Temperature profile in a two-stage fixed bed reactor for catalytic partial oxidation of methane to syngas

Detailed axial temperature distribution has been studied in a two-stage process for catalytic partial oxidation of methane to syngas, which consists of two consecutive fixed bed reactors with oxygen or air separately introduced. The first stage of the reactor, packed with a combustion catalyst, is used for catalytic combustion of methane at low initial temperature. While the second stage, filled with a partial oxidation catalyst, is used for the partial oxidation of methane to syngas. A pilot-scale reactor packed with up to 80 g combustion catalyst and 80 g partial oxidation catalyst was employed. The effects of oxygen distribution in the two sections, and gas hourly space velocity (GHSV) on the catalyst bed temperature profile, as well as conversion of methane and selectivities to syngas were investigated under atmospheric pressure. It is found that both oxygen splitting ratio and GHSV have significant influence on the temperature profile in the reactor, which can be explained by the synergetic effects of the fast exothermic oxidation reactions and the slow endothermic (steam and CO₂) reforming reactions. Almost no change in activity and selectivity was observed after a stability experiment for 300 h.     

Improving selectivity during methane partial oxidation by use of a membrane reactor

A reactant-swept catalytic membrane reactor for partial oxidation of methane to formaldehyde has been modeled. Kinetic parameters were taken from the literature for a V₂O₅/Sio₂ methane partial oxidation catalyst, and membrane parameters characteristic of commercially available materials were used. The models show that the selectivity for formaldehyde can be significantly improved by using a membrane reactor.     

Selective oxidation of methane with air over silica catalysts

Partial oxidation of methane by oxygen to form formaldehyde, carbon oxides, and C₂ products (ethane and ethene) has been studied over silica catalyst supports (fumed Cabosil and Grace 636 silica gel) in the 630–780 °C temperature range under ambient pressure. The silica catalysts exhibit high space time yields (at low conversions) for methane partial oxidation to formaldehyde, and the C₂ hydrocarbons were found to be parallel products with formaldehyde. Short residence times enhanced both the C₂ hydrocarbons and formaldehyde selectivities over the carbon oxides even within the differential reactor regime at 780 °C. This suggests that the formaldehyde did not originate from methyl radicals, but rather from methoxy complexes formed upon the direct chemisorption of methane at the silica surface at high temperature. Very high formaldehyde space time yields (e.g., 812 g/kg cat h at the gas hourly space velocity = 560 000 (NTP)/kg cat h) could be obtained over the silica gel catalyst at 780 °C with a methane/air mixture of 1.5/1. These yields greatly surpass those reported for silicas earlier, as well as those over many other catalysts. Low CO₂ yields were observed under these reaction conditions, and the selectivities to formaldehyde and C₂ hydrocarbons were 28.0 and 38.8%, respectively, at a methane conversion of 0.7%. A reaction mechanism was proposed for the methane activation over the silica surface based on the present studies, which can explain the product distribution patterns (specifically the parallel formation of formaldehyde and C₂ hydrocarbons).     

Partial Oxidation of Methane to Syngas in a Packed Bed Catalyst Membrane Reactor

The planar membrane reactor configuration was explored for partial oxidation of methane (POM) to syngas. A supported membrane composed of yttria‐stabilized zirconia and La_0.8Sr_0.2Cr_0.5Fe_0.5O_3‐δ was sealed to a stainless holder, and a Ni/Al₂O₃ catalyst bed was placed under the membrane plane with a small slit between them. This reactor configuration would facilitate the POM reaction via oxidation‐reforming mechanism: the oxidation reaction occurring at the membrane surface and the reforming reaction taking place in the catalyst bed. At 800°C and a methane feed rate of 32 mL min^?1, the reactor attained methane throughput conversion over 90%, CO and H₂ selectivity both over 95%, and an equivalent oxygen permeation rate 1.4 mL cm^?2 min^?1. The membrane and catalyst remained intact after the POM testing. The planar membrane reactor configuration explored in this study may lead to the development of a compact reactor for syngas production. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2170–2176, 2016     

Development and Application of Oxygen Permeable Membrane in Selective Oxidation of Light Alkanes

In this paper, oxygen permeable membrane used in membrane reactor for selective oxidation of alkanes will be discussed in detail. The recent developments for the membrane materials will be presented, and the strategy for the selection of the membrane materials will be outlined. The main applications of oxygen permeable membrane in selective oxidation of light alkanes will be summarized, which includes partial oxidation of methane (POM) to syngas and partial oxidation of heptane (POH) to produce H₂, oxidative coupling of methane (OCM) to C₂, oxidative dehydrogenation of ethane (ODE) to ethylene and oxidative dehydrogenation of propane (ODP) to propylene. Achievements for the membrane material developments and selective oxidation of light alkanes in membrane reactor in our group are highlighted.     

