Characterization of Transient behaviors and Operability study of a novel small scale Methanol Synthesis Reactor

Abstract

The dwindling of natural resources, mainly fossil fuels, and the alarming increase in the global average temperatures, are the biggest concerns of the engineering and scientific community of 21st century. Studies have found that known reserves of oil and natural gas will last another 50 years. Coal will last another 110 years, which points towards dire consequences. The experience will not be that of a car slowly running out of gas, but rather like driving off a cliff, since we innately depend on these resources. The realization of these concerns has lead to a rise in the investments all over the globe for Sustainability. The right questions are now being asked. How can we fulfill our demands without compromising the demands of our future generations? One of the keen areas of interest is the conversion of power into fuel. Synthesis of hydrocarbons from sequestrated carbon can produce carbon-neutral fuels that can replace some of the conventional fossil fuels. Methanol has been actively wiping the floor with the research community due to its simplicity of production and less toxic nature. While there are quite a lot of ways of producing methanol, very few of them are carbon neutral. Zero Emission Fuels B.V. has embarked on a venture to produce methanol by a totally carbon neutral process. They begin by capturing carbon dioxide and water from air and splitting the water into hydrogen and oxygen using solar power. Carbon dioxide and hydrogen are then combined in a reactor to form methanol, making a truly carbon-neutral process. They aim to make fuel consumption, a completely circular process while keeping it economic. An experimental characterization of ZEF’s methanol reactor under varying pressures and H2/CO2compositions was done. The new reactor design focuses on heating the feed gases before catalyst bed, more heat integration, reliable sensor data, and the ability to mix gases in desired compositions. Methanol yield, quality, energy efficiency, reactor inlet and outlet temperatures, power requirements were experimentally determined in a transient analysis. It was seen that the reactor produces 4.84 mmol/gcat /hr of methanol at 50 Bar and reactor wall temperature of 250◦C with H2 : CO2 = 3:1 mol% feed gas. The catalyst exhibited partial deactivation during night after shutdown. Contrary to expectation, the reactor produced more methanol at lower pressure. The production was reported at 5.96 mmol/gcat /hr at 35 Bar. Although, only 4.36 mmol/gcat /hr at 25 Bar. Moreover, the pressure reduction caused the natural circulation to slow down, and increase the inlet temperature from 208◦C at 50 Bar to 234◦C at 35 Bar, which is the reason for the observed increase in yield. It can be concluded that the reactor yield under these conditions is limited by kinetics and not thermodynamics. The reduced mass flow rate allowed the reactor to consume less power and show higher energy efficiency. It increased from 34.7% at 50 Bar to 43.2% at 35 Bar. The rate of pressure decline in the reactor was correlated with the methanol yield using gas law by accounting for non-ideality with the compressibility factor. The predicted yield was seen to be in good agreement with experimentally determined. The methanol yield of the reactor with variable feed gas composition was obtained for 50 Bar and 250◦C reactor wall temperature and seen to decrease on either side of the ideal composition. It was concluded that the yield becomes both stoichiometrically and kinetically limited.
It is recommended that similar experiments be done at increasing temperatures and equilibrium yield be determined experimentally. Additionally, the reactor needs to be operated with varying compositions and higher reactor wall temperatures at constant pressure, to obtain the operating line for maximum production of reactor.