An industrial-scale catalytic reactor for ethylene production
via
the oxidative dehydrogenation of ethane (ODH-C2) over a
highly active and selective SnO2-NiO-based catalyst is
investigated using a pseudo-heterogeneous reactor model (describing
both the gas and solid phase and making use of effective kinetic and
transport coefficients). More particularly, the dominant phenomena
at the micro- and macroscale in a packed-bed reactor configuration
with a low tube-to-particle diameter ratio (d
t/d
p) are assessed. First, the
relevance of kinetics and transport phenomena on the reactor performance
is determined. The evaluation of the corresponding characteristic
times demonstrated that axial mass dispersion and axial heat transfer
conduction exert a negligible impact on the concentration and temperature
profiles obtained in the reactor. Fluid dynamics as well as radial
conductive heat transfer mechanisms, on the other hand, must be accounted
for in order to have an accurate simulation of the profiles around
the hot spot position. A sensitivity analysis allowed assessing the
impact of the operating conditions on the performance of the industrial-scale
reactor. Temperature and concentration, mainly around the hot spot,
are highly sensitive to the inlet particle Reynolds number (Rep), the coolant temperature, and the inlet concentration of
ethane and oxygen. Finally, a multi-parametric sensitivity analysis
was used to identify the safety operating window leading to the optimal
macroscopic performance of the reactor: a coolant temperature between
410 and 440 °C, an inlet concentration of ethane from 2 to 4
mol %, an inlet concentration of oxygen from 10 to 14 mol %, and a
Rep from 620 to 1000. Thus, the engineering analysis led
to the development of the most simplified yet comprehensive pseudo-heterogeneous
model with reduced computational costs, which can be used with confidence
in future studies for the industrial implementation of the ODH-C2 catalytic reaction concept.