Partial oxidation of propane to acrolein in a membrane reactor – Experimental data and computer simulation

Acrolein is synthesized in a tubular membrane reactor with a porous membrane acting as oxygen distributor at 450–550 °C with the catalyst Ag_0.01Bi_0.85V_0.54Mo_0.45O₄ by direct partial oxidation of propane. The reaction in the membrane reactor is compared with the reaction in the classical co-feed reactor. If the oxygen is dosed through the porous reactor wall to the tube side of the reactor, higher acrolein yields and selectivities are obtained. The catalyst is located inside the tube, where the propane streams through. For the simulation – based on a kinetic model – the membrane reactor was partitioned into 14 separate sections through which the oxygen supply takes place. In accordance with the experiment the simulations show that the acrolein selectivities will increase if the oxygen is dosed through the reactor wall acting as membrane oxygen distributor.     

Performance of an oxygen-permeable membrane reactor for partial oxidation of methane in coke oven gas to syngas

Perovskite-type oxygen-permeable membrane reactors of BaCo_0.7Fe_0.2Nb_0.1O_3−δ packed with Ni-based catalyst had high oxygen permeability and could be used for syngas production by partial oxidation of methane in coke oven gas (COG). The BCFNO membrane itself had a poor catalytic activity to partial oxidation of CH₄ in COG. After the catalyst was packed on the membrane surface, 92% of methane conversion, 90% of H₂ selectivity, 104% of CO selectivity and as high as 15 ml/cm²/min of oxygen permeation flux were obtained at 1148 K. During continuously operating for 550 h at 1148 K, no degradation of performance of the BCFNO membrane reactor was observed under the condition of hydrogen-rich COG. The possible reaction pathways were proposed to be an oxidation-reforming process. The oxidation of H₂ in COG with the surface oxygen on the permeation side improves the oxygen flux through the membrane, and H₂O reacts with CH₄ by reforming reactions to form H₂ and CO.     

Hydrogen production through chemical looping using NiO/NiAl2O4 as oxygen carrier

A new autothermal route to produce hydrogen from natural gas via chemical looping technology was investigated. Tests were conducted in a micro-fixed bed reactor loaded with 200 mg of NiO/NiAl₂O₄ as oxygen carrier. Methane reacts with a nickel oxide in the absence of molecular oxygen at 800 °C for a period of time as high as 10 min. The NiO is subsequently contacted with a synthetic air stream (21% O₂ in argon) to reconstitute the surface and combust carbon deposited on the surface. Methane conversion nears completion but to minimize combustion of the hydrogen produced, the oxidation state of the carrier was maintained below 30% (where 100% represents a fully oxidized surface). Co-feeding water together with methane resulted in stable hydrogen production. Although the carbon deposition increased with time during the reduction cycle, the production rate of hydrogen remained virtually constant. A new concept is also presented where hydrogen is obtained from methane with inherent CO₂ capture in an energy neutral 3-reactors CFB process. This process combines a methane combustion step where oxygen is provided via an oxygen carrier, a steam methane reforming step catalyzed by the reduced oxygen carrier and an oxidizing step where the O-carrier is reconstituted to its original state.     

Analysis of hydrogen production from methane autothermal reformer with a dual catalyst-bed configuration

This paper presents a performance analysis of a dual-bed autothermal reformer for hydrogen production from methane using a non-isothermal, one dimensional reactor model. The first section of Pt/Al₂O₃ catalyst is designed for oxidation reaction, whereas the second one based on Ni/MgAl₂O₄ catalyst involves steam reforming reaction. The simulation results show that the dual-bed autothermal reactor provides higher reactor temperature and methane conversion compared with a conventional fixed-bed reformer. The H₂O/CH₄ and O₂/CH₄ feed ratios affect the methane conversion and the H₂/CO product ratio. The addition of steam at lower temperatures to the steam reforming section of the dual-bed reactor can produce the synthesis gas with a higher H₂/CO product ratio.     

