Multiphase catalytic reactors: theory, design, manufacturing, and applications

398 Pages·2016·24.375 MB·English

by  Avci, Ahmet Kerim, Önsan, Zeynep Ilsen

Multiphase Catalytic Reactors

Multiphase Catalytic
Reactors
Theory, Design, Manufacturing,
and Applications
Editedby
Zeynep Ilsen Önsan
DepartmentofChemicalEngineering
BoğaziçiUniversity
Istanbul,Turkey
Ahmet Kerim Avci
DepartmentofChemicalEngineering
BoğaziçiUniversity
Istanbul,Turkey
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LibraryofCongressCataloging-in-PublicationData:
Names:Önsan,ZeynepIlsen,editor.|Avci,AhmetKerim,editor.
Title:Multiphasecatalyticreactors:theory,design,manufacturing,and
applications/editedbyZeynepIlsenÖnsan,AhmetKerimAvci.
Description:Hoboken,NewJersey:JohnWiley&SonsInc.,[2016]|Includes
bibliographicalreferencesandindex.
Identifiers:LCCN2016009674|ISBN9781118115763(cloth)|ISBN9781119248477
(epub)|ISBN9781119248460(epdf)
Subjects:LCSH:Phase-transfercatalysis.|Chemicalreactors.
Classification:LCCTP159.C3M852016|DDC660/.2832–dc23
LCrecordavailableathttps://lccn.loc.gov/2016009674
Setin9.5/12ptMinionbySPiGlobal,Pondicherry,India
PrintedintheUnitedStatesofAmerica
10 9 8 7 6 5 4 3 2 1
Contents
ListofContributors,x 2.4.3 Heatandmasstransferwithchemicalreaction,45
2.4.4 Impactofinternaltransportlimitations
Preface,xii
onkineticstudies,47
2.5 Combinationofexternalandinternaltransport
effects,48
Part1 Principlesofcatalyticreactionengineering
2.5.1 Isothermaloveralleffectiveness,48
1 Catalyticreactortypesandtheirindustrialsignificance,3 2.5.2 Nonisothermalconditions,49
ZeynepIlsenÖnsanandAhmetKerimAvci
2.6 Summary,50
1.1 Introduction,3
Nomenclature,50
1.2 Reactorswithfixedbedofcatalysts,3
Greekletters,51
1.2.1 Packed-bedreactors,3
References,51
1.2.2 Monolithreactors,8
1.2.3 Radialflowreactors,9
Part2 Two-phasecatalyticreactors
1.2.4 Trickle-bedreactors,9
1.2.5 Shortcontacttimereactors,10 3 Fixed-bedgas–solidcatalyticreactors,55
JoãoP.LopesandAlírioE.Rodrigues
1.3 Reactorswithmovingbedofcatalysts,11
1.3.1 Fluidized-bedreactors,11 3.1 Introductionandoutline,55
1.3.2 Slurryreactors,13 3.2 Modelingoffixed-bedreactors,57
1.3.3 Moving-bedreactors,14 3.2.1 Descriptionoftransport–reaction
1.4 Reactorswithoutacatalystbed,14 phenomena,57
3.2.2 Mathematicalmodel,59
1.5 Summary,16
3.2.3 Modelreductionandselection,61
References,16
3.3 Averagingoverthecatalystparticle,61
3.3.1 Chemicalregime,64
2 Microkineticanalysisofheterogeneouscatalyticsystems,17
3.3.2 Diffusionalregime,64
ZeynepIlsenÖnsan
3.4 Dominantfluid–solidmasstransfer,66
2.1 Heterogeneouscatalyticsystems,17
3.4.1 Isothermalaxialflowbed,67
2.1.1 Chemicalandphysicalcharacteristicsofsolid
3.4.2 Non-isothermalnon-adiabaticaxialflowbed,70
catalysts,18
2.1.2 Activity,selectivity,andstability,21 3.5 Dominantfluid–solidmassandheattransfer,70
2.2 Intrinsickineticsofheterogeneousreactions,22 3.6 Negligiblemassandthermaldispersion,72
2.2.1 Kineticmodelsandmechanisms,23 3.7 Conclusions,73
2.2.2 Analysisandcorrelationofratedata,27
