Role of catalyst topology in methanol synthesis

Abstract

Methanol synthesis is carried out in a catalytic, packed bed reactor, where the shape and size of catalyst play a critical role in dictating overall reactor performance. In the current study, the effect of five different catalyst shapes including cylindrical, ring, trilobe, wagon wheel, and spherical on the reactor performance was investigated by conducting particle‐scale computational fluid dynamics (CFD) simulations. The predictions of pressure drop, velocity, temperature, reactant distribution and product yield were analyzed. When the performance of the simulated shapes was compared at the same tube Reynolds number of 50,000, internally contoured shapes (wagon wheel and ring) resulted in 40% higher pressure drops due to the tortuous flow path. However, the shape with internal void provided access for the reactant to reach the internal part of catalyst, resulting in higher yield produced per volume of catalyst. The wagon wheel shape produced 15% and 5% more yield per volume against the cylindrical shape and trilobe, respectively. The performance of the wagon wheel can be attributed to the lower diffusion limitation due to higher surface area available for reactant to penetrate the internal part of the catalyst.