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Abstract
A model for membrane reactors is proposed, taking into account the radial concentration pro"les for each reactant, as well as the
temperature pro"les. This model is applicable for a membrane reactor with a "xed bed of catalyst inside the membrane and with
distribution of one of the reactants along the reactor through the membrane. The model predictions are compared with the results
obtained in an experimental reactor, and the e!ect of an increase in the reactor diameter and other changes in the operation
conditions are studied by means of the model. 2001 Elsevier Science Ltd. All rights reserved.
1. Introduction
Membrane reactors have been widely studied during
the last decade, as may be seen in several reviews (Hsieh,
1991, 1996; Shu, Grandjean, Van Seste, & Kaliaguine,
1991; Zaman & Chakma, 1994; Saracco & Specchia,
1994; Falconer, Noble, & Sperry, 1995; Coronas &
SantamarmH a, 1999). Although many possibilities exist, two
main kinds of membrane reactor may be identi"ed:
(a) the membrane is employed to separate selectively one
of the reaction products. This is used to improve the yield
in an equilibrium limited reaction, and has been demonstrated for several dehydrogenation reactions, using
hydrogen-selective membranes; (b) the membrane is employed to distribute one of the reactants along a catalyst
bed. This operation mode has been employed in many
oxidation reactions, such as oxidative coupling of
methane (Coronas, Menendez, & SantamarmH a, 1994a;
Tonkovich, Secker, Reed, Roberts, & Cox, 1995;
Ramachandra, Lu, Ma, Moxer, & Dixon, 1996), oxidative dehydrogenation of ethane (Coronas, Menendez,
& SantamarmH a, 1995a,b; Tonkovich, Zike, Jimenez,
Roberts, & Cox, 1996), propane (Pantazidis, Dalmon, &
0009-2509/01/$ - see front matter 2001 Elsevier Science Ltd. All rights reserved.
PII: S 0 0 0 9 - 2 5 0 9 ( 0 0 ) 0 0 4 2 2 - X
58
(1997) presented models for a membrane reactor employed for OCM, showing that an improved yield is
obtained, when compared with a conventional "xed-bed
reactor. A similar membrane reactor model, with oxygen
distribution and product removal, also for OCM, was
presented by Lu, Dixon, Moser, and Ma (1997). A comparative simulation between a conventional "xed-bed
reactor and a ceramic dense membrane reactor, i.e. made
with oxygen-conducting materials, has been presented by
Kao et al. (1997). Papavassiliou, Lee, Nestlerode, and
Harold (1997) studied in detail the transport through
porous inorganic membranes, aimed at their use in
membrane reactors. Coronas, Gonzalo, Lafarga, and
Menendez (1997) showed how the e!ect of the catalytic
activity of the membrane may a!ect the yield improvements achieved by the oxygen distribution. This model
may explain some experimental results better than models that do not consider the catalytic activity of the
membrane. A simulation using a detailed kinetic model
for oxidative dehydrogenation of butane has been presented by Tellez et al. (1999).
A common hypothesis in all the above simulation
studies was that the radial concentration and temperature pro"les are #at. This approach is probably correct
in most laboratory-scale reactors, where the thickness of
the bed is small (only a few millimeters); however, if
a commercial-scale reactor is envisaged, it is necessary to
have information on the e!ect of the catalyst bed width
on the reactor behaviour. Obviously, in a wide membrane both concentration and temperature pro"les will
appear. From an economic point of view, it is desirable to
employ large diameter tubes, since this will decrease the
required membrane area. Therefore, since oxygen is supplied only from the membrane side, it is probable that
oxygen concentration pro"les would appear in a wide
membrane reactor. Also temperature gradients are more
probable in a wide reactor. Therefore, it was considered
important to have a model of a membrane reactor, taking
into consideration any concentration and temperature
pro"les. In the present work a model has been developed
for the oxidative dehydrogenation of propane in a membrane reactor using kinetics obtained over a V/MgO in
a small-scale reactor. The membrane used was a silicamodi"ed alumina membrane through which oxygen was
allowed to permeate into the enclosed catalyst bed.
Although the present results were obtained for the particular oxidative dehydrogenation of propane the model
may be easily extended to other catalytic selective oxidations. The experimental system is composed of a ceramic
membrane, in which a "xed bed of V/MgO catalyst is
enclosed. The experimental reaction system has been
described previously (e.g. Tellez et al., 1997). Dimensions
of the experimental reaction system are 0.7 cm internal
diameter, 14 cm length, with approximately 2 g of catalysts contained within the tube. A particle size of between
0.25 and 0.50 mm ensured the absence of inner concen-
2. Reactor model
2.1. Reaction kinetics
From the results of an experimental study using a differential reactor of diameter 0.7 cm, in which propane/oxygen or propene/oxygen mixtures were fed to
a bed with a V/MgO catalyst, a Mars}van Krevelen
kinetic equation was deduced. These kinetic expressions
were employed to predict the results for several integral
reactors. For the case of a plug #ow "xed-bed reactor, the
kinetic equations were able to predict propane conversion in close agreement with those obtained experimentally (Ramos et al., 2000). These reaction kinetics
were therefore considered appropriate and were employed in the following 2-D membrane reactor model.
