution on temperature. Running FTS in microchannel reactors is promising, as the sub‐millimeter dimensions can lead to significant intensification that inherently favors robust temperature control. This study involves computer‐based FTS simulations in a heat‐exchange integrated microchannel network composed of horizontal groups of square‐shaped cooling and wall‐coated, catalytic reaction channels. Effects of material type and thickness of the wall separating the channels, side length of the cooling channel, coolant flow rate, and channel wall texture on reaction temperature are investigated. Use of thicker walls with high thermal conductivities and micro‐baffles on the catalytic reaction channel wall favor near‐isothermal conditions. Response of reaction temperature against coolant flow rate is significant. Using cooling channels with smaller side lengths, however, is shown to be insufficient for temperature control. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

Hydrocracking of Fischer‐Tropsch Wax with Tungstovanadophosphoric Salts as Catalysts

The synthesis of liquid hydrocarbons from CO₂ and H₂, based on renewable energy and H₂O electrolysis, respectively, in a power‐to‐liquid process is a promising concept for the substitution of fossil fuels. Such a process is based on Fischer‐Tropsch synthesis followed by hydrocracking to convert waxy products into transportation fuels such as gasoline and diesel oil. Heteropolyacid cesium salts as catalysts show appropriate activity for hydrocracking, and the selectivity in cracking model hydrocarbons and Fischer‐Tropsch wax can be tuned by the vanadium content of the catalyst. Thermal stability and surface properties were investigated, and the catalysts are compared with a classical H‐Y‐type zeolite used for hydrocracking.     

Advancement of Fischer‐Tropsch synthesis via utilization of supercritical fluid reaction media

The Fischer Tropsch Synthesis (FTS) reaction has been studied and for nearly a century for the production of fuels and chemicals from nonpetroleum sources. Research and utilization have occurred in both gas phase (fixed bed) and liquid phase (slurry bed) operation. The use of supercritical fluids as the reaction media for FTS (SCF‐FTS) now has a 20‐year history. Although a great deal of progress in SCF‐FTS has been made on the lab scale, this process has yet to be expanded to pilot or industrial scale. This article reviews the research activities involving supercritical FTS and published in open literature from 1989 to 2008. © 2009 American Institute of Chemical Engineers AIChE J, 2010     

Influence of syngas composition on the transient behavior of a Fischer–Tropsch continuous slurry reactor

The influence of syngas composition on the initial behaviour of a Co/Al₂O₃ catalyst in Fischer–Tropsch reaction has been studied in a continuous perfectly mixed slurry reactor for an inlet H₂/CO ratio between 1.6 and 3.35 keeping other conditions constant (T = 220 °C, P = 2 MPa). Significantly different behaviors of initial deactivation for CO conversion have been observed with different H₂/CO ratios. It was observed that the deactivation increases with increase in H₂/CO ratio and in carbon monoxide conversion. The computed liquid concentrations of CO, H₂ and H₂O have shown that water is the most abundant species in the liquid phase of the reactor during our experiments. The concentration of the water produced by the FT reaction seems to be the key parameter responsible of the initial behavior and then of the initial deactivation. For moderate levels of water ( corresponding to P_H2O/P_H2<0.4), a simple kinetic model assuming a reversible oxidation of cobalt active sites by water in competition with their reduction by hydrogen seems to represent satisfactorily the initial behaviour of the catalyst. For higher water concentrations, the irreversible deactivation should be probably taken into consideration.     

Intrinsic and Effective Kinetics of Cobalt‐Catalyzed Fischer‐Tropsch Synthesis in View of a Power‐to‐Liquid Process Based on Renewable Energy

The production of liquid hydrocarbons based on CO₂ and renewable H₂ is a multi‐step process consisting of water electrolysis, reverse water‐gas shift, and Fischer‐Tropsch synthesis (FTS). The syngas will then also contain CO₂ and probably sometimes H₂O, too. Therefore, the kinetics of FTS on a commercial cobalt catalyst was studied with syngas containing CO, CO₂, H₂, and H₂O. The intrinsic kinetic parameters as well as the influence of pore diffusion (technical particles) were determined. CO₂ and H₂O showed only negligible or minor influence on the reaction rate. The intrinsic kinetic parameters of the rate of CO consumption were evaluated using a Langmuir‐Hinshelwood (LH) approach. The effectiveness factor describing diffusion limitations was calculated by two different Thiele moduli. The first one was derived by a simplified pseudo first‐order approach, the second one by the LH approach. Only the latter, more complex model is in good agreement with the experimental results.     

Hydrocracking of Fischer‐Tropsch waxes: Kinetic modeling via LHHW approach

A lumped kinetic model to describe the hydrocracking of complex mixtures of paraffins, such as Fischer‐Tropsch waxes, has been developed. A Langmuir‐Hinshelwood‐Hougen‐Watson approach has been followed, accounting for physisorption by means of the Langmuir isotherm. Finally, a complete form of the rate expression is used, thus introducing the equilibrium constants for dehydrogenation and protonation elementary steps. To minimize the number of model parameters, the kinetic and thermodynamic constants are defined as functions of the chain length. Vapor–liquid equilibrium is calculated along the reactor, and the hydrocarbons concentrations are described by means of fugacity. The model provides quite a good fitting of experimental results and is able to predict the effects of the operating conditions (temperature, pressure, H₂/wax ratio, and WHSV). Outstandingly, the estimated values and trends of the kinetic and thermodynamic constants (activation energies, Langmuir adsorption constants, etc.) are in line with their physical meaning. © 2010 American Institute of Chemical Engineers AIChE J, 2011