Comprehensive Fischer–Tropsch reactor model with non-ideal plug flow and detailed reaction kinetics

This paper presents a detailed first principle Fischer–Tropsch reactor model including detailed heat transfer calculations and detailed reaction kinetics. The model is based on a large number of components and chemical reactions. The model is tuned to a fixed bed nearplug flow reactor but can also be applied to slurry and micro-channel reactors.The presented model is based on a cascade of ideally stirred reactors. This modelling approach is novel for Fischer–Tropsch reactors and has the advantage of being able to represent none-ideal reactors. Using a large number of components and reactions makes it possible to better represent the product slate than with conventional modelling based on distribution models.The results of the simulations emphasise that temperature control is important. Global conversion and product yields are dependent on operating conditions especially the temperature. The model is used to calculate the dimensions of an industrial reactor from a laboratory scale reactor.     

Modeling and optimization of industrial Fischer–Tropsch synthesis with the slurry bubble column reactor and iron-based catalyst

To optimize industrial Fischer–Tropsch(FT) synthesis with the slurry bubble column reactor(SBCR) and ironbased catalyst, a comprehensive process model for FT synthesis that includes a detailed SBCR model, gas liquid separation model, simplified CO_2 removal model and tail gas cycle model was developed. An effective iteration algorithm was proposed to solve this process model, and the model was validated by industrial demonstration experiments data(SBCR with 5.8 m diameter and 30 m height), with a maximum relative error b 10% for predicting the SBCR performances. Subsequently, the proposed model was adopted to optimize the industrial SBCR performances simultaneously considering process and reactor parameters variations. The results show that C_(5+) yield increases as catalyst loading increases within 10–70 ton and syngas H_2/CO value decreases within1.3–1.6, but it doesn't increase obviously when the catalyst loading exceeds 45 ton(about 15 wt% concentration).Higher catalyst loading will result in higher difficulty for wax/catalyst separation and higher catalyst cost. Therefore, the catalyst loading(45 ton) is recommended for the industrial demonstration SBCR operation at syngas H_2/CO = 1.3, and the C_(5+) yield is about 402 ton" per day, which has an about 16% increase than the industrial demonstration run result.     

Effect of the operation parameters on the Fischer–Tropsch synthesis in fluidized bed reactors

For the Fischer–Tropsch synthesis (FTS), this paper presents a numerical investigation in a 3D fluidized bed reactor. The effect of the operation parameters such as bed temperature, superficial gas velocities, particle size and bed heights is discussed. A 3D-CFD model coupled with FTS chemical kinetics was set up. The computational results are compared with experimental data in terms of the components production rates, etc. The analysis shows that the bed heights, the bed temperature, the superficial gas velocities and particle sizes affect the C_5 + selectivity and the reaction rates. Product yields are dependent on the operating conditions especially the temperature.     

Effect of preparation methods on the structure and catalytic performance of Fe–Zn/K catalysts for CO_2 hydrogenation to light olefins

Potassium promoted iron–zinc catalysts prepared by co-precipitation method(C–Fe–Zn/K),solvothermal method(S–Fe–Zn/K)and hydrothermal method(H–Fe–Zn/K)could selectively convert CO_2to light olefins,respectively.The physicochemical properties of the obtained catalysts were determined by SEM,N_2physisorption,XRD,H_2-TPR,CO_2-TPD and XPS measurements.The results demonstrated that preparation methods had great influences on the morphology,phase structures,reduction and adsorption behavior,and hence the catalytic performance of the catalysts.The samples prepared by hydrothermal and co-precipitation method generated small uniform particles and led to lower specific surface area.In contrast,microspheres with larger specific surface area were formed by self-assembly of nanosheets using solvothermal method.ZnFe_2O_4was the only detectable phase in the fresh C–2Fe–1Zn/K,S–3Fe–1Zn/K and S–2Fe–1Zn/K samples.ZnFe_2O_4and ZnO co-existed with increasing Zncontent in S–1Fe–1Zn/K sample,while ZnO and Fe_2O_3could be observed over H–2Fe–1Zn/K sample.All the used samples contained Fe_3O_4,ZnO and Fe_5C_2.The peak intensity of ZnO was strong in the AR-H–2Fe–1Zn/K sample while it was the lowest in the AR-C–2Fe–1Zn/K sample after reaction.The formation of ZnFe_2O_4increased the interaction between iron and zinc for C–2Fe–1Zn/K and S–Fe–Zn/K samples,causing easier reduction of Fe_2O_3to Fe_3O_4.The surface basicity of the sample prepared by co-precipitation method was much more than that of the other two methods.During CO_2hydrogenation,all the catalysts showed good activity and olefin selectivity.The CO selectivity was increased with increasing Zncontent over S–Fe–Zn/K samples.H–2Fe–1Zn/K catalyst preferred to the production of C_5~+hydrocarbons.CO_2conversion of 54.76%and C_2~=–C_4~=contents of 57.38%were obtained on C–2Fe–1Zn/K sample,respectively.     