The kinetic data were obtained in the temperature range
450}5503C, at propane partial pressures between 2 and
12 kPa and with oxygen partial pressures from 2 to 12
kPa. Experiments feeding reaction products (propene,
water) were also carried out. An inhibition e!ect by water
was found in experiments in which water was fed with the
reactants, and such an e!ect was also included in the
kinetic equations. Experimental data were tested against
several reaction models by a non-linear least-squares
method and the best "t selected. A detailed discussion of
the kinetic modelling may be found in Ramos et al.
(2000). The reaction set describing the process of oxidative dehydrogenation of propane is shown in Table 1,
together with the values of the kinetic constants.
2.2. 2-D model for an isothermal catalytic membrane
reactor
The main di!erence between the membrane reactor
model and conventional models for "xed-bed reactors
lies in the existence of a radial component of gas velocity,
that cannot be neglected, since one of the reactants is fed
through the reactor wall (Fig. 1). In this way, together
with the di!usive transport in the radial direction, a convective radial mass transport term is added.
The 2-D model of a catalytic membrane reactor was
developed with the following assumptions:
(a) Isobaric reactor conditions.
(b) Cylindrical symmetry.
(c) The gas velocity at any point has two components:
axial and radial. The axial component is independent
59
Table 1
Kinetics of oxidative dehydrogenation of propane
Reaction
C H #SoPC H #H O#S
C H #7SoP3CO#4H O#7S
C H #10SoP3CO #4H O#10S
C H #6SoP3CO#3H O#6S
C H #9SoP3CO #3H O#9S
0.5O #SPSo
(1)
(2)
(3)
(4)
(5)
(6)
Reaction rate
r "k P h f
!& &r "k P h f
!& &r "k P h f
!& &r "k P h f
!& &r "k P h f
!& &r "k P h
- 1
where
k P
h "
k P #(k #7k #10k )P
#(6k #9k )P
-
! &
!&
h "1!h
1
1
f "
& - 1#K P
F & Kinetic parameters (k "k exp(!E /R))
G
G
G
i
1
2
k
kmol/kg s bar
1.756;10
18.62
G
E
kJ/mol
154.5
97.36
G
3
0.0196
48.41
4
6.32;10
208.5
5
2.274;10
182.3
K
F
2.765;10
139.9 (*H )
F
6
1.986;10
205.1
with
r
u "u .
P
UR
Fig. 1. Scheme of the membrane reactor employed for selective oxidations, with distribution of oxygen along a catalyst bed.
(d)
(e)
(f )
(g)
of the radial position. This approximation is equivalent to neglecting the pressure drop due to the wall
friction, compared with that due to the particles.
Neglecting the change in volume due to reaction, this
implies that the radial component of gas velocity
varies linearly with the radius (for detailed derivation,
see the appendix).
Radial transport of mass has two components: diffusive and convective.
Mass transport by di!usion in the axial component is negligible compared with the convective
transport.
The ideal gas law is applicable, given the high temperatures and low pressures used.
A pseudo-homogeneous model is adopted for the
catalytic section.
1 * *(P /)
r G
r *r
*r
1 *(u r) P
P G #o l r
#
GH H
r *r P
(1)
(2)
*
1
*(u )
P
j * *
"
r
# P Cp G
G
*z
F Cp r *r *r
*r
P
G G
#o r (!*H )
H
H
(3)
(4)
*P
*P
G "0, except b
- "u ,
U
*r
*r
0
0
q"!j
*
.
K *r
(5)
60
3. Isothermal simulations
In a "rst approach, the membrane reactor was
simulated assuming constant temperature. This allows
the e!ect of oxygen distribution along the reactor to be
observed, as well as the e!ect of operating conditions
(heterogeneous distribution of oxygen, reactor radius).
Basic input data for the isothermal simulations are given
in Table 2.
The results for the 2-D model were "rst compared with
conventional 1-D models for catalytic methane reactions
(Cheng & Xhuai, 1995; Kao et al., 1997). From a comparison of the 2-D model with the results using a 1-D
model, for the same operating conditions (Fig. 2) it is
clear that for the conditions of the experiments both
a 1-D or a 2-D model can predict equally well the
experimental results. This is due to the small diameter of
the experimental system (i.d. 0.7 cm of catalytic bed used).
