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The effect of size and structural properties of Ta2O5/silica sphere was studied.
The various ETB reaction conditions for Ta2O5/silica sphere were studied.
Ta2O5/Q-6 catalyst showed good mechanical strength and catalytic performance.
Ta2O5/Q-6 catalyst tested for hydrodynamic properties in the cold-bed CFB.
a r t i c l e
i n f o
Article history:
Available online 16 October 2014
Keywords:
Ethanol to butadiene
Spherical silica
Tantalum oxide
Circulating uidized bed
a b s t r a c t
The chemical 1,3-butadiene (BD) is usually produced from ethanol and acetaldehyde (ethanol to BD, ETB)
over Ta2O5/SiO2 catalyst in xed-bed system. However, the ETB process has a short catalyst-regeneration
cycle due to rapid deactivation of the catalyst by coke. To overcome this problem, a circulating uidizedbed (CFB) reactor could be used in the ETB reaction for continuous regeneration of deactivated catalyst.
The catalyst supplied to a CFB reactor must be spherical, show good catalytic performance, and be
mechanically strong. In this study, a series of samples of Ta2O5 catalyst on silica spheres with different
pore and particle sizes, were prepared. The catalysts were examined for mechanical strength by an
attrition test and in ETB reaction in the xed-bed reactor. The Ta2O5/Q-6 catalyst, with particles size of
75150 lm, showed good mechanical strength and the best catalytic performance. This optimum spherical catalyst was tested to examine its hydrodynamic properties in a cold-bed CFB reactor.
2014 Elsevier B.V. All rights reserved.
1. Introduction
The chemical 1,3-butadiene (BD) is an important chemical
intermediate in the petroleum industry because BD is a base material used for producing commercially important synthetic rubbers
and polymers [1]. The main application of BD is in the production
of acrylonitrile butadiene styrene and styrene butadiene rubber,
which is used for manufacturing automotive tires. Due to the continuous growth of the global economy, especially in China and
India, the global automotive tire market is also expected to glow
consistently and to reach about USD 180 billion by 2017. This
potential attracts many investors and researchers to the production of BD [2]. At present, the increasing rate of demand for BD
has created a serious decit in BD production by steam cracking
Corresponding authors. Tel.: +82 42 860 7257; fax: +82 42 860 7508
(T.-W. Kim). Tel.: +82 42 860 7504; fax: +82 42 860 7508 (C.-U. Kim).
E-mail addresses: twkim@krict.re.kr (T.-W. Kim), cukim@krict.re.kr (C.-U. Kim).
http://dx.doi.org/10.1016/j.cej.2014.09.110
1385-8947/ 2014 Elsevier B.V. All rights reserved.
218
Fig. 1. CFB reactor apparatus for 1,3-butadiene production from ethanol and
acetaldehyde (1: riser, 2: stripper, 3: regenerator, 4: stripper slide valve, 5:
regenerator slide valve, 6: stripper transfer line, 7: regenerator transfer line, 8: ue
gas control valve, 9: product gas control valve, 10: regenerator air inlet, 11: feed
inlet, 12: riser nitrogen inlet, 13: stripper nitrogen inlet, 14: ue gas outlet, 15:
product gas outlet).
low attrition resistance could cause many problems in the CFB system and could eventually shut down the overall process. Therefore,
it is essential that a spherical Ta2O5/SiO2 catalyst with both good
catalytic performance and signicant mechanical strength be provided as the ETB catalyst in CFB reactors.
In this study, we report for the rst time spherical-shaped tantalumsilica based catalysts in order to apply CFB reactor for the
continuous remove of coke in ETB reaction. The catalytic performance and mechanical strength of the Ta2O5/SiO2 spherical catalysts were examined using a xed-bed reactor and an attrition
test, respectively. After selection of the optimum spherical catalyst,
having both high catalytic activity and attrition resistance, we
evaluated the hydrodynamic properties of the optimum catalyst
using a cold-bed, circulating uidized bed reactor.
2. Materials and methods
2.1. Preparation of Ta2O5 supported spherical silica catalysts
Commercial silica spheres (CARiACT Q-n, where n stands for
the pore size of the silica) were obtained from Fuji Silysia. All
Fig. 2. Nitrogen sorption isotherms and pore size distributions of the catalysts.
