Effect of an axial-radial plate reactor modifications on a mega methanol plant production
-
Zahra Eksiri
Abstract
Axial-radial flow plate reactors have been recently considered as efficient and practical types of reactors for methanol synthesis. Generally, an axial–radial reactor (AR) consists of two main parts namely the axial section and the radial section and the vast majority of the feed enters the radial section. Moreover, the structure of AR has a space above the axial part, which can add an adiabatic bed in the system. In this study, the performance of two novels AR configurations is investigated to improve the effectiveness of the axial–radial plate reactor. In the first configuration, the optimum length of the adiabatic bed is calculated and the adiabatic bed is located above the axial section inside the AR and is named IAAR. Therefore, in IAAR the feed of the axial section just enters the adiabatic bed and warms up. On the other configuration, the adiabatic bed with the optimum length is placed outside the reactor and is named OAAR. Therefore, in OAAR the total feed passes through the adiabatic bed, highly warms up, then cools to the optimum temperature in a heat exchanger, and finally enters AR. Two-dimensional mathematical modeling via orthogonal collocation on the finite element method is developed to compare the performance of two configurations. The results show that the maximum proportion of methanol produces in IAAR, which is approximately 3.8% higher than that produced in conventional AR due to utilizing an adiabatic bed inside the AR and superior gas distribution in the process. Momentum, mass, and heat equations are calculated and molar flow rates, mole fractions and temperatures are depicted along the radius and the length of the three configurations.
Acknowledgment
The authors would like to recognize the support of the Petrochemical Research and Technology Company.
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
Research funding: None declared.
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.
Nomenclature
- av
Specific surface area of catalyst pellet (m2 m−3)
- Acz
Axial cross section area of the element (m2)
- Cpf
Specific heat of the gas at constant pressure (J mol−1K−1)
- C
Concentration (mol/m3)
- dp
Particle diameter (m)
- Ei
activation energy for elementary reaction step i, kJ/kmol
- F
Total molar flow rate (mol s−1)
- hf
Gas-solid heat transfer coefficient (W m−2 K−1)
- kg
Mass transfer coefficient (m s−1)
- K
Conductivity of gas phase (W m−1 K−1)
- ki
reaction rate coefficient (mol kg−1 s−1 bar−1/2)
- L
Reactor length (m)
- Mi
Molecular weight of component i (g mol−1)
- P
Total pressure (for exothermic side: bar; for endothermic side: Pa)
- R
Universal gas constant (J mol−1 K−1)
- Ri
Inner radius (m)
- Ro
Outer radius (m)
- Rp
Particle radius (m)
- r
Radial direction
- z
Axial direction
reaction rate (mol kg−1 s−1)
- T
temperature (K)
- U
Overall heat transfer coefficient between exothermic and endothermic sides (W m−2 K−1)
velocity (m/s)
- Z
Compressibility factor
- Greek letters
- ∆Hi
Enthalpy of reaction
- εs
void fraction of catalyst
Porosity of bed
- μi
viscosity of fluid phase (kg m−1 s−1)
Bed density (kg m−3)
density of fluid phase (kg m−3)
density of catalyst (kg m−3)
catalyst effectiveness factor
- Superscripts
- g
In bulk gas phase
- s
At the surface of the catalyst
- Coolant
Coolant in the plates
- Subscripts
- r
Radial direction
- z
Axial direction
- j
Component number
- i
Reaction number index
References