Nomenclature,74
2.3 External(interphase)transportprocesses,32
Greekletters,75
2.3.1 Externalmasstransfer:Isothermalconditions,33
References,75
2.3.2 Externaltemperatureeffects,35
2.3.3 Nonisothermalconditions:Multiplesteady 4 Fluidized-bedcatalyticreactors,80
states,36 JohnR.Grace
2.3.4 Externaleffectivenessfactors,38
4.1 Introduction,80
2.4 Internal(intraparticle)transportprocesses,39 4.1.1 Advantagesanddisadvantages offluidized-bed
2.4.1 Intraparticlemassandheattransfer,39 reactors,80
2.4.2 Masstransferwithchemicalreaction:Isothermal 4.1.2 Preconditionsforsuccessfulfluidized-bed
effectiveness,41 processes,81
v
vi Contents
4.1.3 Industrialcatalyticprocessesemploying 5.3 Massandheattransferinthree-phasefixed-bed
fluidized-bedreactors,82 reactors,104
5.3.1 Gas–liquidmasstransfer,105
4.2 Keyhydrodynamicfeaturesofgas-fluidizedbeds,83
5.3.2 Liquid–solidmasstransfer,105
4.2.1 Minimumfluidizationvelocity,83
5.3.3 Heattransfer,106
4.2.2 Powdergroupandminimumbubbling
velocity,84 5.4 Scale-upandscale-downoftrickle-bedreactors,108
4.2.3 Flowregimesandtransitions,84 5.4.1 Scalingupoftrickle-bedreactors,108
4.2.4 Bubblingfluidizedbeds,84 5.4.2 Scalingdownoftrickle-bedreactors,109
4.2.5 Turbulentfluidizationflowregime,85 5.4.3 Salientconclusions,110
4.2.6 Fastfluidizationanddensesuspension 5.5 Trickle-bedreactor/bioreactormodeling,110
upflow,85
5.5.1 Catalytichydrodesulfurizationandbed
4.3 Keypropertiesaffectingreactorperformance,86 clogginginhydrotreatingtrickle-bed
4.3.1 Particlemixing,86 reactors,110
4.3.2 Gasmixing,87 5.5.2 Biomassaccumulationandcloggingin
4.3.3 Heattransferandtemperatureuniformity,87 trickle-bedbioreactorsforphenol
4.3.4 Masstransfer,88 biodegradation,115
4.3.5 Entrainment,88 5.5.3 Integratedaqueous-phaseglycerolreforming
4.3.6 Attrition,89 anddimethylethersynthesisintoan
4.3.7 Wear,89 allothermaldual-bedreactor,121
4.3.8 Agglomerationandfouling,89
Nomenclature,126
4.3.9 Electrostaticsandotherinterparticleforces,89
Greekletters,127
4.4 Reactormodeling,89
Subscripts,128
4.4.1 Basisforreactormodeling,89
Superscripts,128
4.4.2 Modelingofbubblingandsluggingflow
regimes,90 Abbreviations,128
4.4.3 Modelingofreactorsoperatinginhigh-velocity
References,128
flowregimes,91
4.5 Scale-up,pilottesting,andpracticalissues,91 6 Three-phaseslurryreactors,132
4.5.1 Scale-upissues,91 VivekV.Buwa,ShantanuRoyandVivekV.Ranade
4.5.2 Laboratoryandpilottesting,91
6.1 Introduction,132
4.5.3 Instrumentation,92
6.2 Reactordesign,scale-upmethodology,andreactor
4.5.4 Otherpracticalissues,92
selection,134
4.6 Concludingremarks,92
6.2.1 Practicalaspectsofreactordesignand
Nomenclature,93 scale-up,134
Greekletters,93 6.2.2 Transporteffectsatparticlelevel,139
References,93 6.3 Reactormodelsfordesignandscale-up,143
6.3.1 Lowerordermodels,143
Part3 Three-phasecatalyticreactors 6.3.2 Tank-in-series/mixingcellmodels,144
6.4 Estimationoftransportandhydrodynamic
5 Three-phasefixed-bedreactors,97
parameters,145
IonIliutaandFaïçalLarachi
6.4.1 Estimationoftransportparameters,145
