Modeling the Drying Process of Porous Catalysts: Impact of the Pore Size Distribution

The distribution of catalytically active species in heterogeneous porous catalysts strongly influences their performance and durability in industrial reactors. A drying model for investigating this redistribution was developed and implemented using the finite volume method. This model embeds an analytical approach regarding the permeability and capillary pressure from arbitrary pore size distributions. Subsequently, a set of varying pore size distributions are investigated, and their impact on the species redistribution during drying is quantified. It was found that small amounts of large pores speed up the drying process and reduce internal pressure build up significantly while having a negligible impact on the final distribution of the catalytically active species. By further increasing the amount of large pores, the accumulation of species at the drying surface is facilitated.

Supported TiO2-ZnWO4 Photocatalytic Nanofibrous Membranes for Flow-Through and Fixed-Bed Reactors

We developed utilization models of supported electrospun TiO2-ZnWO4 photocatalytic nanofibrous membranes for air and water purifications using a noncomplex system with facile adaptation for large-scale processes. For this uniquely designed and multimode catalyst, ZnWO4 is selected for a visible light activity, while TiO2 is incorporated to enhance physical stability. Morphological structures of the TiO2-ZnWO4 membrane are characterized by scanning electron microscopy and scanning electron microscopy-energy-dispersive X-ray spectroscopy. The distinguished growth of ZnWO4 nanorods at the surface of the TiO2-ZnWO4 membrane is revealed by transmission electron microscopy (TEM). The relaxation process and charge transfer mechanism are proposed following the examination of interface and band gap (2.76 eV) between TiO2 and ZnWO4 particles via HR-TEM and UV-vis spectrophotometry. For the gas-phase reaction, a transparent photocatalytic converter is designed to support the pleated TiO2-ZnWO4 membrane for toluene decomposition under visible light. To obtain a crack-free and homogeneous fiber structure of the pleated TiO2-ZnWO4 membrane, 1 h of nanofibrous membrane fabrication via a Nanospider machine is required. On the other hand, a fiberglass-supported TiO2-ZnWO4 membrane is fabricated as a fixed-bed photocatalyst membrane for methylene blue decomposition under natural sunlight. It is observed that using the calcination temperature at 800 °C results in the formation of metal complexes between fiber glass and the TiO2-ZnWO4 membrane. The TiO2-ZnWO4 membrane successfully decomposes toluene vapor up to 40% under a continuous-flow circumstance in a borosilicate photocatalytic converter and 70% for methylene blue in solution within 3 h. Finally, the mechanically robust and supported TiO2-ZnWO4 nanofibrous membranes are proven for an alternate potential in environmental remediation.

Thermal management of natural gas production from coke oven gas by optimizing catalyst distribution and operation conditions

In this work, 3D particle-resolved CFD simulations have been performed to investigate the thermal effects of natural gas production from coke oven gas. The catalyst packing structures with uniform, gradient rise and gradient descent distribution and the operating conditions of pressure, wall temperature, inlet temperature and feed velocity are optimized for reduced hot spot temperature. The simulation results show that compared with packing structures with uniform distribution and gradient descent distribution, the gradient rise distribution could effectively reduce the hot spot temperature without affecting the reactor performance in the reactor with upflow reactants feeding, of which the reactor bed temperature rise is 37 K. Under the conditions with the pressure of 20 bar, wall temperature of 500 K, inlet temperature of 593 K, inlet flow rate of 0.04 m/s, the packing structure with gradient rise distribution exhibits the minimum reactor bed temperature rise of 19 K. By optimizing the catalyst distribution and operation conditions, the hot spot temperature of CO methanation process could be dramatically reduced by 49 K at the sacrifice of slightly reduced CO conversion.