Tuning millisecond chemical reactors for the catalytic partial oxidation of cyclohexane

It is demonstrated that millisecond partial oxidation of cyclohexane can be tuned by varying the catalyst and operating conditions to generate product distributions that favor (1) oxygenates, (2) olefins, or (3) syngas (H₂ and CO). High selectivities to parent oxygenates require low conversions using low-temperature catalysts, such as Ag or Co. Olefins are favored by Pt or Pt-Sn and H₂ addition eliminates the production of CO and CO₂, thereby increasing olefin selectivities. For syngas, Rh is the catalyst of choice. Finally, a Pt-10% Rh single gauze gives high selectivities to both oxygenates and olefins.Conventional methods for the partial oxidation of cyclohexane are liquid-phase processes that are plagued by poor conversions, high recycle costs, long residence times (minutes to hours), and expensive catalysts. In contrast, with a cyclohexane–oxygen feed at C₆H₁₂/O₂=2, a Pt-10% Rh single gauze catalyst can give total selectivities exceeding 80% to oxygenates and olefins at 25% cyclohexane conversion and complete oxygen conversion. The products consist of nearly 60% selectivity to the C₆ products, cyclohexene and 5-hexenal. The temperature profile attained in the single-gauze reactor allows the preservation of these highly non-equilibrium products.Alternative catalysts for cyclohexane oxidation to oxygenates and olefins include α-alumina monoliths coated with Pt, Rh, Pt-Rh, Pt-Sn, Co, Mo or Ag. The Co, Mo and Ag catalysts give very high selectivities to C₆ oxygenates but are hindered by poor conversions (<5%) of both cyclohexane and oxygen at these millisecond contact times. H₂ addition to cyclohexane oxidation feed mixtures over Pt and Pt-Sn is shown to significantly increase the selectivities to C₆ olefins while reducing the formation of CO and CO₂.Cyclohexane oxidation in air over Rh monoliths enables the production of high yields (>95%) of syngas. This process could find applications in the automotive industry as the production of hydrogen from liquid fuels becomes important.     

Experimental Investigations of Catalytic Partial Oxidation of Methane to Synthesis Gas in Various Types of Fluidized‐Bed Reactors

The partial oxidation of methane to synthesis gas over Ni/α‐Al₂O₃ catalysts (1 and 5 wt.‐% Ni loading, 71–160 and 250–355 μm particle diameter) was investigated in different types of fluidized‐bed reactors, i.e., the bubbling fluidized bed (FlB), the spout fluid bed (SFB) and the internally circulating fluidized bed (ICFB). A methane‐to‐oxygen ratio of 2:1 was used in all experiments and the temperature was varied between 700 and 800 °C. Gas velocities and catalyst masses were adjusted to assure a stable and controllable reactor operation. A nearly isothermal operation was established in all reactors. The thermodynamic equilibrium values were achieved in the FlB and SFB reactor whereas in the ICFB reactor slightly lower conversions and selectivities were obtained. Taking the direct scale‐up concept of the ICFB reactor into account, significant higher space‐time yields were obtained in this reactor than in the industrial‐scale bubbling fluidized‐bed reactor. No increase of the space‐time yield in comparison to the FlB was obtained in the SFB reactor.     

A robust mixed‐conducting multichannel hollow fiber membrane reactor

To accelerate the commercial application of mixed‐conducting membrane reactor for catalytic reaction processes, a robust mixed‐conducting multichannel hollow fiber (MCMHF) membrane reactor was constructed and characterized in this work. The MCMHF membrane based on reduction‐tolerant and CO₂‐stable SrFe_0.8Nb_0.2O_3‐δ (SFN) oxide not only possesses a good mechanical strength but also has a high oxygen permeation flux under air/He gradient, which is about four times that of SFN disk membrane. When partial oxidation of methane (POM) was performed in the MCMHF membrane reactor, excellent reaction performance (oxygen flux of 19.2 mL min^?1 cm^?2, hydrogen production rate of 54.7 mL min^?1 cm^?2, methane conversion of 94.6% and the CO selectivity of 99%) was achieved at 1173 K. And also, the MCMHF membrane reactor for POM reaction was operated stably for 120 h without obvious degradation of reaction performance. © 2015 American Institute of Chemical Engineers AIChE J, 61: 2592–2599, 2015     

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%.     