5.1 Introduction,97
6.4.2 Estimationofhydrodynamicparameters,146
5.2 Hydrodynamicaspectsofthree-phasefixed-bed
6.5 Advancedcomputationalfluiddynamics
reactors,98
(CFD)-basedmodels,147
5.2.1 Generalaspects:Flowregimes,liquidholdup,
6.6 Summaryandclosingremarks,149
two-phasepressuredrop,andwettingefficiency,98
5.2.2 Standardtwo-fluidmodelsfortwo-phase Acknowledgments,152
downflowandupflowinthree-phasefixed-bed Nomenclature,152
reactors,100
Greekletters,153
5.2.3 Nonequilibriumthermomechanicalmodelsfor
Subscripts,153
two-phaseflowinthree-phasefixed-bed
reactors,102 References,153
Contents vii
7 Bioreactors,156 Greekletters,208
PedroFernandesandJoaquimM.S.Cabral Superscripts,208
7.1 Introduction,156 Subscripts,208
7.2 Basicconcepts,configurations,andmodesof References,209
operation,156
7.2.1 Basicconcepts,156 9 Microreactorsforcatalyticreactions,213
7.2.2 Reactorconfigurationsandmodesof EvgenyRebrovandSouravChatterjee
operation,157 9.1 Introduction,213
7.3 Massbalancesandreactorequations,159 9.2 Single-phasecatalyticmicroreactors,213
7.3.1 Operationwithenzymes,159 9.2.1 Residencetimedistribution,213
7.3.2 Operationwithlivingcells,160 9.2.2 Effectofflowmaldistribution,214
7.4 Immobilizedenzymesandcells,164 9.2.3 Masstransfer,215
7.4.1 Masstransfereffects,164 9.2.4 Heattransfer,215
7.4.2 Deactivationeffects,166 9.3 Multiphasemicroreactors,216
7.5 Aeration,166 9.3.1 Microstructuredpackedbeds,216
9.3.2 Microchannelreactors,218
7.6 Mixing,166
9.4 Conclusionsandoutlook,225
7.7 Heattransfer,167
Nomenclature,226
7.8 Scale-up,167
Greekletters,227
7.9 Bioreactorsforanimalcellcultures,167
Subscripts,227
7.10 Monitoringandcontrolofbioreactors,168
References,228
Nomenclature,168
Greekletters,169
Part5 Essentialtoolsofreactormodelinganddesign
Subscripts,169
10 Experimentalmethodsforthedeterminationof
References,169
parameters,233
RebeccaR.Fushimi,JohnT.GleavesandGregory
Part4 Structuredreactors S.Yablonsky
10.1 Introduction,233
8 Monolithreactors,173
JoãoP.LopesandAlírioE.Rodrigues 10.2 Considerationofkineticobjectives,234
8.1 Introduction,173 10.3 Criteriaforcollectingkineticdata,234
8.1.1 Designconcepts,174 10.4 Experimentalmethods,234
8.1.2 Applications,178 10.4.1Steady-stateflowexperiments,235
8.2 Designofwall-coatedmonolithchannels,179 10.4.2Transientflowexperiments,237
8.2.1 Flowinmonolithicchannels,179 10.4.3Surfacescienceexperiments,238
8.2.2 Masstransferandwallreaction,182 10.5 Microkineticapproachtokineticanalysis,241
8.2.3 Reactionanddiffusioninthecatalytic
10.6 TAPapproachtokineticanalysis,241
washcoat,190
10.6.1TAPexperimentdesign,242
8.2.4 Nonisothermaloperation,194
10.6.2TAPexperimentalresults,244
8.3 Mappingandevaluationofoperating
10.7 Conclusions,248
regimes,197
References,249
8.3.1 Diversityintheoperationofamonolith
reactor,197
11 Numericalsolutiontechniques,253
8.3.2 Definitionofoperatingregimes,199
AhmetKerimAvciandSedaKeskin
8.3.3 Operatingdiagramsforlinearkinetics,201
11.1 Techniquesforthenumericalsolutionofordinary
8.3.4 Influenceofnonlinearreactionkinetics,202