Abashar, M., and A. Al-Rabiah. 2018. “Investigation of the Efficiency of Sorption-Enhanced Methanol Synthesis Process in Circulating Fast Fluidized Bed Reactors.” Fuel Processing Technology 179: 387–98, https://doi.org/1010.1016/j.fuproc.2018.07.028.10.1016/j.fuproc.2018.07.028Search in Google Scholar
Amirabadi, S., S. Kabiri, R. Vakili, D. Iranshahi, and M. R. Rahimpour. 2013. “Differential Evolution Strategy for Optimization of Hydrogen Production Via Coupling of Methylcyclohexane Dehydrogenation Reaction and Methanol Synthesis Process in a Thermally Coupled Double Membrane Reactor.” Industrial and Engineering Chemistry Research 52: 1508–22, https://doi.org/1010.1021/ie301583w.10.1021/ie301583wSearch in Google Scholar
Bayat, M., M. Hamidi, Z. Dehghani, M. Rahimpour, and A. Shariati. 2014. “Hydrogen/Methanol Production in a Novel Multifunctional Reactor with In Situ Adsorption: Modeling and Optimization.” International Journal of Energy Research 38: 978–94, https://doi.org/10.1002/er.3092.Search in Google Scholar
Bayat, M., and M. Rahimpour. 2013. “Production of Hydrogen and Methanol Enhancement Via a Novel Optimized Thermally Coupled Two‐membrane Reactor.” International Journal of Energy Research 37: 105–20, https://doi.org/10.1002/er.2947.Search in Google Scholar
Cui, X., and S. K. Kær. 2020. “A Comparative Study on Three Reactor Types for Methanol Synthesis from Syngas and CO2.” Chemical Engineering Journal 393: 124632, https://doi.org/10.1016/j.cej.2020.124632.Search in Google Scholar
Dwivedi, P. N., and S. Upadhyay. 1977. “Particle-Fluid Mass Transfer in Fixed and Fluidized Beds.” Industrial and Engineering Chemistry Process Design and Development 16: 157–65, https://doi.org/10.1021/i260062a001.Search in Google Scholar
Eksiri, Z., M. R. Mozdianfard, A. Mirvakili, and M. R. Rahimpour. 2020. “Two-Dimensional Modeling Investigation of the Modern Methanol Plate Reactors.” Chemical Engineering Research and Design 162: 212–27, https://doi.org/10.1016/j.cherd.2020.08.009.Search in Google Scholar
Finlayson, B. A. 2003. Nonlinear Analysis in Chemical Engineering. Bruce Alan Finlayson.Search in Google Scholar
Holman, J. 2009. Heat Transfer. New York: McGraw-Hill Education.Search in Google Scholar
Khademi, M., A. Jahanmiri, and M. Rahimpour. 2009. “A Novel Configuration for Hydrogen Production from Coupling of Methanol and Benzene Synthesis in a Hydrogen-Permselective Membrane Reactor.” International Journal of Hydrogen Energy 34: 5091–107, https://doi.org/10.1016/j.ijhydene.2009.04.007.Search in Google Scholar
Khademi, M., M. Rahimpour, and A. Jahanmiri. 2010. “Differential Evolution (DE) Strategy for Optimization of Hydrogen Production, Cyclohexane Dehydrogenation and Methanol Synthesis in a Hydrogen-Permselective Membrane Thermally Coupled Reactor.” International Journal of Hydrogen Energy 35: 1936–50, https://doi.org/10.1016/j.ijhydene.2009.12.080.Search in Google Scholar
Khanipour, M., A. Mirvakili, A. Bakhtyari, M. Farniaei, and M. R. Rahimpour. 2017. “Enhancement of Synthesis Gas and Methanol Production by Flare Gas Recovery Utilizing a Membrane Based Separation Process.” Fuel Processing Technology 166: 186–201, https://doi.org/10.1016/j.fuproc.2017.06.008.Search in Google Scholar
Kirk, R. E., D. F. Othmer, M. Grayson, and D. Eckroth. 1978. Encyclopedia of Chemical Technology, 3rd ed. Wiley‐Interscience.Search in Google Scholar
Lange, J.-P. 2001. “Methanol Synthesis: A Short Review of Technology Improvements.” Catalysis Today 64: 3–8, https://doi.org/10.1016/s0920-5861(00)00503-4.Search in Google Scholar