Modelling of packed bed membrane reactors for autothermal production of ultrapure hydrogen

The conceptual feasibility of a packed bed membrane reactor for the autothermal reforming (ATR) of methane for the production of ultrapure hydrogen was investigated. By integrating H₂ permselective Pd-based membranes under autothermal conditions, a high degree of process integration and intensification can be accomplished which is particularly interesting for small scale H₂ production units. A two-dimensional pseudo-homogeneous packed bed membrane reactor model was developed that solves the continuity and momentum equations and the component mass and energy balances. In adiabatic operation, autothermal operation can be achieved; however, large axial temperature excursions were seen at the reactor inlet, which are disadvantageous for membrane life and catalyst performance. Different operation modes, such as cooling the reactor wall with sweep gas or distributive feeding of O₂ along the reactor length to moderate the temperature profile, are evaluated. The concentration polarisation because of the selective hydrogen removal along the membrane length was found to become significant with increasing membrane permeability thereby constraining the reactor design. To decrease the negative effects of mass transfer limitations to the membrane wall, a small membrane tube diameter needs to be selected. For a relatively small ratio of the membrane tube diameter to the particle diameter, the porosity profile needs to be taken into account to prevent overestimation of the H₂ removal rate. It is concluded that autothermal production of H₂ in a PBMR is feasible, provided that the membranes are positioned outside the inlet region with large temperature gradients.     

Synthesis gas production in methane conversion using the P|yttria-stabilized zirconia|Ag electrochemical membrane system

The electrochemical membrane reactor of YSZ (yttria-stabilized zirconia) solid electrolyte coated with Pd and Ag as anode and cathode, respectively, has been applied to the partial oxidation of methane to synthesis gas (CO + H₂). The Pd|YSZ|Ag catalytic system has shown a remarkable activity for CO production at 773 K, and the selectivity to CO was quite high (96.3%) under oxygen pumping condition at 5 mA. The H₂ production strongly depended on the oxidation state of the Pd anode surface. Namely, the H₂ treatment of the Pd anode at 773 K for 1 h drastically reduced the rate of H₂ production, while air treatment enhanced the H₂ production rate. From the results of the partial oxidation of CH₄ with molecular oxygen, it is considered that the reaction site of the electrochemical oxidation of CH₄ to synthesis gas was the Pd–YSZ–gas-phase boundary (triple-phase boundary). In addition, it is found that the oxygen species pumped electrochemically over the Pd surface demonstrated similar activity to adsorbed oxygen over Pd, PdO_ad, for the selective oxidation of CH₄ to CO, when the Pd supported on YSZ was used as a fixed-bed catalyst for CH₄ oxidation with the adsorbed oxygen. The difference with respect to the H₂ formation between the electrochemical membrane system and the fixed-bed catalyst reactor results from differences in the average particle size of Pd and the way of the oxygen supply to the Pd surface. This revised version was published online in July 2006 with corrections to the Cover Date.     

Fluidised bed membrane reactor for ultrapure hydrogen production via methane steam reforming: Experimental demonstration and model validation

Hydrogen is emerging as a future alternative for mobile and stationary energy carriers in addition to its use in chemical and petrochemical applications. A novel multifunctional reactor concept has been developed for the production of ultrapure hydrogen from light hydrocarbons such as methane for online use in downstream polymer electrolyte membrane fuel cells. A high degree of process intensification can be achieved by integrating perm-selective hydrogen membranes for selective hydrogen removal to shift the methane steam reforming and water-gas-shift equilibriums in the favourable direction and perm-selective oxygen membranes for selective oxygen addition to supply the required reaction energy via partial oxidation of part of the methane feed and enable pure CO₂ capture without costly post-treatment. This can be achieved in a proposed novel multifunctional bi-membrane bi-section fluidised bed reactor [Patil, C.S., van Sint Annaland, M., Kuipers, J.A.M., 2005. Design of a novel autothermal membrane assisted fluidized bed reactor for the production of ultrapure hydrogen from methane. Industrial and Engineering Chemistry Research 44, 9502-9512]. In this paper, an experimental proof of principle for the steam reforming/water-gas-shift section of the proposed novel fluidised bed membrane reactor is presented. A fluidised bed membrane reactor for steam reforming of methane/water-gas-shift on a commercial noble metal-based catalyst has been designed and constructed using 10 H₂ perm-selective Pd membranes for a fuel cell power output in the range of 50-100 W. It has been experimentally demonstrated that by the insertion of the membranes in the fluidised bed, the thermodynamic equilibrium constraints can indeed be overcome, i.e., increased CH₄ conversion, decreased CO selectivity and higher product yield (H₂ produced/CH₄ reacted). Experiments at different superficial gas velocities and also at different temperatures and pressures (carried out in the regime without kinetic limitations) revealed enhanced reactor performance at higher temperatures and pressures (3-4 bar). With a phenomenological two-phase reactor model for the fluidised bed membrane reactor, incorporating a separately developed lumped flux expression for the H₂ permeation rate through the used Pd-based membranes, the measured data from the fluidised bed membrane reactor could be well described, provided that axial gas back-mixing in the membrane-assisted fluidised bed reactor is negligible. This indicates that the membrane reactor behaviour approached that of an ideal isothermal plug flow reactor with maximum H₂ permeation.     