Structured clay minerals-based nanomaterials for sustainable photo/thermal carbon dioxide conversion to cleaner fuels: A critical review

In efforts to achieve a sustainable development goal, the utilization of CO₂ to generate renewable fuels is promising, as it is a sustainable technology that provides affordable and clean energy. To realize the production of renewable green fuels, a proficient and low-cost technology is required. Using photo/thermal catalytic process, the goal of sustainable CO₂ hydrogenation can be achieved. There have been several types of catalysts under exploration, however, they are expensive with limited availability. In the current development, green materials such as mineral clays are emerging as cocatalyst/supports for CO₂ hydrogenation. Clays are bestowed with various beneficial properties such as a large surface area, high porosity, abundant basic sites, excellent thermal stability and chemical corrosion resistance. Clays are promising materials that can drastically reduce the cost in catalyst preparation, partially fulfil the energy demand and reduce greenhouse gas emission. This review aims to focus on the various types of clays and their applications in the field of photo/thermal CO₂ hydrogenation to renewable fuels. Firstly, the classifications of clays are provided, whereby they can be differentiated based on their silicate layers, namely 1:1 and 2:1 type clay and their properties are thoroughly discussed to provide advantages and applications. The applications of various clays such as kaolinite, halloysite, montmorillonite, attapulgite, saponite and volkonskoite for CO₂ hydrogenation reactions are systematically discoursed. In addition, various approaches to improve the capability of raw clays as catalyst support are critically discussed, which include thermal treatment, exfoliation, acid-leaching and pillaring approaches. A critical discussion regarding the engineering aspects to further enhance clay-based catalyst for CO₂ hydrogenation are further disclosed. In short, clays are freely available materials that can be found in abundance. However, there are many more different types of natural green clays that have not been studied and explored in various energy applications.

Numerical Simulation Study of Mixed Particle Size Calcination Processes in the Calcination Zone of a Parallel Flow Regenerative Lime Kiln

Limestone of different particle sizes is often calcined together to improve production efficiency, but the calcination effect of mixed particle size limestone is difficult to guarantee. To investigate the effect of different particle size combinations on calcination, this study uses a porous media model and a shrinking core model to simulate the calcination process for a single particle size and two mixed particle sizes in a Parallel Flow Regenerative lime kiln (PFR lime kiln). The results of the study show that an increase in void fraction has a small effect on the gas temperature. The temperature also does not change with particle sizes. At the same time, the decomposition is poor near the wall and better the closer to the center of the calcination zone. In addition, when the particle sizes differ by 2 times, the decomposition of small limestone particles had less influence, and the decomposition of large particles was also better. When the particle sizes differ by 3 times, the decomposition of both limestone sizes is more affected, especially for the larger limestone size, where only the outer surface is involved in the decomposition.

Influence of Foam Morphology on Flow and Heat Transport in a Random Packed Bed with Metallic Foam Pellets-An Investigation Using CFD

Open-cell metallic foams used as catalyst supports exhibit excellent transport properties. In this work, a unique application of metallic foam, as pelletized catalyst in a packed bed reactor, is examined. By using a wall-segment Computational Fluid Dynamics (CFD) setup, parametric analyses are carried out to investigate the influence of foam morphologies (cell size ϕ=0.45−3 mm and porosity ε=0.55−0.95) and intrinsic conductivity on flow and heat transport characteristics in a slender packed bed (N=D/dp=6.78) made of cylindrical metallic foam pellets. The transport processes have been modeled using an extended version of conventional particle-resolved CFD, i.e., flow and energy in inter-particle spaces are fully resolved, whereas the porous-media model is used for the effective transport processes inside highly-porous foam pellets. Simulation inputs include the processing parameters relevant to Steam Methane Reforming (SMR), analyzed for low (Rep~100) and high (Rep~5000) flow regimes. The effect of foam morphologies on packed beds has shown that the desired requirements contradict each other, i.e., an increase in cell size and porosity favors the reduction in pressure drop, but, it reduces the heat transfer efficiency. A design study is also conducted to find the optimum foam morphology of a cylindrical foam pellet at a higher Rep~5000, which yields ϕ = 0.45, ε = 0.8. Suitable correlations to predict the friction factor and the overall heat transfer coefficient in a foam-packed bed have been presented, which consider the effect of different foam morphologies over a range of particle Reynolds number, 100≤Rep≤5000.

