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Abstract
As syngas to dimethyl ether (DME) reaction is highly exothermic and the catalyst temperature window is very narrow, fluidized-bed
reactor is an ideal candidate as it is highly effective both in heat and mass transfer. In this paper, a new mechanism and kinetics model
for DME synthesis are established and a laboratory fluidized-bed reactor is set up. Experiments are carried out to assess the performance
of DME synthesis in this reactor. The experimental results show that CO conversion and DME productivity are higher than those of fixed
bed or slurry reactor. Two two-phase models are used to simulate DME synthesis in the lab fluidized-bed reactor with the bubble phase
assumed to be in plug flow, and the dense phase in plug flow (P–P model) and in fully back-mixed flow (P–M model). Comparison
between calculated and experimental results shows P–M is more valid than P–P model, and then influences of different parameters on
reactor performance are investigated based on P–M model.
䉷 2004 Elsevier Ltd. All rights reserved.
1. Introduction exist any problem for the storage, transportation and usage
of DME.
Dimethyl ether (DME), as a multi-source, multi-purpose At present, DME is commercially prepared by dehydra-
product, has received growing attention considering global tion of methanol using acidic porous catalysts such as zeo-
environment pollution and energy supply problem today. lites, silica–alumina, alumina, etc. It has been reported that
DME can be produced from syngas, which is from natu- using syngas as a starting material, DME can be prepared in
ral gas, coal or biomass. DME has wide applications, such a one-step process, which is more thermodynamically and
as LPG substitute, transportation fuel, propellant, chemical economically favorable than the two-step process of syngas
feedstock and fuel cell fuel (Ng et al., 1999). to methanol and further to DME.
Been identified as a potential diesel and cooking fuel, Three reactions take place in the syngas-to-DME process,
DME has many excellent characteristics. It has an oxygen namely,
concentration of 34.78% and can be burned without soot
Methanol synthesis reaction
emission, while for traditional diesel fuels, one cannot expect
simultaneous NOx and soot emission control target. It has a CO2 + 3H2 ⇔ CH3 OH + H2 O
boiling point of −25 ◦ C, which is 20 ◦ C higher than LPG and H = −56.33 kJ/mol (1)
can be liquidized at 0.54 MPa (20 ◦ C). Therefore, based on
the matured technology of LPG application, there does not Methanol dehydration reaction
0009-2509/$ - see front matter 䉷 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ces.2004.07.031
5456 W.-Z. Lu et al. / Chemical Engineering Science 59 (2004) 5455 – 5464
XCO(%)
3CO + 3H2 ⇔ CH3 OCH3 + CO2
50
H = −256.615 kJ/mol (4)
40
Reactions (1) and (3) are catalyzed by a methanol synthe- 30
sis catalyst (Cu/ZnO/Al2 O3 ) and Reaction (2) by an acidic 20
catalyst (e.g. HZSM-5). These three reactions form a syn-
10
ergistic system yielding higher syngas conversion or greater
productivity when compared to the syngas-to-methanol pro- 0
4 5 6
cess. The synergy works in the following manner: methanol,
Cu-ZnO-Al2O3 : HZSM-5(wt)
which would otherwise be near its equilibrium value, is con-
sumed by Reaction (2), and water formed by Reactions (2)
Fig. 1. Activity of Cu–ZnO–Al2 O3 /HZSM-5 catalyst P = 3 MPa,
and (1) is consumed by Reaction (3), while Reaction (3) H2 /CO = 1, SV = 3000 ml/g/h.
generates hydrogen which improves Reaction (1).
All the three reactions are reversible and exothermic.
Moreover, the catalyst for Reactions (1) and (3) is subject
to severe deactivation when overheated to above 270 ◦ C. To in a fixed bed or slurry reactor. Then a two-phase model is
avoid thermodynamic limitations and excessive catalyst de- used to simulate DME synthesis in a fluidized-bed reactor,
activation, conventional gas-phase reactors must be operated and simulation results are compared with those from exper-
at a low per-pass conversion to maintain reactor temperature iments. Finally, the influences of different factors, such as
below 270 ◦ C, implementing a high-syngas recycle rate, and pressure, temperature, H2 /CO ratio in feed gas and space
resulting in large capital investments and operating costs. In velocity are simulated and analyzed.
addition, in order to avoid serious pressure drop, the diam-
eter of catalyst particles in fixed-bed reactor is usually over
4 mm, which brings a certain inner mass-transfer resistance.
