Intensification of the Sasol SPD Reactor — Realizing Potential

Abstract

Intensification of slurry phase reactors can contribute significantly to capital cost reduction in the gas-to-liquid (GTL) process. It has previously been shown that the scope exists to potentially double the volumetric conversion of Sasol’s existing G1 commercial slurry phase reactors. Tests have successfully been completed in Sasol Technology’s semicommercial pilot plant that have demonstrated +50% (G2) and +100% (G3) reactor capacities. A G2 reactor design, based on lessons learned from the G1 ORYX GTL reactor, reduction of design margins and more effective layout of reactor internals, has been completed for GTL project execution. The combined use of computer-aided design tools (CAD, CMFD, FEA, CPFD, or DEM and 3D printing) has enabled a feasible conceptual G3 reactor design to be established. Future key focus areas include not only intensification of its production capacities but also economic optimization and cost-effective manufacturing and construction strategies.

GTL using efficient cobalt Fischer-Tropsch catalysts

“…A combined use of computer aided design (CAD) tools, such as computational fluid dynamics (CFD), finite element analysis (FEA), discreet element modelling (DEM) and 3D printing, as well as SPD TM DR test work has enabled a feasible conceptual G3 reactor design to be established. By extending the knowledge base of void fraction, catalyst concentration and feed gas velocity, the SPD TM DR demonstration program has shown that a slurry bed reactor capacity of 200% of the G1 ORYX GTL reactor design is also now possible [48]. The conceptual design of a reactor supporting such capacities can be progressed through detailed design and manufacturability studies in order to support an increase in volumetric conversion efficiency in future third generation GTL projects.…”

Production of Customized Reactors by 3D Printing for Corrosive and Exothermic Reactions

“…15−18 In recent years, there have been more and more publications dealing with 3D printed reactors. 19,20 While a large fraction of the publications deals with production of reactors in polymer and as labware, some recent publications are targeting reactors made in metal that improve simultaneously the reaction conversion and/or selectivity, together with heat transfer. 21−23 In the production of fine chemicals and pharmaceutical components, it is common to use 50% or 85% solutions of sulfuric acid in water.…”

“…Additive manufacturing technologies like 3D printing can have an unprecedented effect in boosting efficiency of reactors and, in general, of chemical engineering, due to the large possibilities of customization. This technology enables the construction of a reactor that is targeted to perform a given chemistry instead of tailoring the operating conditions of a standard reactor to fit the chemistry. − In recent years, there have been more and more publications dealing with 3D printed reactors. , While a large fraction of the publications deals with production of reactors in polymer and as labware, some recent publications are targeting reactors made in metal that improve simultaneously the reaction conversion and/or selectivity, together with heat transfer. − …”

Rapid Prototyping for Photochemical Reaction Engineering

“…Especially for chemical reaction engineering the use of 3D printers opens totally new degrees of freedom for the reactor design, enabling the development of highly adapted reactors. , , , , …”