Non-Idealities in Lab-Scale Kinetic Testing: A Theoretical Study of a Modular Temkin Reactor

The Temkin reactor can be applied for industrial relevant catalyst testing with unmodified catalyst particles. It was assumed in the literature that this reactor behaves as a cascade of continuously stirred tank reactors (CSTR). However, this assumption was based only on outlet gas composition or inert residence time distribution measurements. The present work theoretically investigates the catalytic CO2 methanation as a test case on different catalyst geometries, a sphere, and a ring, inside a single Temkin reaction chamber under isothermal conditions. Axial gas-phase species profiles from detailed computational fluid dynamics (CFD) are compared with a CSTR and 1D plug-flow reactor (PFR) model using a sophisticated microkinetic model. In addition, a 1D chemical reactor network (CRN) model was developed, and model parameters were adjusted based on the CFD simulations. Whereas the ideal reactor models overpredict the axial product concentrations, the CRN model results agree well with the CFD simulations, especially under low to medium flow rates. This study shows that complex flow patterns greatly influence species fields inside the Temkin reactor. Although residence time measurements suggest CSTR-like behavior, the reactive flow cannot be described by either a CSTR or PFR model but with the developed CRN model.

Development of Solid–Fluid Reaction Models—A Literature Review

A comprehensive review is carried out on the models and correlations for solid/fluid reactions that result from a complex multi-scale physicochemical process. A simulation of this process with CFD requires various complicated submodels and significant computational time, which often makes it undesirable and impractical in many industrial activities requiring a quick solution within a limited time frame, such as new product/process design, feasibility studies, and the evaluation or optimization of the existing processes, etc. In these circumstances, the existing models and correlations developed in the last few decades are of significant relevance and become a useful simulation tool. However, despite the increasing research interests in this area in the last thirty years, there is no comprehensive review available. This paper is thus motivated to review the models developed so far, as well as provide the selection guidance for model and correlations for the specific application to help engineers and researchers choose the most appropriate model for feasible solutions. Therefore, this review is also of practical relevance to professionals who need to perform engineering design or simulation work. The areas needing further development in solid–fluid reaction modelling are also identified and discussed.

State-of-the-art in methane-reforming reactor modeling: challenges and new insights

The reforming of methane is an important industrial process, and reactor modeling and simulation is frequently employed as a design and analysis tool in understanding this process. While much research work is devoted to catalyst formulations, reaction mechanisms, and reactor designs, this review aims to summarize the literature concerning the simulation of methane reforming. Applications in industrial practice are highlighted, and the three main approaches to representing the reactions are briefly discussed. An overview of simulation studies focusing on methane reforming is presented. The three central methods for fixed-bed reactor modeling are discussed. Various approaches and modern examples are discussed, presenting their modeling methods and key findings. The overall objective of this paper is to provide a dedicated review of simulation work done for methane reforming and provide a reference for understanding this field and identifying possible new paths.

Particle-Resolved Computational Fluid Dynamics as the Basis for Thermal Process Intensification of Fixed-Bed Reactors on Multiple Scales

Process intensification of catalytic fixed-bed reactors is of vital interest and can be conducted on different length scales, ranging from the molecular scale to the pellet scale to the plant scale. Particle-resolved computational fluid dynamics (CFD) is used to characterize different reactor designs regarding optimized heat transport characteristics on the pellet scale. Packings of cylinders, Raschig rings, four-hole cylinders, and spheres were investigated regarding their impact on bed morphology, fluid dynamics, and heat transport, whereby for the latter particle shape, the influence of macroscopic wall structures on the radial heat transport was also studied. Key performance indicators such as the global heat transfer coefficient and the specific pressure drop were evaluated to compare the thermal performance of the different designs. For plant-scale intensification, effective transport parameters that are needed for simplified pseudo-homogeneous two-dimensional plug flow models were determined from the CFD results, and the accuracy of the simplified modeling approach was judged.

