Simultaneous Increase of H2 and Gasoline Production by Optimizing Thermally Coupled Methanol Steam Reforming with Fischer-Tropsch Synthesis
Abstract
The worldwide growing of gaseous pollutions amount has attracted a great deal of attention for development of clean energy resources like hydrogen. Recently, methanol steam reforming (MSR) has been considered as an effective method for hydrogen production compared to other fuels for reforming. Indeed, advantages of methanol such as its good accessibility and properties like its low boiling point and low probability of coke formation as well as high hydrogen to carbon ratio encourage utilizing this substance in reforming process. Therefore, in this work, MSR as an endothermic reaction has been innovatively coupled with Fischer-Tropsch (FT) exothermic synthesis in order to enhance the yield of hydrogen and gasoline production. Presence of membrane in the proposed thermally coupled membrane reactor (TCMR) promotes H2 separation as the desired product. A homogeneous one-dimensional steady- state model was considered in the present work. Differential evolution (DE) optimization technique was used to optimize feed molar flow rates and inlet temperatures in both endothermic and exothermic reaction sides with the aim of maximizing gasoline and H2 yields (in both sides). Results show 42.1 % increase in gasoline yield production and simultaneously high H2 production yield of 68.5 % in exothermic side compared with the industrial FT reactor that is considered as conventional reactor (CR). Moreover, the suggested configuration can be considered as an energy and cost effective strategy as a result of supplying required energy for endothermic section by generated heat in the exothermic side.
Nomenclature
- Ac
reactor cross sectional area, m2
- Ai
inside area, m2
- Ao
outside area, m2
- Ap
perimeter area of the side, m
- Cp
specific Heat capacity of gas phase, J.mol-1.K-1
- Di
inside diameter, m
- Do
outside diameter, m
- dp
particle diameter, m
- Ei
activation energy, J.mol-1
- Fi
molar flow rate for component i, mol.s-1
- h
gas-solid heat transfer coefficient, W.m-2.K-1
- hi
heat transfer coefficient between fluid phase and reactor wall in exothermic side, W. m-2.K-1
- ho
heat transfer coefficient between fluid phase and reactor wall in endothermic side, W. m-2.K-1
- JH2
hydrogen permeation rate, mole. m-2. s-1
- ki
the pre-exponential factor, or frequency factor in the ith rate constant, mol.kg -1.s-1
- Kw
thermal conductivity of reactor wall, W.m-1.K-1
- KWGS
equilibrium constant of water gas shift reaction
- L
reactor length, m
- m
CO exponent in reaction rate equation
- Mw,i
molecular weight of component i, g. mol-1
- n
H2 exponent in reaction rate equation
- N
number of component
- P
total pressure, Pa
- PCO
CO partial pressure, kPa
- PH2
H2 partial pressure, kPa
- PH2O
H2O partial pressure, kPa
- PCO2
CO2 partial pressure, kPa
- PM
methanol partial pressure, kPa
- Q
volumetric flow rate, m3.s-1
- R
universal gas constant, J.mol-1.K-1
- Ri
reaction rate for the ith reaction
- Rp
particle radius, m
- rj
reaction rate for the jth reaction
- rM
MSR reaction rate, mol.kg-1.s-1
- RWGS
water gas shift reaction rate, mol.kg-1.s-1
- T
temperature, K
- Tref
reference temperature, K
- U
overall heat transfer coefficient between exothermic and endothermic sides, W. m-2. K-1