Online measurement of solids motion in fluidized bed reactor with different distributor for Fischer–Tropsch synthesis

In this paper, the distributions of particle velocity in a gas–solid fluidized bed with branched pipe distributor or circle distributor were measured by using a laser Doppler velocimetry. Our results show that, within a certain range of superficial gas velocity, when using circle distributor, the particle velocity is large and the distribution of the particle velocity is even more compared with the branched pipe distributor. On the basis of the amplitude of tangential movement statistics, the amplitude of tangential movement statistics (AVATMS) decreases with increasing the axial height under the appropriate superficial gas velocity.     

Cobalt catalysts for Fischer–Tropsch synthesis: The effect of support,precipitant and pH value

In this report,Co-based catalysts supported on ZnO,Al_2O_3 and ZrO_2 as well as the ZrO_2 derived from different precipitants and different pH values were prepared by co-precipitation method.Their catalytic Fischer–Tropsch synthesis(FTS)performance was investigated in a fixed-bed reactor.The results revealed that Co catalyst supported on ZrO_2 exhibited better FTS catalytic performance than that supported on ZnO or Al_2O_3.For the Co/ZrO_2catalyst,different precipitants showed the following an activity order of NaOHNa_2CO_3NH_4OH,and the best pH value is 13.The catalysts were characterized by N_2adsorption–desorption,XRF,XRD,H_2-TPR,H_2-TPD and TEM.It was found that the main factor affecting the CO conversion of the catalyst was the amounts of low-temperature active adsorption sites.Moreover,the selectivity of C_5~+hydrocarbons had a positive relationship with the peak temperature of the weak hydrogen adsorption sites.The higher the peak temperature,the higher the C_5~+selectivity is.     

Effect of support and promoter on the catalytic performance and structural properties of the Fe–Co–Mn catalysts for Fischer–Tropsch synthesis

Co-precipitated Fe–Co–Mn catalysts were tested for production of light olefins via Fischer–Tropsch synthesis. The effects of different supports such as Al₂O₃, SiO₂, TiO₂ and MgO and subsequently the effect of optimum support loading and also the effect of different promoters including Li, Cs, K, Rb and Ru on the catalytic performance and structure of Fe–Co–Mn catalyst were investigated. It was found that the Fe–Co–Mn catalyst containing 10 wt% MgO has shown the better catalytic performance. Characterization of the catalyst precursors and calcined samples was carried out using XRD, SEM, EDS, BET, TPR, TGA and DSC.     

Improvement of the Fischer–Tropsch Synthesis Activity of Co/SiO2 Catalyst by the Stepwise Impregnation Method with Chelating Agents

Co/SiO₂ catalysts were prepared by a stepwise impregnation of aqueous solutions containing Co nitrate or chelating agent, nitrilotriacetic acid (NTA) or trans-1,2-diaminocyclohexane-N,N,N′,N′-tetraacetic acid (CyDTA), with various concentrations of Co²⁺ and the chelating agent. Fischer–Tropsch synthesis activity of Co/SiO₂ catalysts having Co loadings of 5–20 mass% as metallic Co was improved by the stepwise impregnation method with these chelating agents. The catalyst prepared with CyDTA (Co loading = 20 mass%, Co²⁺/CyDTA = 4 mol mol⁻¹) yielded 1,500 and 815 g kg-cat⁻¹ h⁻¹ of C₅₊ and C_10–20 hydrocarbons at 503 K and 1.1 MPa, respectively, which was much greater than that with the catalyst prepared from the aqueous solution containing both Co nitrate and NTA.     

Cobalt Particle Size Effects in the Fischer–Tropsch Synthesis and in the Hydrogenation of CO2 Studied with Nanoparticle Model Catalysts on Silica

We have investigated the effect of cobalt nanoparticle size in Fischer–Tropsch synthesis (CO/H₂) and have compared it to data obtained for carbon dioxide hydrogenation (CO₂/H₂) using model catalysts produced by colloidal methods. Both reactions demonstrated size dependence, in which we observed an increase of the turnover frequency with increasing average particle size. In both case, a maximum activity was found for cobalt particles around 10–11 nm in size. Regarding the selectivity, no size-dependent effect has been observed for the CO₂ hydrogenation, whereas CO hydrogenation selectivity depends both on the temperature and on the size of the particles. The hydrogenation of CO₂ produces mainly methane and carbon monoxide for all sizes and temperatures. The Fischer–Tropsch reaction exhibited small changes in the selectivity at low temperature (below 250 °C) while at high temperatures we observed an increase in chain growth with the increase of the size of cobalt particles. At 250 °C, large crystallites exhibit a higher selectivity to olefin than to the paraffin equivalents, indicating a decrease in the hydrogenation activity.     

