Applying Reaction Kinetics to Pseudohomogeneous Methanation Modeling in Fixed‐Bed Reactors

Coffee Pulp Gasification for Syngas Obtention and Methane Production Simulation Using Ni Catalysts Supported on Al2O3 and ZrO2 in a Packed Bed Reactor

The methanation of CO2 is of great interest in power-to-gas systems and contributes to the mitigation of climate change through carbon dioxide capture and the subsequent production of high-added-value products. This study investigated CO2 methanation with three Ni catalysts supported on Al2O3 and ZrO2, which were simulated using a mathematical model of a packed bed reactor designed based on their chemical kinetics reported in the literature. The simulated reactive system was fed with syngas obtained from residual coffee pulp obtained after a solvent phytochemical extraction process under several gasification conditions. The results reflect a high degree of influence of the catalyst support, preparation method, and syngas composition on CO2 and H2 conversions and CH4 selectivity. For all the syngas compositions, the Ni/ZrO2 catalysts showed the best values for CO2 conversion and H2 conversion for the Ni/Al2O3 catalyst except in gasification at 700 °C and using the Ni/ZrO2p catalyst.

A 3D Transient CFD Simulation of a Multi-Tubular Reactor for Power to Gas Applications

A 3D stationary CFD study was conducted in our previous work, resulting in a novel reactor design methodology oriented to upgrading biogas through CO2 methanation. To enhance our design methodology incorporating relevant power to gas operational conditions, a novel transient 3D CFD modelling methodology is employed to simulate the effect of relevant dynamic disruptions on the behaviour of a tubular fixed bed reactor for biogas upgrading. Unlike 1D/2D models, this contribution implements a full 3D shell cooled methanation reactor considering real-world operational conditions. The reactor’s behaviour was analysed considering the hot-spot temperature and the outlet CH4 mole fraction as the main performance parameters. The reactor start-up and shutdown times were estimated at 330 s and 130 s, respectively. As expected, inlet feed and temperature disruptions prompted “wrong-way” behaviours. A 30 s H2 feed interruption gave rise to a transient low-temperature hot spot, which dissipated after 60 s H2 feed was resumed. A 20 K rise in the inlet temperature (523–543 K) triggered a transient low-temperature hot spot (879 to 850 K). On the contrary, a 20 K inlet temperature drop resulted in a transient high-temperature hot spot (879 to 923 K), which exposed the catalyst to its maximum operational temperature. The maximum idle time, which allowed for a warm start of the reactor, was estimated at three hours in the absence of heat sources. No significant impacts were found on the product gas quality (% CH4) under the considered disruptions. Unlike typical 1D/2D simulation works, a 3D model allowed to identify the relevant design issues like the impact of hot-spot displacement on the reactor cooling efficiency.

A CFD Design Approach for Industrial Size Tubular Reactors for SNG Production from Biogas (CO2 Methanation)

A tubular reactor based on the disk and doughnut concept was designed as an engineering solution for biogas upgrading via CO2 methanation. CFD (Computational Fluid Dynamics) benchmarks agreed well with experimental and empirical (correlation) data, giving a maximum error of 8.5% and 20% for the chemical reaction and heat transfer models, respectively. Likewise, hot spot position was accurately predicted, with a 5% error. The methodology was used to investigate the effect of two commercially available coolants (thermal oil and molten salts) on overall reactor performance through a parametric study involving four coolant flow rates. Although molten salts did show higher heat transfer coefficients at lower coolant rates, 82% superior, it also increases, by five times, the pumping power. A critical coolant flow rate (3.5 m3/h) was found, which allows both a stable thermal operation and optimum pumping energy consumption. The adopted coolant flow range remains critical to guarantee thermal design validity in correlation-based studies. Due to the disk and doughnut configuration, coolant flow remains uniform, promoting turbulence (Re ≈ 14,000 at doughnut outlet) and maximizing heat transfer at hot spot. Likewise, baffle positioning was found critical to accommodate and reduce stagnant zones, improving the heat transfer. Finally, a reactor design is presented for SNG (Synthetic Natural Gas) production from a 150 Nm3 h−1 biogas plant.