- yi
mole fraction of component i, mol. mol-1
- Z
axial coordinate, m
- Greek letters
- α
catalyst activity
- ΔH
heat of reaction, J.mol-1
- ΔHf,i
enthalpy of formation of component i, J.mol-1
- ε
void fraction of catalyst
- εB
void fraction of catalytic bed
- η
catalyst effectiveness factor
- μ
viscosity of gas phase, Pa.s
- μm
viscosity of mixture, Pa.s
- υij
stoichiometric coefficient of component i in the j
- ρb
bulk density of reactor, kg.m-3
- ρ
density of fluid phase, kg.m-3
- Subscript
- i
component numerator
- j
reaction number
- k
reaction side index (1: exothermic side (FTS), 2: endothermic side (MSR), 3:permeation side)
- Abbreviations
- BTL
biomass to liquid
- CR
conventional reactor
- CTL
coal to liquid
- DE
differential evolution
- FT
Fischer-Tropsch
- FTS
Fisher-Tropsch synthesis
- GTL
gas to liquid
- MSR
methanol steam reforming
- NIOC
National Iranian Oil Company
- OTCMR
optimized thermally coupled membrane reactor
- RIPI
Iranian Research Institute of Petroleum Industry
- SR
steam reforming
- TCMR
thermally coupled membrane reactor
- WGS
water gas shift
References
[1] Wang T, Wang J, Jin Y. Slurry Reactors for Gas-to-Liquid Processes: A Review. Ind Eng Chem Res. 2007;46:5824–47.10.1021/ie070330tSuche in Google Scholar
[2] Tavasoli A, Tre´Panier M, Malek Abbaslou RMK, Dalai A, Abatzoglou N. FischereTropsch synthesis on mono- and bimetallic Co and Fe catalysts supported on carbon nanotubes. Fuel Technol. 2009;90:1486–94.10.1016/j.fuproc.2009.07.007Suche in Google Scholar
[3] Dry ME. The Fischer–tropsch synthesis. Catal Sci Technol. 1981;1:159–255.10.1007/978-3-642-49988-3_4Suche in Google Scholar
[4] Bartholomew CH. Recent Developments in Fischer–tropsch catalysis. Catal Let. 1990/1991;7(1–4):303–15.10.1007/BF00764511Suche in Google Scholar
[5] Nakhaei Pour A, Housaindokht MR, Tayyari SF, Zarkesh J, Kamali Shahri SM. Water-gas-shift kinetics over a Fe/Cu/La/Si catalyst in Fischer–tropsch synthesis. Chem Eng Res Design. 2011;8(9):262–69.10.1016/j.cherd.2010.07.008Suche in Google Scholar
[6] Adib H, Haghbakhsh R, Saidi M, Takassi MA, Sharifi F, Koolivand M, et al. Modeling and optimization of Fischer–tropsch synthesis in the presence of Co (III)/Al2O3 catalyst using artificial neural networks and genetic algorithm. J Nat Gas Sci Eng. 2013;10:14–24.10.1016/j.jngse.2012.09.001Suche in Google Scholar
[7] Rahimpour MR, Mirvakili A, Paymooni K. Simultaneous hydrogen production and utilization via coupling of FischereTropsch synthesis and decalin dehydrogenation reactions in GTL technology. Int J Hydrogen Energy. 2011;3(6):2992–3006.10.1016/j.ijhydene.2010.11.099Suche in Google Scholar
[8] http://www.ripi.ir/index.php (Accessed 4 October 2017).Suche in Google Scholar
[9] Akhtar A, Pareek VK, Tade MO. Modern trends in CFD simulations: application to GTL technology. Chem Prod Modeling. 2006;2(1(1)). DOI: 10.2202/1934-2659.1000Suche in Google Scholar
[10] Eliason SA, Bartholomew CH. Reaction and deactivation kinetics for FischereTropsch synthesis on unpromoted and potassium-promoted iron catalysts. Appl Catal A Gen. 1999;186:229–43.10.1016/S0926-860X(99)00146-5Suche in Google Scholar
[11] Nowicki L, Ledakowicz SB, Bukur D. Hydrocarbon selectivity model for the slurry phase Fischer-Tropsch synthesis on precipitated iron catalysts. Chem Eng Sci. 2001;56:1175–80.10.1016/S0009-2509(00)00337-7Suche in Google Scholar