Manenti, F., S. Cieri, and M. Restelli. 2011. “Considerations on the Steady-State Modeling of Methanol Synthesis Fixed-Bed Reactor.” Chemical Engineering Science 66: 152–62, https://doi.org/10.1016/j.ces.2010.09.036.Search in Google Scholar
McKetta, J. J.Jr 1998. Encyclopedia of Chemical Processing and Design: Volume 64-Waste: Hazardous: Management Guide to Waste: Nuclear: Minimization During Decommissioning. Boca Raton: CRC Press.Search in Google Scholar
Meyer, J. J., P. Tan, A. Apfelbacher, R. Daschner, and A. Hornung. 2016. “Modeling of a Methanol Synthesis Reactor for Storage of Renewable Energy and Conversion of CO2–comparison of Two Kinetic Models.” Chemical Engineering & Technology 39: 233–45, https://doi.org/10.1002/ceat.201500084.Search in Google Scholar
Mirvakili, A., S. Chahibakhsh, M. Ebrahimzadehsarvestani, E. Soroush, and M. R. Rahimpour. 2019. “Modeling and Assessment of Novel Configurations to Enhance Methanol Production in Industrial Mega-Methanol Synthesis Plant.” Journal of the Taiwan Institute of Chemical Engineers 104: 40–53, https://doi.org/10.1016/j.jtice.2019.09.018.Search in Google Scholar
Mirvakili, A., and M. Rahimpour. 2015. “Mal-Distribution of Temperature in an Industrial Dual-Bed Reactor for Conversion of CO2 to Methanol.” Applied Thermal Engineering 91: 1059–70, https://doi.org/10.1016/j.applthermaleng.2015.08.067.Search in Google Scholar
Mirvakili, A., M. Rostami, K. Paymooni, M. Rahimpour, and B. Moghtaderi. 2012. “Hydrogen Looping Approach in Optimized Methanol Thermally Coupled Membrane Reactor.” International Journal of Hydrogen Energy 37: 235–49, https://doi.org/10.1016/j.ijhydene.2011.09.034.Search in Google Scholar
Nimkar, S. C., R. K. Mewada, and M. A. Rosen. 2017. “Exergy and Exergoeconomic Analyses of Thermally Coupled Reactors for Methanol Synthesis.” International Journal of Hydrogen Energy 42: 28113–27, https://doi.org/10.1016/j.ijhydene.2017.09.055.Search in Google Scholar
Panahandeh, M., J. Fathikaljahi, and M. Taheri. 2003. “Steady‐State Modeling and Simulation of an Axial‐Radial Ammonia Synthesis Reactor.” Chemical Engineering & Technology: Industrial Chemistry‐Plant Equipment‐Process Engineering‐Biotechnology 26: 666–71, https://doi.org/10.1002/ceat.200390101.Search in Google Scholar
Perry, R. H., D. O. N. W. A. Green, and J. O. H. Maloney. 1997. Perry’s Chemical Engineers’ Handbook. New York: McGraw-Hill Professional Publishing.Search in Google Scholar
Rafiee, A. 2020. “Modelling and Optimization of Methanol Synthesis from Hydrogen and CO2.” Journal of Environmental Chemical Engineering 8: 104314.10.1016/j.jece.2020.104314Search in Google Scholar
Rahmani, F., M. Haghighi, P. Estifaee, and M. R. Rahimpour. 2012. “A Comparative Study of Two Different Membranes Applied for Auto-Thermal Methanol Synthesis Process.” Journal of Natural Gas Science and Engineering 7: 60–74, https://doi.org/10.1016/j.jngse.2012.04.001.Search in Google Scholar
Rahimpour, M., and M. Lotfinejad. 2008. “A Comparison of Auto-Thermal and Conventional Methanol Synthesis Reactor in the Presence of Catalyst Deactivation.” Chemical Engineering and Processing: Process Intensification 47: 2121–30, https://doi.org/10.1016/j.cep.2007.10.024.Search in Google Scholar
Redondo, B., M. T. Shah, V. K. Pareek, and R. P. Utikar. 2019. “Intensified Isothermal Reactor for Methanol Synthesis.” Chemical Engineering and Processing - Process Intensification 143: 107606, https://doi.org/10.1016/j.cep.2019.107606.Search in Google Scholar