Manufacture of DME in one step in slurry reactor was 2. Catalyst and kinetics
proposed by Air Product and Chemicals, Inc. (Brown et al.,
1991). This kind of reactor can provide not only an efficient The selected catalyst is Cu–ZnO–Al2 O3 /HZSM-5, man-
heat management, but also a very high mass-transfer resis- ufactured by co-precipitation deposition method with the
tance, as an extra liquid phase is added. This is demonstrated component for methanol synthesis, Cu–ZnO–Al2 O3 , and
by the experimental results reported by Du et al. (1993) that for methanol dehydration, HZSM-5. Fig. 1 shows the
and Guo et al. (2000), where the apparent activity energies activity of Cu–ZnO–Al2 O3 /HZSM-5 at different tempera-
of methanol synthesis by CO hydrogenation and methanol tures in a lab fixed-bed reactor. The optimum ratio of the
dehydration reactions have been determined as 102.4 and two components is about 5.0 for Cu–ZnO–Al2 O3 /HZSM-5
99.8 kJ/mol in a gas-phase fixed-bed reactor, and as 14.1 catalyst.
and 23.5 kJ/mol in a slurry reactor, respectively, thus im- According to the recent analytical results by XPS and
plying a considerable inter-phase mass-transfer resistance. XAES method (Li, 2004), the main active center for
The fluidized-bed reactor is proposed as an ideal reactor methanol synthesis on this catalyst is Cu(0), which was
for the DME synthesis (Xiao and Lu, 2002). Compared with proposed to be Cu clusters (Nakatsuji and Hu, 2000),
the slurry reactor and fixed-bed reactor, the gas–solid mass- but not Cu atom. The key intermediate of the methanol
transfer resistance in a fluidized-bed reactor is so small that synthesis, which is formed from the CO2 and Cu–Cu clus-
it can be neglected, and excellent temperature control is also ters, is supposed to be the ring-type ester. This kind of
achievable due to the vigorous mixing of catalyst particles ester also has the structure of two C–O bonds observed
in the bed. Simulation of fluidized-bed reactor for DME by others (Neophytides et al., 1992), and can be hydro-
synthesis has been performed by Lu et al. (2003) using P–P genated more easily than formate species, although formate
model, which shows the great advantage of fluidized-bed is usually assumed to be the key intermediate (Bussche
over fixed-bed or slurry reactor. and Froment, 1996). Water gas shift reaction also takes
In this paper, a laboratory fluidized-bed reactor, 0.026 m place on Cu clusters and it proceeds through two steps:
in diameter and 2 m high, is established. Experiments are H2 O dehydrogenation to provide adsorbed O and CO2
carried out to assess the performance of DME synthesis in formed by the quick reaction of CO with adsorbed O (Sun
the fluidized-bed reactor, and results show that CO conver- et al., 1998). Thus the reaction mechanisms for CO2 hy-
sion and DME productivity are better compared with those drogenation to methanol and water gas shift reaction are as
W.-Z. Lu et al. / Chemical Engineering Science 59 (2004) 5455 – 5464 5457
Filter
The two-phase model, representing the bubble phase and
H2
the surrounding dense phase, has proved to be the most suit-
FIC able model for the fluidized-bed reactor modeling (Werther,
1980), and the details of this model can be found in Kunii
PIC
CO
et al. (1991) with the hydrodynamic and transport property
To
correlations listed in Table 1. It postulates that the gas in
FIC vent excess of that necessary for the catalyst particles to fluidize
passes through the bed in the form of bubbles.
CO2 GC
The assumption of plug flow in the bubble phase is usu-
ally valid, but it becomes very doubtful whether the dense
TC1-
phase should be modeled as being fully back-mixed (P–M
FIC 4 model) or in plug flow (P–P model). Wagialla et al. (1991)
To
vent adopted P–M model for the simulation of methanol synthe-
N2
sis, but Fernandes and Lona (2001) adopted P–P model for
the simulation of polyethylene production.
Fig. 2. Schematic view of the fluidized-bed reactor system. Kunii and Levenspiel (1969, 1991) conclude that the in-
crease of the ratio of bed height-to-diameter (Lf /dt ), espe-
ln KP ,2 =4019/T + 3.707 ln T − 2.783 × 10−3 T cially over 10, leads to plug flow in dense phase, and that
there is also a general principle to judge the flow type in
+3.8 × 10−7 T 2 − 6.561 × 104 /T 3 − 26.64,
dense phase: if u0 /umf > 3–11, the reverse flow of gas in
(18) dense phase may happen, because the increase of gas ve-
locity leads to more back-mixing of solid particles in dense
log KP ,3 =2167/T − 0.5194 log T + 1.037 × 10−3 T phase. In this paper, u0 /umf is between 2 and 8 under typical
−2.331 × 10−7 T 2 − 1.2777. (19) conditions, and the ratio of bed height to diameter (Lf /dt )