[12] Rahimpour MR, Elekaei H. A comparative study of combination of Fischer–tropsch synthesis reactors with hydrogen-permselective membrane in GTL technology. Fuel Process Technol. 2009;90:747–61.10.1016/j.fuproc.2009.02.011Suche in Google Scholar
[13] Rahimpour MR, Mirvakili A, Paymooni K. Differential evolution (DE) strategy for optimization of hydrogen production and utilization in a thermally coupled membrane reactor for decalin dehydrogenation and FischereTropsch synthesis in GTL technology. Int J Hydrogen Eenergy. 2011;3(6):4917–33.10.1016/j.ijhydene.2011.01.061Suche in Google Scholar
[14] Rahimpour MR, Mirvakili A, Paymooni K. A novel water perm-selective membrane dual-type reactor concept for FischereTropsch synthesis of GTL (gas to liquid) technology. Energy. 2011;36:1223–35.10.1016/j.energy.2010.11.023Suche in Google Scholar
[15] Rahimpour MR, Mirvakili A, Paymooni K, Moghtaderi B. A comparative study between a fluidized-bed and a fixed-bed water perm-selective membrane reactor with in situ H2O removal for FischereTropsch synthesis of GTL technology. J Nat Gas Sci Eng. 2011;3:484–95.10.1016/j.jngse.2011.05.003Suche in Google Scholar
[16] Jayhooni SMH, Mirvakili A, Rahimpour MR. Nanofluid concept for enhancement of hydrogen utilization and gasoline production in fixed bed reactor FischereTropsch synthesis of GTL (gas to liquid) technology. J Nat Gas Sci Eng. 2012;9:172–83.10.1016/j.jngse.2012.05.014Suche in Google Scholar
[17] Mazloomi K, Gomes C. Hydrogen as an energy carrier: prospects and challenges. Rene Sustain Energy Rev. 2012;16:3024–33.10.1016/j.rser.2012.02.028Suche in Google Scholar
[18] Shirasaki Y, Tsuneki T, Ota Y, Yasuda I, Tachibana S, Nakajima H,A. Development of membrane reformer system for highly efficient hydrogen production fromnatural gas. Int J Hydrogen Energy. 2009;34:4482–87.10.1016/j.ijhydene.2008.08.056Suche in Google Scholar
[19] Khademi MH, Rahimpour MR, Jahanmiri A. Differential evolution (DE) strategy for optimization of hydrogen production, cyclohexane dehydrogenation and methanol synthesis in a hydrogen-permselective membrane thermally coupled reactor. Int J Hydrogen Energy. 2010;3(5):1936 –50.10.1016/j.ijhydene.2009.12.080Suche in Google Scholar
[20] Rahimpour MR, Bayat M. Production of ultrapure hydrogen via utilizing fluidization concept from coupling of methanol and benzene synthesis in a hydrogen-permselective membrane reactor. Int J Hydrogen Energy. 2011;3(6):6616–20 .10.1016/j.ijhydene.2011.02.095Suche in Google Scholar
[21] Hodoshima S, Arai H, Saito Y. Liquid-film-type catalytic decalin dehydrogeno-aromatization for long-term storage and long-distance transportation of hydrogen. Int J Hydrogen Energy. 2003;28:197–204.10.1016/S0360-3199(02)00032-0Suche in Google Scholar
[22] Hodoshima S, Arai H, Saito Y. Catalytic decaline dehydrogenation/naphthalene hydrogenation pair as a hydrogen source for fuel-cell vehicle. Int J Hydrogen Energy. 2003;28:1255–62.10.1016/S0360-3199(02)00250-1Suche in Google Scholar
[23] Hodoshima S, Takaiwa S, Shono A, Satoh K, Saito Y. Hydrogen storage by decalin/naphthalene pair and hydrogen supply to fuel cells by use of superheated liquid-film-type catalysis. Appl Catal. 2005;283:235–42.10.1016/j.apcata.2005.01.010Suche in Google Scholar
