Different reactor configurations for enhancement of CO2 methanation

Greenhouse gas emissions are a massive concern for scientists to minimize the effect of global warming in the environment. In this study, packed bed, coated wall, and membrane reactors were investigated using three novel nickel catalysts for the methanation of CO2. CFD modelling methodologies were implemented to develop 2D models. The validity of the model was investigated in a previous study where experimental and simulated results in a packed bed reactor were in a good agreement. It was observed that the coated wall reactor had poorer performance compared to the packed bed, approximately 30% difference between the results, as the residence time of the former was lower. In addition, two membrane configurations were proposed, including a membrane packed bed and membrane coated wall reactor. Additional studies were performed in the coated wall reactor revealing that lower flow rates lead to higher conversion values. As for the bed thickness the optimum layer was found to be 1 mm. In both membrane reactor configurations, the effect of the thickness of M1 membrane, which indicates the membrane for the removal of H2O, didn't show difference while the reduction of the thickness of M2 membrane, which indicates the membrane for the removal of CO2, H2 and H2O, showed better results in terms of conversion.

Computational Studies on Microreactors for the Decomposition of Formic Acid for Hydrogen Production Using Heterogeneous Catalysts

Sustainable alternatives to conventional fuels have emerged recently, focusing on a hydrogen-based economy. The idea of using hydrogen (H₂) as an energy carrier is very promising due to its zero-emission properties. The present study investigates the formic acid (FA) decomposition for H₂ generation using a commercial 5 wt.% Pd/C catalyst. Three different 2D microreactor configurations (packed bed, single membrane, and double membrane) were studied using computational fluid dynamics (CFD). Parameters such as temperature, porosity, concentration, and flow rate of reactant were investigated. The packed bed configuration resulted in high conversions, but due to catalyst poisoning by carbon monoxide (CO), the catalytic activity decreased with time. For the single and double membrane microreactors, the same trends were observed, but the double membrane microreactor showed superior performance compared with the other configurations. Conversions higher than 80% were achieved, and even though deactivation decreased the conversion after 1 h of reaction, the selective removal of CO from the system with the use of membranes lead to an increase in the conversion afterwards. These results prove that the incorporation of membranes in the system for the separation of CO is improving the efficiency of the microreactor.

Lignin to value-added products: Research updates and prospects

Due to the urgent need for renewable and clean energy, the efficient use of lignin is of wide interest. A comprehensive understanding of the mechanisms of lignin depolymerization and the generation of high-value products will contribute to the global control of the formation of efficient lignin utilization. This review explores the lignin value-adding process and discusses the link between lignin functional groups and value-added products. Mechanisms and characteristics of lignin depolymerization methods are presented, and challenges and prospects for future research are highlighted.

Critical Techniques for Overcoming the Diffusion Limitations in Heterogeneously Catalytic Depolymerization of Lignin

Heterogeneously catalyzed depolymerization of lignin to value-added chemicals is increasingly attractive but highly challengeable. Particularly, the diffusion limitation of lignin macromolecule to the solid catalyst surface is a big barrier, which significantly decreases the yield of monomer while increasing char formation. Therefore, for the potential industrial utilization of lignin, new knowledge focused on the size of lignin particles is of great importance to offer guidance for promoting lignin depolymerization and suppressing condensation in the heterogeneously catalytic systems. In this Review, the size of lignin particles and macromolecules are summarized. Previous approaches for improving the mass diffusion including enhancing the solubility of lignin and exploitation of hierarchical and "solubilized" materials are also discussed. Based on these, a constructive perspective is proposed. Thus, this work provides a new insight on the rational design of heterogeneous catalytic techniques for efficient utilization of the aromatic polymer of lignin.

Numerical analysis on a catalytic pyrolysis reactor design for plastic waste upcycling using CFD modelling

Catalytic pyrolysis technologies are a current trend to address plastic waste upcycling, offering lower energy consumption and higher value products when compared to conventional thermal pyrolysis. In this study, catalytic pyrolysis of HDPE was simulated using computational fluid dynamics (CFD) in order to analyze the physical behaviour of a designed fluidized bed reactor unit on a pilot scale. Dimensionless numbers were used for heat and mass transfer assessment to provide useful insights for the scale-up of this technology. A fluidized bed reactor configuration was selected for its effective heat/mass transfer and compatibility with ZSM-5 catalyst. Calculations were performed on a set of temperatures (300–500 °C) and feed rates (0.5–1 kg m⁻² s⁻¹) to determine the best performing conditions. Tradeoffs between conversion, production rate and heat consumption were discussed. The key results of this study indicate that a feed rate of 1 kg m⁻² s⁻¹ at 500 °C yields the best gasoline production while consuming the lowest amount of energy per kilogram of product.

