Optimal design of a large scale Fischer-Tropsch microchannel reactor module using a cell-coupling method

Jung, Inhwa; Na, Jonggeol; Park, Seong-Ho; Jeongwoo, Jeon; Mo, Yong; Yi, Jong Yeol; Chung, Jong Tae; Han, Chonghun

doi:10.1016/j.fuproc.2016.12.004

Cited by 9 publications

(5 citation statements)

References 29 publications

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“…Furthermore, t r is much larger than t ext and t wd but close to t c , suggesting that the decision step is the catalytic reaction step. As shown in Table , wall-coating approach represents 5 times larger j H than fixed-bed; temperature along the reactor can thus be better controlled during the reaction, which is in good agreement with the literature. ,, …”

Section: Analysis Of the Mass And Heat Transfersupporting

confidence: 87%

“…As shown in Table 3, wall-coating approach represents 5 times larger j H than fixed-bed; temperature along the reactor can thus be better controlled during the reaction, which is in good agreement with the literature. 6,36,37 Apart from the heat transfer factor j H , mass transfer factor j D , and characteristic times, the pressure drop of unit length was also evaluated in this paper. The Hagen−Poiseuille equation and Kozeny−Carman model were used and the calculation formulas are as follows…”

Section: Analysis Of the Mass And Heat Transfermentioning

confidence: 99%

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Novel Cobalt Carbide Catalyst Wall-Coating Method for FeCrAlloy Microchannels Exemplified on Direct Production of Lower Olefins from Syngas

Zhang

et al. 2019

Ind. Eng. Chem. Res.

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Wall-coating is an attractive approach for immobilizing catalyst into microchannels due to potential enhancement in heat and mass transfer and a small pressure drop. A novel hybrid method was thus developed for efficiently wall-coating special cobalt carbide catalyst into FeCrAlloy microchannels on the direct production of lower olefins from syngas. The effect of pretreatment was investigated to form a uniform Al2O3 layer on the surface of FeCrAlloy substrate. The small loss of coated catalyst layer in the mechanical adherence test by exposing the FeCrAlloy substrate to a fast nitrogen flow indicated its outstanding stability in the immobilization of cobalt carbide catalyst. The coating catalyst exhibited a stable and good activity after reaching the steady state. Additionally, calculations revealed that the wall-coated and fixed-bed microreactors had comparable mass transfer factor j D, but the former provided a five times larger heat transfer factor j H and 100 times lower pressure drop per unit length, confirming in detail the advantages of wall-coating. The proposed wall-coating strategy can be applied for immobilizing other catalyst within metallic microchannels, providing a practical technical solution for industrial implementation of microreactors.

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Section: Analysis Of the Mass And Heat Transfersupporting

confidence: 87%

Section: Analysis Of the Mass And Heat Transfermentioning

confidence: 99%

Novel Cobalt Carbide Catalyst Wall-Coating Method for FeCrAlloy Microchannels Exemplified on Direct Production of Lower Olefins from Syngas

Zhang

et al. 2019

Ind. Eng. Chem. Res.

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“…Na researched the optimisation of catalyst loading in Fischer-Tropsch microchannel reactors, using the distribution of catalyst loading in microchannel reactors as a variable and considering C5+ productivity and temperature rise in microchannels as optimisation objects by using computational fluid dynamics, it was found that C5+ productivity was increased to 22% and ΔTmax was decreased to 63.2% by using a genetic algorithm (GA) [22]. Recently, Jung researched the structure optimisation of Fischer-Tropsch microchannel reactors, considering such structure parameters as the length, width, and height of microchannels in microreactor as variables, using reactor core volume and reaction temperature rise were used as optimisation objects by utilising the coupling method and artificial neural networks [23].…”

Section: Nomenclaturementioning

confidence: 99%

Methanol steam reforming performance optimisation of cylindrical microreactor for hydrogen production utilising error backpropagation and genetic algorithm

