Computational Fluid Dynamics study of the CREC Riser Simulator: Mixing patterns

Risk Minimization in Scale-Up of Biomass and Waste Carbon Upgrading Processes

Improving the odds and pace of successful biomass and waste carbon utilization technology scale-up is crucial to decarbonizing key industries such as aviation and materials within timelines required to meet global climate goals. In this perspective, we review deficiencies commonly encountered during scale-up to show that many nascent technology developers place too much focus on simply demonstrating that technologies work in progressively larger units ("profit") without expending enough up-front research effort to identify and derisk roadblocks to commercialization (collecting "information") to inform the design of these units. We combine this conclusion with economic and timeline data collected from technology scale-up and piloting operations at the National Renewable Energy Laboratory (NREL) to motivate a more scientific, risk-minimized approach to biomass and waste carbon upgrading scale-up. Our proposed approach emphasizes maximizing information collection in the smallest, most agile, and least expensive experimental setups possible, emulating the mentality embraced by R&D across the petrochemical industry. Key points are supported by examples of successful and unsuccessful scale-up efforts undertaken at NREL and elsewhere. We close by showing that the U.S. national laboratory system is uniquely well equipped to serve as a hub to facilitate effective scale-up of promising biomass and waste carbon upgrading technologies.

The CREC Fluidized Riser Simulator a Unique Tool for Catalytic Process Development

The CREC Riser Simulator is a mini-fluidized bench scale unit invented and implemented in 1992, at the CREC (Chemical Reactor Engineering Centre), University of Western Ontario The CREC Riser Simulator can be operated at short reaction times, in the 3 s to 20 s range. The present review describes and evaluates the original basic concept of the 1992-CREC Riser Simulator Unit, and the improved design of the 2019-CREC Riser Simulator. Both the initial and the enhanced units are specially engineered to allow the rigorous assessment of both catalyst performance and catalytic reaction kinetics. Kinetic parameters of relatively simple and accurate mathematical models can be calculated using experimental data from the CREC Riser Simulator. Since its inception in 1992, the CREC Riser Simulator has been licensed to and manufactured for a significant number of universities and companies around the world. Several examples of scenarios where the CREC Riser Simulator can be employed to develop fluidized bed catalytic and heterogeneous reactor simulations are reported in this review. Among others, they include (a) hydrocarbon catalytic cracking, (b) the catalytic conversion of tar derived biomass chemical species, (c) steam and dry catalytic methane reforming, (d) the catalytic oxydehydrogenation of light paraffins, (e) the catalytic desulfurization of gasoline, and (f) biomass derived syngas combustion via chemical looping. In this review, special emphasis is given to the application of the CREC Riser Simulator to TIPB (tri-iso-propyl-benzene) catalytic cracking and the light paraffins catalytic oxydehydrogenation (PODH).