Catalytic pyrolysis technologies are a current trend to address plastic waste upcycling, offering lower energy consumption and higher value products when compared to conventional thermal pyrolysis.

Hydrogenation of carbon dioxide (CO2) to fuels in microreactors: a review of set-ups and value-added chemicals production

A review of CO2 hydrogenation to fuels and value-added chemicals in microreactors.

Characterization of single-phase flow hydrodynamics in a Berty reactor using computational fluid dynamics (CFD)

This work studies the flow characteristics in a Berty reactor, a gradientless reactor for kinetic studies, using three-dimensional (3D) computational fluid dynamics (CFD), and a non-ideal continuous stirred tank reactor (CSTR) model.

Theoretical Investigation of the Deactivation of Ni Supported Catalysts for the Catalytic Deoxygenation of Palm Oil for Green Diesel Production

For the first time, a fully comprehensive heterogeneous computational fluid dynamic (CFD) model has been developed to predict the selective catalytic deoxygenation of palm oil to produce green diesel over an Ni/ZrO2 catalyst. The modelling results were compared to experimental data, and a very good validation was obtained. It was found that for the Ni/ZrO2 catalyst, the paraffin conversion increased with temperature, reaching a maximum value (>95%) at 300 °C. However, temperatures greater than 300 °C resulted in a loss of conversion due to the fact of catalyst deactivation. In addition, at longer times, the model predicted that the catalyst activity would decline faster at temperatures higher than 250 °C. The CFD model was able to predict this deactivation by relating the catalytic activity with the reaction temperature.

Decomposition of Additive-Free Formic Acid Using a Pd/C Catalyst in Flow: Experimental and CFD Modelling Studies

The use of hydrogen as a renewable fuel has gained increasing attention in recent years due to its abundance and efficiency. The decomposition of formic acid for hydrogen production under mild conditions of 30 °C has been investigated using a 5 wt.% Pd/C catalyst and a fixed bed microreactor. Furthermore, a comprehensive heterogeneous computational fluid dynamic (CFD) model has been developed to validate the experimental data. The results showed a very good agreement between the CFD studies and experimental work. Catalyst reusability studies have shown that after 10 reactivation processes, the activity of the catalyst can be restored to offer the same level of activity as the fresh sample of the catalyst. The CFD model was able to simulate the catalyst deactivation based on the production of the poisoning species CO, and a sound validation was obtained with the experimental data. Further studies demonstrated that the conversion of formic acid enhances with increasing temperature and decreasing liquid flow rate. Moreover, the CFD model established that the reaction system was devoid of any internal and external mass transfer limitations. The model developed can be used to successfully predict the decomposition of formic acid in microreactors for potential fuel cell applications.

Modelling of packed bed and coated wall microreactors for methanol steam reforming for hydrogen production

A Computational Fluid Dynamics (CFD) study has been conducted to assess the performance of packed bed and coated wall microreactors for the steam reforming of methanol with a CuO/ZnO/Al₂O₃ based catalyst (BASF F3-01). The results obtained were compared to experimental data from the literature to assess the validity and robustness of the models, and a good validation has been obtained. The performance of the packed bed and coated wall microreactors is similar at a constant reforming temperature. It was found that methanol conversion is enhanced with increasing temperature, residence time, steam to methanol ratio, and catalyst coating thickness. Furthermore, internal and external mass transfer phenomena were investigated using the models, and it was found that there were no internal and external mass transfer resistances for this reactor configuration. Further studies demonstrated that larger catalyst pellet sizes led to the presence of internal mass transfer resistance, which in turn causes lower methanol conversions. The CFD models have exhibited a sound agreement with the experimental data, hence they can be used to predict the steam reforming of methanol in microreactors.

A Computational Fluid Dynamics (CFD) study has been conducted to assess the performance of packed bed and coated wall microreactors for the steam reforming of methanol with a CuO/ZnO/Al₂O₃ based catalyst (BASF F3-01).