equals to about 40. Thus it seems that the assumption of
flow type in dense phase should be determined by the com-
3. Experimental parison of simulation with experimental results.
Table 1
Hydrodynamic and transport property correlations
0.029 0.021
f
Bed voidage at minimum fluidization mf = 0.586 1.0
Ar ,
p
where
dp3
Ar = f (p − f ) g —
2
f
f
Superficialvelocity at minimum fluidization umf = f dp
25.252 + 0.0651Ar − 25.25
Bubble diameter dB = dBM − (dBM − dBO ) exp −0.3zdt
where
0.4
dBM = 0.652 A u0 − umf ,
0.4
dBo = 0.347 An u0 − umf ,
An = 7.85 × 10−5
Bubble rising velocity ub = u0 − umf + 0.711(gd B )0.5
Volume fraction of bubble phase to overall bed = Qb /ub /A
Dense-phase volumetric flow rate Qd = umf A
Bubble-phase volumetric flow rate Qb = (u0 − umf )A0
Expanded bed height H = Hmf /(1 − )
1 1 1
(Kbd )ib = (Kbc )ib + (Kcd )ib ,
u 1/2
Dim g 1/4
mf
(Kbc )ib = 4.5 dB + 5.85 5/4 ,
Overall mass-transfer coefficient (bubble phase–dense phase) based on bubble volume dB
1/2
mf Dim ub
(Kcd )ib = 6.78 3
dB
1−xi
Diffusivity of component i in gas mixture Dim = n
(x /D )
j = 1 j ij
j = i
Dij = 0.04357 T 3/2 1 1
Binary diffusivity 1/3
P (Vi
1/3
+Vj )2 Mi + M j
1 1 1
(Hbd )b = (Hbc )b + (Hcd )b ,
1/2
u kg g g 1/2 Cpg
mf g Cpg
Overallheat-transfer coefficient (bubble-dense phase) based on bubble volume (Hbc )b = 4.5 dB + 5.85 5/2 ,
dB
k
g g Cpg mf ubr 1/2
(Hcd )b = 6.78 dB
The mass balance for the ith component in the dense phase Rearranging Eq. (7) and integrating (noting that Nib =
is given by (Nib )in at z = 0) we obtain:
Dense phase (plug flow):
Nid Nib (Nib )in Nid
dNid Nid Nib − =− − e−ai z , (23)
=−(Kbd )ib − A + p (1 − mf )(1 − ) Qd Qb Qb Qd
dz Qd Qb
3
where
× ij rj . (21)
j =1
(Kbd )ib
i = , (24)
Dense phase (fully back-mixed flow): ub
H
Nid Nib since
Nid =(Nid )in − (Kbd )ib − A dz
0 Qd Qb
3 (Nib )in (Ni )in
= (25)
+AH (1 − mf )(1 − )p ij rj , (22) Qb uin A
j =1
then
where ij refers to stoichiometric coefficient of component
i in reaction j (negative for reactants, positive for products
Nid Nib (Ni )in Nid
and zero for components not appearing in reaction), and rj − =− − e−ai z . (26)
Qd Qb uin A Qd
refers to kinetic rate of reaction j .
5460 W.-Z. Lu et al. / Chemical Engineering Science 59 (2004) 5455 – 5464
Table 3
Comparison of different reactor performance for DME synthesis
Fluidized bed Slurry reactor ( Wang et al., 2001) Fixed bed ( Lu et al., 2002)
CO conversion (XCO ) 48.5% 17% 10.7%
DME selectivity (SDME ) 97% 70% 91.9%
DME productivity (PDME ) 0.49 g/g/h 0.2 g/g/h 0.5 g/g/h
Space velocity (SV ) 3000 ml/g/h 3000 ml/g/h 15, 000 ml/g/h
100 100
90 Experiment 90 Experiment
P-P model P-P model
80 80
P-M model P-M model
70 70
60 60
XCO(%)
XCO(%)
50 50
40 40
30 30
20 20
10 10
0 0
0.5 1.0 1.5 2.0 2.5 1 2 3 4 5
H2 /CO P(MPa)
Fig. 3. Effect of feed composition on simulation and experiment results: Fig. 4. Effect of pressure on simulation and experiment results:
P = 3 MPa, T = 260 ◦ C, SV = 3000 ml/gcat/h. H2 /CO = 1, T = 260 ◦ C, SV = 3000 ml/gcat/h.
100
90 Experiment
be as high as up to 48.5% and 97.0%, respectively, with the P-P Model
DME productivity of 0.49 g/gcat/h, which is 2.45 times of 80
P-M Model
experiment result from slurry reactor. In a fixed-bed reactor, 70
the corresponding levels are 10.7% and 91.9% (Lu et al., 60
XCO(%)
PDME(g/gcat/h)
0.4
PDME(g/gcat/h)
0.4
60 60
%
50 0.3
%
50 0.3
40 40
0.2 XCO 0.2
30 30
SDME
20 XCO 20 XCO (Equil)
0.1 0.1
SDME 10 PDME
10
PDME 0 0.0
0 0.0 270
250 260 280 290 300
0.5 1.0 1.5 2.0 2.5
H2/CO T(oC)
60
The effect of temperature is shown in Fig. 8, which re-
50 0.3
%
PDME(g/gcat/h)
60 s−1
0.4 N
%
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