[24] Mastalir A, Frank B, Szizybalski A, Soerijan H. Steam reforming of methanol over Cu/ZrO2/CeO2 catalysts: a kinetic study. J Catal. 2005;230:464–75.10.1016/j.jcat.2004.12.020Suche in Google Scholar
[25] Kyung Lee J, Bong Ko J, Hyun Kim D. Methanol steam reforming over Cu/ZnO/Al2O3 catalyst: kinetics and effectiveness factor. Appl Catal A Gen. 2004 ;278(1):25–35.10.1016/j.apcata.2004.09.022Suche in Google Scholar
[26] Rostrup-Nielsen JR. Conversion of hydrocarbons and alcohols for fuel cells. Phys Chem Chem Phys. 2001;3:283–88.10.1039/b004660oSuche in Google Scholar
[27] Avci AK, Oensan ZI, Trimm DL. On-board hydrogen generation for fuel cell-powered vehicles: the use of methanol and propane. Top Catal. 2003;22(3–4):359–67.10.1023/A:1023504826480Suche in Google Scholar
[28] Lindström B, Pettersson LJ. Hydrogen generation by steam reforming of methanol over copper-based catalysts for fuel cell applications. International Journal of Hydrogen Energy. 2001;26:923–3310.1016/S0360-3199(01)00034-9Suche in Google Scholar
[29] Agrell J, Boutonnet M, Fierro JLG. Production of hydrogen from methanol over binary Cu/ZnO catalysts: part II. Catalytic activity and reaction pathways. Appl Catal A Gen. 2003;253:213–23.10.1016/S0926-860X(03)00521-0Suche in Google Scholar
[30] Brown LF. A comparative study of fuels for on-board hydrogen production for fuel-cell-powered automobiles. Int J Hydrogen Energy. 2001;26:381–97.10.1016/S0360-3199(00)00092-6Suche in Google Scholar
[31] Jiang CJ, Trimm DL, Wainwright MS. Kinetic mechanism for the reaction between methanoland water over a Cu-ZnO-Al2O3 catalyst. Appl Catal A Gen. 1993;97:145–58.10.1016/0926-860X(93)80081-ZSuche in Google Scholar
[32] Agrell J, Birgersson H, Boutonnet M, Melian I. Production of hydrogen from methanol over Cu/ZnO catalysts promoted by ZrO2 and Al2O3. J Catal. 2003b;219:389–403.10.1016/S0021-9517(03)00221-5Suche in Google Scholar
[33] Agrell J, Birgersson H, Boutonnet M. Steam reforming of methanol over a Cu/ZnO/Al2O3 catalyst: a kinetic analysis and strategies for suppression of CO formation. J Power Sources. 2002;106(1–2):249–57.10.1016/S0378-7753(01)01027-8Suche in Google Scholar
[34] Önsan ZI, Trimm DL. Onboard fuel conversion for hydrogen-fuel-cell-driven vehicles. Catal Rev Sci Eng. 2001;43:31–84.10.1081/CR-100104386Suche in Google Scholar
[35] Önsan ZI. Catalytic processes for clean hydrogen production from hydrocarbons. Turkish J Chem. 2007;31:531–50.Suche in Google Scholar
[36] Fierro ML, Cubeiro JL. Selective production of hydrogen by partial oxidation of methanol over ZnO-supported palladium catalysts. J Catal. 1998;179:150–62.10.1006/jcat.1998.2184Suche in Google Scholar
[37] Amphlett JC, Mann RF, Peppley BA, Thurgood CP. A deactivation model for methanol-steam reformation on Cu/ZnO/Al2O3 catalyst for optimizing the production of fuel-cell hydrogen. Stud Surf Sci Catal. 2001;139:205–12.10.1016/S0167-2991(01)80199-3Suche in Google Scholar
[38] Suh J-S, Lee M-T, Greif R, Grigoropoulos CP. A study of steam methanol reforming in a microreactor. J Power Sources. 2007;173:458–66.10.1016/j.jpowsour.2007.04.038Suche in Google Scholar
[39] Buxbaum RE, Kinney AB. Hydrogen transport through tubular membranes of palladium-coated tantalum and niobium. Ind Eng Chem Res. 1996;35(2):530–37.10.1021/ie950105oSuche in Google Scholar