219
Total conversion
BD selectivity
inch stainless steel (SUS) tube reactor [7]. The reaction temperature was controlled by a type-K thermocouple (Omega) and a PID
controller. A mixture of ethanol (99.9 wt%, Samchun) and acetaldehyde (85 wt%, Aldrich) with ethanol, to provide an acetaldehyde
molar ratio of 2.5 [17,21], was fed into the catalytic reactor at
0.66 ml/h by a high-performance liquid chromatography (HPLC)
pump. The catalyst (0.25 g) was loaded in the middle of the SUS
tube. Before the reaction, the catalyst was warmed up to the
reaction temperature (350 C, heating rate = 5.0 C/min) with a
5 ml/min ow of the carrier gas (N2). The reaction was then performed with a liquid hourly space velocity (LHSV) of 1.0 h1 at
350 C. The efuent gas products were measured using a gas chromatograph (6100GC, Young Lin Instrument Co.) equipped with a
ame ionization detector (FID). Products were detected by the
C moleBD in products
100
Total C moles in products except for EtOH and AA
Table 1
Physical properties of catalysts.
a
b
c
d
e
f
Samples
Ta (wt%)a
Vt (cm3 g1)c
wavg (nm)d
wBJH (nm)e
Dbulk (g/ml)f
Ta2O5/Q-3
Ta2O5/Q-6
Ta2O5/Q-10
1.84
1.90
1.91
688
530
214
0.37
0.58
1.15
2.2
5.9
13.3
2.0
7.3
16.6
0.77
0.53
0.38
0.30
0.21
2.93
220
Fig. 3. SEM images of catalysts: (a) Ta2O5/Q-3, (b) Ta2O5/Q-5, and (c) Ta2O5/Q-10.
Fig. 4. EtOH/AA total conversion (open symbol) and BD selectivity (solid symbol) of Ta2O5/Q-n catalysts (circle: Ta2O5/Q-3, square: Ta2O5/Q-6, triangle: Ta2O5/Q-10).
Table 2
Catalytic performance of Ta2O5 supported Q-n catalysts in a xed bed reactor at 350 C, LHSV of 1 h1 at 30 h.
Sample
Ta2O5/Q-3
Ta2O5/Q-6
Ta2O5/Q-10
*
10.9
31.5
30.6
Propylene
Butene isomers
1,3-BD
Ethoxy ethane
Ethyl acetate
Crotonaldehyde
Acetic acid
Others*
4.6
2.7
1.8
1.1
1.6
1.2
0.7
1.6
1.6
47.8
72.0
70.3
4.9
0.2
2.0
3.4
0.6
2.0
18.0
0.3
6.4
0.6
6.6
3.7
19.0
14.4
11.0
Unidentied compounds mainly consisting of heavier compounds than acetic acid in GC chromatography.
221
Fig. 5. SEM images of Ta2O5/Q-6 catalysts of different particle size: (a) 75150 lm, (b) 75200 lm, (c) 200300 lm, and (d) 300500 lm.
sion of tantalum oxide within the silica [7]. The detailed product
selectivities are shown in Table 2, including unidentied compounds. These were heavy compounds and would mainly cause
deactivation of the catalyst by creation of coke. The formation of
heavy compounds was gradually reduced with increasing mesopore size of the catalysts. This indicates that a catalyst with large
mesopores forms lesser amounts of heavy compounds compared
with catalysts with small mesopores, due to better accessibility
and diffusion of the reactants and the products [7].
The optimum spherical silica-supported tantalum oxide catalyst is Ta2O5/Q-6 because Ta2O5/Q-6 showed both good catalytic
performance and good mechanical strength, which are essential
for the catalyst in a CFB reactor. To investigate the effect of the particle size of the Ta2O5/Q-6 catalyst for the ETB reaction, we prepared four Ta2O5/Q-6 samples with different particle sizes
(Fig. 5): 75150, 75200, 200300, and 300500 lm. As shown
in Fig. 6 and Table 3, the conversions of particles less than
300 lm were 30.133.4% at a reaction time of 30 h, and the BD
selectivity increased with decreasing particle size of the catalyst.