Rezaie, N., A. Jahanmiri, B. Moghtaderi, and M. Rahimpour. 2005. “A Comparison of Homogeneous and Heterogeneous Dynamic Models for Industrial Methanol Reactors in the Presence of Catalyst Deactivation.” Chemical Engineering and Processing: Process Intensification 44: 911–21, https://doi.org/10.1016/j.cep.2004.10.004.Search in Google Scholar
Samimi, F., M. Feilizadeh, M. Ranjbaran, M. Arjmand, and M. R. Rahimpour. 2018. “Phase Stability Analysis on Green Methanol Synthesis Process from CO2 Hydrogenation in Water Cooled, Gas Cooled and Double Cooled Tubular Reactors.” Fuel Processing Technology 181: 375–87, https://doi.org/10.1016/j.fuproc.2018.10.004.Search in Google Scholar
Skrzypek, J., M. Lachowska, and H. Moroz. 1991. “Kinetics of Methanol Synthesis Over Commercial Copper/Zinc Oxide/Alumina Catalysts.” Chemical Engineering Science 46: 2809–13, https://doi.org/10.1016/0009-2509(91)85150-v.Search in Google Scholar
Thirabunjongcharoen, S., P. Bumroongsakulsawat, P. Praserthdam, S. Charojrochkul, S. Assabumrungrat, and P. Kim-Lohsoontorn. 2020. “Thermally Double Coupled Reactor Coupling Aqueous Phase Glycerol Reforming and Methanol Synthesis.” Catalysis Today.10.1016/j.cattod.2020.03.043Search in Google Scholar
Tijm, P., F. Waller, and D. Brown. 2001. “Methanol Technology Developments for the New Millennium.” Applied Catalysis A: General 221: 275–82, https://doi.org/10.1016/s0926-860x(01)00805-5.Search in Google Scholar
Yaws, C. L. 2009. Transport Properties of Chemicals And Hydrocarbons: Viscosity, Thermal Conductivity, and Diffusivity of C1 to C100 Organics And Ac to Zr Inorganics. New York: William Andrew.Search in Google Scholar
Supplementary Material
The online version of this article offers supplementary material (https://doi.org/10.1515/ijcre-2020-0195).
© 2021 Walter de Gruyter GmbH, Berlin/Boston
Articles in the same Issue
- Frontmatter
- Articles
- Effect of an axial-radial plate reactor modifications on a mega methanol plant production
- Numerical simulation of three-dimensional passive micromixer based on the principle of Koch fractal
- Development of activated carbon from sawdust by pyrolysis and methylene blue adsorption
- Multistep concentration of lizardite/antigorite from chrysotile mine tailings – case of the Carey Mine site in East-Broughton (Québec)
- CFD-based structure optimization of plate bundle in plate-fin heat exchanger considering flow and heat transfer performance
- A numerical study on combined baffles quick-separation device
- Decolorization and mineralization of diazo dye under artificial and solar light assisted Fenton and photo-Fenton conditions
- Selective catalytic reduction of NO by Co-Mn based nanocatalysts
- Friedel-Crafts alkylation of benzene with benzyl alcohol over H-MCM-22
Articles in the same Issue
- Frontmatter
- Articles
- Effect of an axial-radial plate reactor modifications on a mega methanol plant production
- Numerical simulation of three-dimensional passive micromixer based on the principle of Koch fractal
- Development of activated carbon from sawdust by pyrolysis and methylene blue adsorption
- Multistep concentration of lizardite/antigorite from chrysotile mine tailings – case of the Carey Mine site in East-Broughton (Québec)
- CFD-based structure optimization of plate bundle in plate-fin heat exchanger considering flow and heat transfer performance
- A numerical study on combined baffles quick-separation device
- Decolorization and mineralization of diazo dye under artificial and solar light assisted Fenton and photo-Fenton conditions
- Selective catalytic reduction of NO by Co-Mn based nanocatalysts
- Friedel-Crafts alkylation of benzene with benzyl alcohol over H-MCM-22