Zheng

Zhou

et al. 2019

Chemical Engineering Journal

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To optimise methanol steam reforming performance of cylindrical microreactor for hydrogen production, an error backpropagation algorithm was used to build a mathematical model for reaction performance of different microreactors for hydrogen production. Additionally, a genetic algorithm (GA) was utilised to process the computational model to obtain the optimum reaction parameters. The reliability of the optimum reaction parameters of cylindrical microreactor for hydrogen production was verified by experiments. Firstly, take plate microreactor as an example, the porosity of porous copper fiber sintered sheet (PCFSS), reaction temperature of methanol steam reforming for hydrogen production, injection velocity of the methanol and water mixture, and catalyst loading of PCFSS were considered as input data, whereas methanol conversion was used as output data. The computational model for specific testing system was gained by utilising input and output data from specific testing system to train the mathematical model for different microreactors, combining with matrix laboratory (MATLAB) neural network toolbox and designed MATLAB program. The E max of 5% for plate microreactor and E max of 3.2% for cylindrical microreactor verified the good predictive ability and reliability of the computational model for plate and cylindrical microreactor, indicating the reliability and universal applicability of the mathematical model for different microreactors. Secondly, the effects and mechanisms of PPI, reaction temperature, injection velocity, and catalyst loading on methanol conversion were studied, relying on the computational model. Finally, the optimum reaction parameters were acquired using GA, MATLAB neural network toolbox and designed MATLAB program. The validity of the optimum reaction parameters of cylindrical microreactor for hydrogen production was confirmed by experiments. This study provides a reference method for methanol steam reforming performance optimisation for hydrogen production.Highlights >Error backpropagation algorithm is used to built general mathematical model.>Computational model is established based on general mathematical model.>Computational model shows good reliability and predictive ability. >Relations between reaction parameters and performance are studied. > Optimum reaction parameters are obtained by using genetic algorithm.Graphical abstract

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“…Such methods are widely used in various physical applications, e.g., for the optimization of chemical reactions in conventional sized reactors [12][13][14], the optimization of semiconductors [15,16], glass cooling processes [17,18], or for the optimal shape design of microchannel cooling systems [19,20], aircrafts [21,22], and polymer spin packs [23,24]. The optimization of microchannel reactors has also been investigated previously using derivative-free approaches only, e.g., in [25][26][27][28]. To the best of our knowledge, the derivative-based optimization of microchannel reactors with methods from PDE-constrained optimization has not been considered in the literature so far.…”

Section: Introductionmentioning

confidence: 99%

Optimal control of the Sabatier process in microchannel reactors

2021

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We consider the optimization of a chemical microchannel reactor by means of PDE-constrained optimization techniques, using the example of the Sabatier reaction. To model the chemically reacting flow in the microchannels, we introduce a three- and a one-dimensional model. As these are given by strongly coupled and highly nonlinear systems of partial differential equations (PDEs), we present our software package cashocs which implements the adjoint approach and facilitates the numerical solution of the subsequent optimization problems. We solve a parameter identification problem numerically to determine necessary kinetic parameters for the models from experimental data given in the literature. The obtained results show excellent agreement to the measurements. Finally, we present two optimization problems for optimizing the reactor’s product yield. First, we use a tracking-type cost functional to maximize the reactant conversion, keep the flow rate of the reactor fixed, and use its wall temperature as optimization variable. Second, we consider the wall temperature and the inlet gas velocity as optimization variables, use an objective functional for maximizing the flow rate in the reactor, and ensure the quality of the product by means of a state constraint. The results obtained from solving these problems numerically show great potential for improving the design of the microreactor.

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Optimal design of a large scale Fischer-Tropsch microchannel reactor module using a cell-coupling method

Cited by 9 publications

References 29 publications

Novel Cobalt Carbide Catalyst Wall-Coating Method for FeCrAlloy Microchannels Exemplified on Direct Production of Lower Olefins from Syngas

Novel Cobalt Carbide Catalyst Wall-Coating Method for FeCrAlloy Microchannels Exemplified on Direct Production of Lower Olefins from Syngas

Methanol steam reforming performance optimisation of cylindrical microreactor for hydrogen production utilising error backpropagation and genetic algorithm

Optimal control of the Sabatier process in microchannel reactors

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