A novel cyclic process for synthesis gas production

This paper reports a novel cyclic partial oxidation process for the production of synthesis gas with the in situ separation of oxygen from air. A perovskite-type oxide, La_0.8Sr_0.2Co_0.5Fe_0.5O_3−δ, is employed in the experimental study of the process as an oxygen retaining material. Air and methane are periodically brought into contact with the oxide packed in a fixed-bed reactor. The oxide, during the air step, exclusively retains oxygen while partial oxidation reaction occurs during the methane step utilizing the retained oxygen. Although combustion and cracking reactions occur in addition to the partial oxidation reaction during the methane step, high methane conversion is achieved and hydrogen and CO are produced with high selectivity.     

Autothermal Reforming of Methane with Integrated CO2 Capture in a Novel Fluidized Bed Membrane Reactor. Part 2 Comparison of Reactor Configurations

The reactor performance of two novel fluidized bed membrane reactor configurations for hydrogen production with integrated CO₂ capture by autothermal reforming of methane (experimentally investigated in Part 1) have been compared using a phenomenological reactor model over a wide range of operating conditions (temperature, pressure, H₂O/CH₄ ratio and membrane area). It was found that the methane combustion configuration (where part of the CH₄ is combusted in situ with pure O₂) largely outperforms the hydrogen combustion concept (oxidative sweeping combusting part of the permeated H₂) at low H₂O/CH₄ ratios (<2) due to in situ steam production, but gives a slightly lower hydrogen production rate at higher H₂O/CH₄ ratios due to dilution with combustion products. The CO selectivity was always much lower with the methane combustion configuration. Whether the methane combustion or hydrogen combustion configuration is preferred depends strongly on the economics associated with the H₂O/CH₄ ratio.     

Partial oxidation of methane to synthesis gas over Rh/α-Al2O3 at high temperatures

The partial oxidation of methane to synthesis gas has been studied in a continuous flow reactor using a Rh/α-Al₂O₃ catalyst under conditions as close as possible to those industrially relevant: pressures up to 800 kPa and temperatures higher than 1274 K in order to avoid the formation of carbon and to obtain high equilibrium selectivities to CO and H₂. Intrinsic kinetic data were obtained when the feed was diluted with helium. Gas-phase reactions were found to occur at 500 kPa when the feed was not diluted. A reaction network has been derived from experimental results in which oxygen conversions range from 0 to 1. CO₂, C₂H₆ and H₂O are the primary products. C₂H₄ is formed by oxidative dehydrogenation of C₂H₆. CO and H₂ are formed by reforming of CH₄ by CO₂ and H₂O; an additional direct route to CO and H₂ at low oxygen conversions cannot be excluded. The catalyst appears to be present in two states, the transition being at an oxygen conversion of 0.4 under the conditions used. The support probably enhances oxidation reactions by reverse spillover of oxygen or hydroxyl species onto rhodium. The support as such behaves similarly to the catalyst at low oxygen conversions, but shows no reforming activity. This revised version was published online in July 2006 with corrections to the Cover Date.     

钙钛矿型混合导体透氧膜SrFe0.6Cu0.3Ti0.1O3－δ的制备与表征

Dense membrane with the composition of SrFe0.6Cu0.3Ti0.1O3-δ （SFCTO） was prepared by solid state reaction method. Oxygen permeation flux through this membrane was investigated at operating temperature ranging from 750℃ to 950℃ and different oxygen partial pressure. XRD measurements indicated that the compound was able to form single-phased perovskite structure in which part of Fe was replaced by Cu and Ti. The oxygen desorption and the reducibility of SFCTO powder were characterized by thermogravimetric analysis and temperature programmed reduction analysis, respectively. It was found that SFCTO had good structure stability under low oxygen pressure at high temperature. The addition of Ti increased the reduction temperature of Cu and Fe. Performance tests showed that the oxygen permeation flux through a 1.5 mm thick SFCTO membrane was 0.35-0.96 ml·min ^-1·cm^-2 under air/helium oxygen partial pressure gradient with activation energy of 53.2 kJ·mol^-1. The methane conversion of 85%, CO selectivity of 90% and comparatively higher oxygen permeation flux of 5 ml·min^-1·cm^- 2 were achieved at 850℃, when a SFCTO membrane reactor loaded with Ni-Ce/Al2O3 catalyst was applied for the partial oxidation of methane to syngas.