Enhancing propylene production from catalytic cracking of Arabian Light VGO over novel zeolites as FCC catalyst additives

The catalytic cracking of vacuum gas oil over fluid catalytic cracking (FCC) catalyst containing novel additives was investigated to enhance propylene yield. A conventional ZSM-5, mesoporous ZSM-5 (Meso-Z), TNU-9 and SSZ-33 zeolite were tested as additives to a commercial equilibrium USY FCC catalyst (E-Cat). Their catalytic performance was assessed in a fixed-bed micro-activity test unit (MAT) at 520 °C and various catalyst/oil ratios. The cracking activity of all E-Cat/additives did not decrease by using these additives. The highest propylene yield of 12.2 wt.% was achieved over E-Cat/Meso-Z compared with 9.0 wt.% each over E-Cat/ZSM-5 and E-Cat/TNU-9, at similar gasoline yield penalty. The enhanced production of propylene over Meso-Z is attributed to its mesopores that suppressed secondary and hydrogen transfer reactions and offered easier transport and accessibility to active sites. The lower enhancement of propylene over the large-pore SSZ-33 additive was due to its high-hydrogen transfer activity. Gasoline quality was improved by the use of all additives, as octane rating increased by 7-12 numbers for all E-Cat/additives.     

不同氧化锰载体对费托钴基催化剂合成低碳烯烃的影响

制备不同的Co/MnO_x (Co/MnO、Co/MnO₂、Co/Mn₂O₃、Co/Mn₃O₄) 催化剂,并利用XRD、SEM、TEM、BET、TPR、DRIFTS、XPS表征手段分析催化剂的理化性质,比较不同氧化锰载体对催化性能的影响,考察催化剂对低碳烯烃(C₂⁼～C₄⁼)的选择性影响。结果表明催化剂Co/MnO和Co/Mn₃O₄更容易还原,并且CO的吸附量较大,有利于实现较高的CO转化率;Co/Mn₂O₃和Co/Mn₃O₄中CO桥式吸附更高,有利于生成更多的-CH₂-物种。综合考虑催化剂的活性和C₂⁼～C₄⁼选择性,Co/Mn₃O₄的费托合成(FTS)性能最好,其中C₂⁼～C₄⁼选择性为50.91%,烯烷比(O/P)为3.40。     

Fischer-Tropsch diesel production over calcium-promoted Co/alumina catalyst: Effect of reaction conditions

The effects of reaction conditions on the Fischer-Tropsch activity and product distribution of an alkali-earth metal promoted cobalt based catalyst were studied. The influence of the promoter on the reducibility and cobalt particle size was studied by different techniques, including N₂ adsorption, X-ray diffraction, temperature-programmed reduction, temperature-programmed desorption and acid-base titrations. Experiments were carried out on a bench-scale fixed bed reactor and catalysts were prepared by incipient wetness impregnation. It was observed that addition of a small amount of calcium oxide as a promoter (0.6 wt.%) improved the cobalt oxide reducibility and reduced the formation of cobalt-aluminate species. A positive correlation between basicity and particle size was observed. In terms of FTS results, CO conversion and selectivity were found to be enhanced by the addition of this promoter. It was important to note that the addition of calcium shifted the distribution to mainly C₁₆-C₁₈ hydrocarbons fraction, which could be greatly considered for a diesel formulation. Furthermore, the variation of the reaction conditions seemed to influence product distribution in a lesser extent than unpromoted catalyst. Also, a displacement of hydrocarbon distribution to higher molecular weight with decreasing space velocity and temperature was observed. Moreover, the addition of calcium to the cobalt based catalyst was found to greatly maintain selectivity to for a wide range of H₂/CO molar ratios.     

Investigation on catalytic distillation for ethyl acetate production with different catalytic packing structures

The catalytic packing is the core component of the catalytic distillation, and how the catalyst exists in the packing has significant influence on the process. To investigate the effect of catalyst packings on the catalytic distillation process, the classical ethyl acetate reactive distillation system was utilized, and a supported catalytic packing(SCP) was prepared in comparison with the conventional tea-bag catalytic packing(TBP). Laboratory scale experiments showed that the ethyl acetate conv...     