Coupling Euler-Euler and Microkinetic Modeling for the Simulation of Fluidized Bed Reactors: an Application to the Oxidative Coupling of Methane

We propose a numerical methodology to combine detailed microkinetic modeling and Eulerian-Eulerian methods for the simulation of industrial fluidized bed reactors. An operator splitting-based approach has been applied to solve the detailed kinetics coupled with the solution of multiphase gas-solid flows. Lab and industrial reactor configurations are simulated to assess the capability and the accuracy of the method by using the oxidative coupling of methane as a showcase. A good agreement with lab-scale experimental data (deviations below 10%) is obtained. Moreover, in this specific case, the proposed framework provides a 4-fold reduction of the computational cost required to reach the steady-state when compared to the approach of linearizing the chemical source term. As a whole, the work paves the way to the incorporation of detailed kinetics in the simulation of industrial fluidized reactors.

Influence of Macroscopic Wall Structures on the Fluid Flow and Heat Transfer in Fixed Bed Reactors with Small Tube to Particle Diameter Ratio

Fixed bed reactors are widely used in the chemical, nuclear and process industry. Due to the solid particle arrangement and its resulting non-homogeneous radial void fraction distribution, the heat transfer of this reactor type is inhibited, especially for fixed bed reactors with a small tube to particle diameter ratio. This work shows that, based on three-dimensional particle-resolved discrete element method (DEM) computational fluid dynamics (CFD) simulations, it is possible to reduce the maldistribution of mono-dispersed spherical particles near the reactor wall by the use of macroscopic wall structures. As a result, the lateral convection is significantly increased leading to a better radial heat transfer. This is investigated for different macroscopic wall structures, different air flow rates (Reynolds number Re = 16 ...16,000) and a variation of tube to particle diameter ratios (2.8, 4.8, 6.8, 8.8). An increase of the radial velocity of up to 40%, a reduction of the thermal entry length of 66% and an overall heat transfer increase of up to 120% are found.

Wooden Activated Carbon Production for Dioxin Removal via a Two-Step Process of Carbonization Coupled with Steam Activation from Biomass Wastes

A two-step process of carbonization coupled with steam activation was proposed for wooden activated carbon production from four kinds of biomass waste materials. The TG-FTIR results show that the carbonization process started at around 250 °C and finished at 500 °C for the coconut shell, pinewood, and plywood. The carbonization temperature of corn straw was lower than those of the other three samples, which was attributed to the higher concentration of ash content. FTIR results for the volatile compounds during carbonization show that CH₄, CO, CO₂, and hydrocarbons are the main detected gaseous species. The CH₄ and C _m H _n yields of pinewood and plywood are higher than those of the coconut shell and corn straw. The carbonization results on the tubular furnace reactor show that furfural and phenol and its derivatives are the main tar compounds in waste carbonization. Carbonization experiments show that a temperature of 500 °C and residence time of 30 min are the optimized parameters for the three biomass wastes. The char yields are 26.4, 25.73, and 30.38% for pinewood, plywood, and coconut shell, respectively. CFD modeling has proven that using 20% of the volatiles could achieve lowest pollution and provide heat for carbonization of biomass waste. The steam activation results show that an activation temperature of 800 °C and activation time of 30 min are suitable for all three biomass samples, which could obtain optimized AC yields and adsorption quality for dioxin.

Ex situ upgrading of pyrolysis vapors over PtTiO2: extraction of apparent kinetics via hierarchical transport modeling

Chemical reaction kinetics enable predictive scaling studies and process sensitivity analyses that can substantially accelerate commercial deployment of new catalytic transformation technologies.

Enhancing the Thermal Performance of Slender Packed Beds through Internal Heat Fins

Slender packed beds are widely used in the chemical and process industry for heterogeneous catalytic reactions in tube-bundle reactors. Under safety and reaction engineering aspects, good radial heat transfer is of outstanding importance. However, because of local wall effects, the radial heat transport in the vicinity of the reactor wall is hindered. Particle-resolved computational fluid dynamics (CFD) is used to investigate the impact of internal heat fins on the near wall radial heat transport in slender packed beds filled with spherical particles. The simulation results are validated against experimental measurements in terms of particle count and pressure drop. The simulation results show that internal heat fins increase the conductive portion of the radial heat transport close to the reactor wall, leading to an overall increased thermal performance of the system. In a wide flow range (100<Rep<1000), an increase of up to 35% in wall heat transfer coefficient and almost 90% in effective radial thermal conductivity is observed, respectively.