Assessing the performance of an industrial SBCR for Fischer–Tropsch synthesis: Experimental and modeling

Abstract

The main objective of this study is to predict the performance of an industrial‐scale (ID = 5.8 m) slurry bubble column reactor (SBCR) operating with iron‐based catalyst for Fischer–Tropsch (FT) synthesis, with emphasis on catalyst deactivation. To achieve this objective, a comprehensive reactor model, incorporating the hydrodynamic and mass‐transfer parameters (gas holdup, εG, Sauter‐mean diameter of gas bubbles, d32, and volumetric liquid‐side mass‐transfer coefficients, kLa), and FT as well as water gas shift reaction kinetics, was developed. The hydrodynamic and mass‐transfer parameters for He/N2 gaseous mixtures, as surrogates for H2/CO, were obtained in an actual molten FT reactor wax produced from the same reactor. The data were measured in a pilot‐scale (0.29 m) SBCR under different pressures (4–31 bar), temperatures (380–500 K), superficial gas velocities (0.1–0.3 m/s), and iron‐based catalyst concentrations (0–45 wt %). The data were modeled and predictive correlations were incorporated into the reactor model. The reactor model was then used to study the effects of catalyst concentration and reactor length‐to‐diameter ratio (L/D) on the water partial pressure, which is mainly responsible for iron catalyst deactivation, the H2 and CO conversions and the C5+ product yields. The modeling results of the industrial SBCR investigated in this study showed that (1) the water partial pressure should be maintained under 3 bars to minimize deactivation of the iron‐based catalyst used; (2) the catalyst concentration has much more impact on the gas holdup and reactor performance than the reactor height; and (3) the reactor should be operated in the kinetically controlled regime with an L/D of 4.48 and a catalyst concentration of 22 wt % to maximize C5+ products yield, while minimizing the iron catalyst deactivation. Under such conditions, the H2 and CO conversions were 49.4% and 69.3%, respectively, and the C5+ products yield was 435.6 ton/day. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3838–3857, 2015

Simultaneous effect of particle size and solid concentration on the hydrodynamics of slurry bubble column reactors

“…Slurry bubble column reactors (SBCR) have widespread applications in chemical, petrochemical, biochemical, and environmental processes . Indeed, SBCR are one of the most preferred reactors to conduct a multitude of well‐known industrial applications, namely, Fischer–Tropsch synthesis (FT), catalytic chlorination of alkenes, and the hydroconversion of petroleum residues and heavy oils . They are characterized by their low maintenance and operating costs and the absence of mechanically moving parts.…”

NICE’s Indirect Coal-to-Liquid Process for Producing Clean Transportation Fuels Using Fischer-Tropsch Synthesis

“…Therefore, these parameters for He/ N 2 gaseous mixtures, as surrogates for H 2 /CO, were measured in our pilot-scale SBCR (0.3 m ID, 3 m high), operating with an actual F-T reactor wax provided by NICE under typical synthesis conditions (T = 380-550 K, P = 4-31 bar, u g = 0.1-0.3 m/s, C s = 0-45 wt%). This pilot-scale SBCR, shown in Figure 6, is available at our Reactor and Process Engineering Laboratory (RAPEL), University of Pittsburgh and additional details can be found elsewhere (Sehabiague et al, 2015). The measured hydrodynamic and mass transfer parameters were then modeled incorporated into the reactor model for F-T SBCR developed by Sehabiague and Morsi (Sehabiague et al, 2008;Sehabiague & Morsi, 2013).…”

Efficient synthesis of iron nanoparticles by self‐agglomeration in a fluidized bed

“…Iron nanoparticles (Fe NPs) have a vast range of potential applications in powder metallurgy, chemical engineering, and the biomedical and environmental industries, such as components of magnetic fluids, catalysts for the Fischer‐Tropsch synthesis and carbon nanotube growth, magnetic resonance imaging (MRI) contrast agents, nickel‐iron batteries, thermal batteries, and sorbents for environmental remediation . In recent years, Fe NPs have been considered for use as oxygen carriers (OCs) in chemical looping combustion (CLC) systems …”