Effects of large pore zeolite additions in the catalytic pyrolysis catalyst on the light olefins production

To increase the light olefins selectivity of catalytic pyrolysis catalyst for heavy oil processing, the effects of large pore zeolite additions on the selectivity to light olefins (ethylene and propylene) were studied in a micro-activity test (MAT) unit at 625 °C by using Daqing heavy oil and n-decene/n-decane as feedstocks. Rare earth containing ultra-stable Y, Hβ and four types of alkali-treated Hβ with different pore size distributions were employed as the large pore zeolite components. The yields of C₂–C₃ light olefins showed a volcano trend with the increasing amount of large pore zeolite additions. They reached up to 24.5 and 26.7 wt%, respectively, when an optimum combination of zeolites ZSM-5 and RE-USY or ZSM-5 and alkali-treated Hβ was used. Moreover, increasing the pore size of large pore zeolites also led to the increases in the yields of light olefins, the maximum total yields of ethylene and propylene reached up to 26.7 wt% when the total pore volume of the zeolite Hβ added was 0.452 cm³ g⁻¹.     

Study on the catalytic degradation of sodium lignosulfonate to aromatic aldehydes over nano-CuO: Process optimization and reaction kinetics

As one of the few renewable aromatic resources, the research of depolymerization of lignin into high-value chemicals has attracted extensive attention in recent years. Catalytic wet aerobic oxidation (CWAO) is an effective technology to convert lignin like sodium lignosulfonate (SL), a lignin derivative, into aromatic aldehydes such as vanillin and syringaldehyde. However, how to improve the yield of aromatic aldehyde and conversion efficiency is still a challenge, and many operating conditions that significantly affect the yield of these aromatic compounds have rarely been investigated systematically. In this work, we adopted the stirred tank reactor (STR) for the CWAO process with nano-CuO as catalyst to achieve the conversion of SL into vanillin and syringaldehyde. The effect of operating conditions including reaction time, oxygen partial pressure, reaction temperature, SL concentration, rotational speed, catalyst amount, and NaOH concentration on the yield of single phenolic compound was systematically investigated. The results revealed that all these operating conditions exhibit a significant effect on the aromatic aldehyde yield. Therefore, they should be regulated in an optimal value to obtain high yield of these aldehydes. More importantly, the reaction kinetics of the lignin oxidation was explored. This work could provide basic data for the optimization and design of industrial operation of lignin oxidation.     

甲醇与C4烯烃共裂解效应和催化剂稳定性

以改性ZSM-5分子筛为催化剂,在固定床反应器上,以甲醇与C<,4>烯烃共裂解制备乙烯和丙烯.结果表明,共裂解有利于促进乙烯和丙烯的生成,对副产物甲烷和碳氧化合物的生成有明显抑制作用,C<,4>烯烃的转化得到促进,C<,5>以上烃类的含量相对增加.同时,甲醇与C<,4>烯烃共裂解时,由于吸热和放热反应能量上的互补以及C...     

Effect of normal paraffins separation from naphtha on reaction kinetics for olefins and aromatics production

The objective of this study is to investigate the effect of the normal paraffins (n-paraffins) separation by the simulated moving-bed (SMB) on reaction kinetics of the naphtha thermal cracking (NTC) and catalytic reforming (NCR) for the olefins and aromatics production, respectively. First a process simulation of the SMB unit integrated to the petrochemical complex (PCC) was performed. Chemical reaction kinetics of NTC and NCR were proposed and validated. And a retrofit PCC with the SMB unit (rPCC) was compared to a conventional PCC (cPCC) in terms of products composition, flow rate, and energy consumption. It was found that olefins and aromatics yields of NTC and NCR can increase by 14 wt% (41 kt/yr) and 11 wt% (127 kt/yr) for the naphtha capacity of 2475 kt/yr, respectively. However, the total energy consumption of rPCC increased by about 67.8 MW (or 25%) because of the desorbent recovery in the SMB unit.     

Kinetic modeling formulation of the methanol to olefin process: Parameter estimation

Detailed kinetic models at the elementary step level were developed for the methanol to olefins (MTO) process over SAPO-34 catalyst. Starting from believable mechanisms, forming primary products was modeled rigorously by the Hougen–Watson formalism. Discrimination of kinetic equations and calculation of the parameters of best fit were performed by solving the mass conservation equations of the main products of the kinetic scheme. For rate constants, preexponential factors and apparent activation energies were then calculated according to the Arrhenius equation. For thermodynamic constants, the difference between apparent activation energies of forward and reverse reaction was considered. The kinetic model fits well the experimental data, which is obtained in a fixed bed reactor. The results showed that rising space-time is favorable for olefin yields while an optimum temperature might produce the maximum olefin.     

A method to determine the relative value of the barriers of carbon chain growth and termination in Fischer-Tropsch synthesis: elementary reaction kinetics for chain growth

A method is established, by which the difference of the reaction activation barriers of carbon chain growth and termination in Fischer-Tropsch (FT) synthesis can be determined from experiments. A FT synthesis is carried out on Fe/Zn catalyst. We apply the method to analyze the experimental result and obtain the difference of reaction activation barriers of carbon chain growth and termination of -olefins on the catalyst.