[40] Asgari A, Rahimpour MR. Modeling and simulation of ammonia removal from purge gases of ammonia plants using a catalytic Pd–ag membrane reactor. J Hazard Mater. 2008;153:557–65.10.1016/j.jhazmat.2007.08.095Suche in Google Scholar PubMed
[41] Rahimpour MR, Alizadehhesar K. Enhancement of carbon dioxide removal in a hydrogen-permselective methanol synthesis reactor. Int J Hydrogen Energy. 2009;34:1349–62.10.1016/j.ijhydene.2008.10.089Suche in Google Scholar
[42] Itoh N, Membrane Reactor A. Using Palladium. AIChE J. 1987;33:1576–78.10.1002/aic.690330921Suche in Google Scholar
[43] Rahimpour MR, Khosravanipour Mostafazadeh A, Barmaki MM. Application of hydrogen-permselective Pd-based membrane in an industrial single-type methanol reactor in the presence of catalyst deactivation. Fuel Proc Technol. 2008;8(9):1396–408 .10.1016/j.fuproc.2008.06.013Suche in Google Scholar
[44] Forghani AA, Elekaei H, Rahimpour MR. Enhancement of gasoline production in a novel hydrogen-permselective membrane reactor in Fischer–Tropsch synthesis of GTL technology. International Journal of Hydrogen Energy. 2009 5;34(9):3965–7610.1016/j.ijhydene.2009.02.038Suche in Google Scholar
[45] Rahimpour MR, Arab Aboosadi Z, Jahanmiri AH. Synthesis gas production in a novel hydrogen and oxygen perm-selective membranes tri-reformer for methanol production. J Nat Gas Sci Eng. 2012;9:149–59.10.1016/j.jngse.2012.06.007Suche in Google Scholar
[46] Wang YN, Xu YY, Xiang HW, Li YW, Zhang BJ. Modeling of catalyst pellets for Fischer-Tropsch synthesis. Ind Eng Chem Res. 2001;40:4324–35.10.1021/ie010080vSuche in Google Scholar
[47] Gallucci F, Paturzo L, Basile A. Hydrogen recovery from methanol steam reforming in a dense membrane reactor: simulation study. Ind Eng Chem Res. 2004;43:2420–32.10.1021/ie0304863Suche in Google Scholar
[48] Ergun S. Flow through packed columns. Chem Eng Progress. 1952;48:89–94.Suche in Google Scholar
[49] Perry RH, Green DW, Maloney JO. Perry’s chemical engineers’ handbook, 7th ed. United States of America: McGraw-Hill, 1997Suche in Google Scholar
[50] Smith JM. Chemical engineering kinetics. New York: McGraw-Hill; 1980.Suche in Google Scholar
[51] Graaf GH, Scholtens H, Stamhuis EJ, Beenackers AACM. Intra-particle diffusion limitations in low-pressure methanol synthesis. Chel Eng Sci. 1990;45:773–83.10.1016/0009-2509(90)85001-TSuche in Google Scholar
[52] Fogler HS. Elements of Chemical Reaction Engineering, 2nd ed. London: Prentice-Hall, 1992.Suche in Google Scholar
[53] Pandu Rangaiah G. Multiobjective optimization: techniques and applications in chemical engineering. Adv Process Sys Eng. 2008;1:29–155Suche in Google Scholar
[54] Price K, Storn R. Differential evolution e a simple evolution strategy for fast optimization. Dr Dobb’s J. 1997;78:2218–24.Suche in Google Scholar
[55] Babu BV, Angira R. Modified differential evolution (MDE) for optimization of non-linear chemical processes. Comput Chem Eng. 2006;30:989–1002.10.1016/j.compchemeng.2005.12.020Suche in Google Scholar
[56] Babu BV, Sastry KKN. Estimation of heat-transfer parameters in a trickle-bed reactor using differential evolution and orthogonal collocation. Comput Chem Eng. 1999;23:327–39.10.1016/S0098-1354(98)00277-4Suche in Google Scholar
[57] Storn R, Price K. Differential Evolution (DE). Journal of Global Optimization. 1997:341–359.10.1023/A:1008202821328Suche in Google Scholar