differentialequations,253
8.3.5 Performanceevaluation,203
11.1.1Explicittechniques,253
8.4 Three-phaseprocesses,204
11.1.2Implicittechniques,254
8.5 Conclusions,207
11.2 Techniquesforthenumericalsolutionofpartial
Nomenclature,207 differentialequations,255
viii Contents
11.3 Computationalfluiddynamicstechniques,256 13.4.2Reactorsforhydroprocessing,310
11.3.1Methodologyofcomputationalfluid 13.4.3Catalystactivationincommercial
dynamics,256 hydrotreaters,316
11.3.2Finiteelementmethod,256
13.5 Reactormodelingandsimulation,317
11.3.3Finitevolumemethod,258
13.5.1Processdescription,317
11.4 Casestudies,259 13.5.2Summaryofexperiments,317
11.4.1Indirectpartialoxidationofmethaneina 13.5.3Modelingapproach,319
catalytictubularreactor,259 13.5.4Simulationofthebench-scaleunit,320
11.4.2Hydrocarbonsteamreformingin 13.5.5Scale-upofbench-unitdata,323
spatiallysegregatedmicrochannel 13.5.6Simulationofthecommercial
reactors,261 unit,324
11.5 Summary,265 Nomenclature,326
Nomenclature,266 Greekletters,327
Greekletters,267 Subscripts,327
Subscripts/superscripts,267 Non-SIunits,327
References,267 References,327
Part6 Industrialapplicationsofmultiphasereactors 14 Catalyticreactorsforfuelprocessing,330
GuntherKolb
12 ReactorapproachesforFischer–Tropschsynthesis,271
14.1 Introduction—Thebasicreactionsoffuel
GaryJacobsandBurtronH.Davis
processing,330
12.1 Introduction,271
14.2 Theoreticalaspects,advantages,anddrawbacksof
12.2 Reactorsto1950,272
fixedbedsversusmonoliths,microreactors,and
12.3 1950–1985period,274 membranereactors,331
12.4 1985topresent,276 14.3 Reactordesignandfabrication,332
12.4.1Fixed-bedreactors,276 14.3.1Fixed-bedreactors,332
12.4.2Fluidized-bedreactors,280 14.3.2Monolithicreactors,332
12.4.3Slurrybubblecolumnreactors,281 14.3.3Microreactors,332
12.4.4Structuredpackings,286 14.3.4Membranereactors,333
12.4.5Operationatsupercriticalconditions
14.4 Reformers,333
(SCF),288
14.4.1Fixed-bedreformers,336
12.5 Thefuture?,288 14.4.2Monolithicreformers,337
References,291 14.4.3Plateheatexchangersandmicrostructured
reformers,342
13 Hydrotreatingofoilfractions,295 14.4.4Membranereformers,344
JorgeAncheyta,AntonAlvarez-Majmutovand
14.5 Water-gasshiftreactors,348
CarolinaLeyva
14.5.1Monolithicreactors,348
13.1 Introduction,295 14.5.2Plateheatexchangersandmicrostructured
13.2 TheHDTprocess,296 water-gasshiftreactors,348
13.2.1Overview,296 14.5.3Water-gasshiftinmembranereactors,350
13.2.2Roleinpetroleumrefining,297 14.6 Carbonmonoxidefinecleanup:Preferentialoxidation
13.2.3Worldoutlookandthesituationof andselectivemethanation,350
Mexico,298 14.6.1Fixed-bedreactors,352
13.3 FundamentalsofHDT,300 14.6.2Monolithicreactors,352
13.3.1Chemistry,300 14.6.3Plateheatexchangersandmicrostructured
13.3.2Reactionkinetics,303 reactors,353
13.3.3Thermodynamics,305 14.7 Examplesofcompletefuelprocessors,355
13.3.4Catalysts,306 14.7.1Monolithicfuelprocessors,355
13.4 ProcessaspectsofHDT,307 14.7.2Plateheatexchangerfuelprocessorsonthe
13.4.1Processvariables,307 meso-andmicroscale,357