Fig. 6. EtOH/AA total conversion (open symbol) and BD selectivity (solid symbol) of
Ta2O5/Q-6 catalysts of different particle size (circle: 75150 lm, square: 75
200 lm, triangle: 200300 lm, diamond: 300500 lm).
222
Table 3
Catalytic performance of Ta2O5 supported Q-6 catalysts with different particle size in a xed bed reactor at 350 C, LHSV of 1 h1 at 30 h.
Particle size (lm)
75150
75200
200300
300500
*
33.4
30.1
31.5
24.6
Propylene
Butene isomers
1,3BD
Ethoxy ethane
Ethyl acetate
Crotonaldehyde
Acetic acid
Others*
3.2
4.0
2.7
4.0
1.7
1.7
1.6
1.5
1.7
1.7
1.6
1.6
75.2
74.6
72.0
71.0
0.3
0.2
0.2
0.9
0.5
0.6
0.6
0.8
0.3
0.2
0.3
0.2
0.4
0.3
2.6
0.3
16.8
16.8
17.4
20.0
Unidentied compounds mainly consisting of heavier compounds than acetic acid in GC chromatography.
The smallest particle size, 75150 lm, for the Ta2O5/Q-6 catalyst,
shows the best catalytic performance, while the largest particle
size, 300500 lm, displayed the lowest catalytic activity. Small
particle sizes should facilitate the diffusion of reactants and products during the catalytic reaction, which is an effect similar to that
from large mesopores as discussed above [7]. In addition, the selectivity of heavy compounds (others in Table 3) in the particle size
range 300500 lm was 20.0%, which is the largest amount among
the catalysts due to relatively hard diffusion of reactants and products from the catalyst with large particle size, compared with that
of those with small particle size.
Fig. 7. Increase of differential pressure between top and bottom of the regenerator
with an increase in the amount of catalyst in the stand pipe region of the
regenerator.
Fig. 8. Decrease in the differential pressure of the regenerator with time for degree
of opening of the slide valve in the regenerator at 10 l/min of riser gas velocity.
Fig. 9. Effect of riser gas ow rate and degree of opening of the slide valve on the
catalyst circulation rate (CCR).
Fig. 9 displayed the effect of the riser gas-ow rate and degree
of opening of the slide valve on the CCR, calculated from above the
equation. The catalyst circulated well, when the riser gas velocity
was above 0.64 m/s, which is equal to a riser gas-ow rate of
6 l/min. The catalyst ow rates gradually increased with increasing
riser gas rate, up to 10 l/min. As the degree of opening of the slide
valve increased, the circulating rate of the catalyst also increased.
From the CCR results, the operating range of the CFB reactor using
Ta2O5/Q-6 catalyst can be controlled from 2.0 to 30 kg/h.
4. Conclusions
Spherical silica supported tantalum oxide samples with different pore and particle sizes were prepared and investigated as catalysts for a cold-bed test of a CFB reactor. The catalytic
performance of these catalysts was evaluated using a xed-bed
reactor to select an optimum catalyst for the CFB reactor. The catalyst having both moderately large mesopores and high surface
area showed good attrition resistance, as well as the highest catalytic activity due to the facile diffusion of reactants and products,
and the effective dispersion of the tantalum oxide. In addition,
the smallest particle size also exhibited the best catalytic performance for the ETB reaction because of an effect similar to that from
large pore size. The optimum catalyst was Ta2O5/Q-6 with
75150 lm particle size, and it was loaded into the CFB pilot plant
for the examination of its hydrodynamic properties before the ETB
hot-bed test. From the cold-bed CFB test, it was determined that
the Ta2O5/Q-6 catalyst could be circulated at rates from 2.0 to
30 kg/h in the CFB reactor. In the future, the additional studies
are needed to perform an ETB reaction in the hot-bed CFB reactor,
and to nd optimal process conditions for maximum production of
BD in the CFB reactor.
Acknowledgment
The authors would like to acknowledge funding from the project program of Korea Research Institute of Chemical Technology
(KRICT).
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