[58] Angira R, Babu BV. Optimization of process synthesis and design problems: A modified differential evolution approach. Chem Eng Sci. 2006;61:4707–21.10.1016/j.ces.2006.03.004Suche in Google Scholar
[59] Parvasi P, Khosravanipour Mostafazadeh A, Rahimpour MR. Dynamic modeling and optimization of a novel methanol synthesis loop with hydrogen-permselective membrane reactor. Int J Hydrogen Energy. 2009;34:3717–33.10.1016/j.ijhydene.2009.02.062Suche in Google Scholar
[60] Rahimpour MR, Iranshahi D, Bahmanpour AM. Dynamic optimization of a multi-stage spherical, radial flow reactor for the naphtha reforming process in the presence of catalyst deactivation using differential evolution (DE) method. Int J Hydrogen Energy. 2010;3(5):7498–511.10.1016/j.ijhydene.2010.04.177Suche in Google Scholar
[61] Rahimpour MR, Parvasi P, Setoodeh P. Dynamic optimization of a novel radial-flow, spherical-bed methanol synthesis reactor in the presence of catalyst deactivation using differential evolution (DE) algorithm. Int J Hydrogen Energy. 2009;34:6221–30.10.1016/j.ijhydene.2009.05.068Suche in Google Scholar
[62] Khademi MH, Setoodeh P, Rahimpour MR, Jahanmiri AH. Optimization of methanol synthesis and cyclohexane dehydrogenation in a thermally coupled reactor using differential evolution (DE) method. Int J Hydrogen Energy. 2009;34:6930–44.10.1016/j.ijhydene.2009.06.018Suche in Google Scholar
[63] Marvast A, Sohrabi M, Zarrinpashneh S, Baghmisheh GH. FischereTropsch synthesis: modeling and performance study for Fe-HZSM5 bifunctional catalyst. Chem Eng Technol. 2005;28(1):78–86.10.1002/ceat.200407013Suche in Google Scholar
© 2018 Walter de Gruyter GmbH, Berlin/Boston
Artikel in diesem Heft
- research article
- Numerical Modelling and Sensitivity Analysis of Natural Draft Cooling Towers
- Application of Central Composite Design to Optimize Culture Conditions of Chlorella vulgaris in a Batch Photobioreactor: An Efficient Modeling Approach
- A New Control Scheme for Integrating Processes with Inverse Response and Time Delay
- Simultaneous Increase of H2 and Gasoline Production by Optimizing Thermally Coupled Methanol Steam Reforming with Fischer-Tropsch Synthesis
- Fractional PID Controller Applied to a Chemical Plant with Level and pH Control
- Synthesis of Carbon Integration Networks Coupled with Hydrate Suppression and Dehydration Options
- Analysis of the Effects of Neuro-Fuzzy Control Configuration Parameters on PH Neutralization Process
- An Adaptive Fuzzy Feedforward-Feedback Control System Applied to a Saccharification Process
Artikel in diesem Heft
- research article
- Numerical Modelling and Sensitivity Analysis of Natural Draft Cooling Towers
- Application of Central Composite Design to Optimize Culture Conditions of Chlorella vulgaris in a Batch Photobioreactor: An Efficient Modeling Approach
- A New Control Scheme for Integrating Processes with Inverse Response and Time Delay
- Simultaneous Increase of H2 and Gasoline Production by Optimizing Thermally Coupled Methanol Steam Reforming with Fischer-Tropsch Synthesis
- Fractional PID Controller Applied to a Chemical Plant with Level and pH Control
- Synthesis of Carbon Integration Networks Coupled with Hydrate Suppression and Dehydration Options
- Analysis of the Effects of Neuro-Fuzzy Control Configuration Parameters on PH Neutralization Process
- An Adaptive Fuzzy Feedforward-Feedback Control System Applied to a Saccharification Process