Synthesis Gas and Zinc Production in a Noncatalytic Packed‐Bed Reactor

A noncatalytic packed‐bed reactor has been constructed for management of the reduction of ZnO by methane, which leads to co‐production of synthesis gas and zinc. The reactor consisted of a simple vertical pipe filled with ZnO pellets. These pellets underwent reaction with a pure methane flow. Experimental tests were conducted in the temperature range 860–995 °C at atmospheric pressure in an electrically heated reactor. The results showed complete chemical conversion of methane to synthesis gas in the aforementioned temperature range. In addition, analysis of the product solids indicated that the collected solids in the outlet of the reactor were entirely zinc. The maximum methane flow rates (149–744 mL min^–1) were adjusted to ensure complete chemical conversion of methane. These adjustments were performed for different bed heights at various operating temperatures. Analysis of the product gases revealed high quality synthesis gas production without the influence of methane cracking or other undesired side reactions in the experimental tests. Finally, the governing partial differential equations of the reactor modeling were solved by the finite element method. Consequently, the gaseous profiles along the reactor and the breakthrough curves were predicted and compared with the experimental tests.