Oxygen partial pressure pro"les obtained with the 2-D
model at four reactor lengths for a temperature of 823 K
are shown in Fig. 3. An oxygen partial pressure gradient
is apparent albeit small, with a higher concentration near
the reactor wall, even for conditions that result in similar
behaviour as that predicted by the 1-D model. Values of
the oxygen partial pressure are lower near the inlet
(z/"0.1), increasing progressively with distance along
the reactor.
For larger radius of the reactors simulation was done
at two temperatures with di!erent feed compositions.
For each temperature all other reaction conditions, including reaction temperature and pressure, feed composition and contact time were kept constant. Reactor size
was changed by keeping constant the length/radius ratio.
This allows the e!ect of reactor radius on propane conversion, propylene selectivity and radial pro"les of oxygen partial pressure to be examined (Figs. 4a, b and 5). It
may be seen that both the propane conversion and the
propylene selectivity decrease as the reactor radius increases. It seems that in a narrow reactor it is possible to
have a relatively #at oxygen concentration pro"le,
whereas in a wide reactor large oxygen concentration
di!erences occur at certain values of r/R, whereas the
Table 2
Basic input data
Reactor radius, cm
Catalyst weight, g
Reaction pressure, bar
Reaction temperature, K
= /F , kg h/kmol
!&
Feed composition, C H /N
0.35
2.8
0.70
44.8
1.12
183.5
1.40
358.4
1.12, 120
798, 823
65.3, 130.7
4/42, 4/88
(7)
61
Fig. 2. Comparison of simulated results with experimental results for 1-D and 2-D models (experimental results by Ramos et al. (2000)).
Fig. 3. Oxygen radial partial pressure pro"les and their variation with reactor length, P"1.2 bar, catalyst weight: 2.8 g, total #ow: 200 cm/min,
C H /O /N ratio"4/8/88.
(8)
X
(a)!X (a"0)
!&
dX " ! &
;100,
!&
X (a"0)
!&
>
(a)!> (a"0)
!&
d> " ! &
;100.
!&
> (a"0)
!&
62
Fig. 4. E!ect of reactor radius on: (a) propane conversion; and (b) propene selectivity and yield.
63
Fig. 5. E!ect of reactor dimensions on radial pro"les of oxygen partial pressure, =/F "130.7 kg h/kmol, "823 K, P"1.2 bar,
!&
C H /O /N "4/8/88.
Fig. 6. E!ect of the oxygen #ow rate on propene yield, other conditions as in Fig. 5.
4. Non-isothermal simulation
This simulation has focused on the e!ects of inlet
temperature of the feed and the thermal conductivity on
propane conversion and selectivity, as well as the temperature pro"les along axis and radius. Fig. 8 shows the
radial average temperature along the reactor axis, for two
values of the membrane thermal conductivity (j ) obK
tained from the thermal properties of alumina quoted in
Kuzman (1976) at two values of the initial temperature
64
Fig. 7. Percentage variation of propane conversion and propene yield, by changing from an uniform distribution of oxygen along the membrane to
a linear variation of permeation, other conditions as the same in Fig. 5: (a) the linear increase mode; and (b) the linear decrease mode
5. Conclusions
A mathematical model of a membrane reactor has
been employed to predict radial concentration and
65
Fig. 8. Radial average temperature pro"le along reactor axis as a function of j , =/F "130.7 kg h/kmol, "773 K, P"1.2 bar,
K
!&
Q
C H /O /N "4/5/88.
Fig. 9. Radial temperature pro"les along reactor length for two values of j , =/F "130.7 kg h/kmol, "773 K, P"1.2 bar,
K
!&
Q
C H /O /N "4/5/88.
Notations
CG
N
D
G
66
d
N
d
R
E
G
f
&F
G
*H
F
*H
H
K
F
k
H
k
H
P
P
G
P
P
q
R
%
R
C
R
r
r
H
S
Q
u , u
U U
u,
P
z
Greek symbols
a
factor of non-uniform distribution
b
permeability of oxygen, kmol/m s bar
e
porosity of catalyst bed
j
e!ective thermal conductivity of catalyst bed,
kJ/m s K
j
thermal conductivity of #uid phase in catalyst
D
bed, kJ/m s K
j
thermal conductivity of membrane, kJ/m s K
K
v
stoichiometric coe$cient of component in reacGH
tion j
o
density of catalyst bed, kg/m
h
fractional surface coverage of oxygen.
h
fractional vacant surface
Q
Subscripts
i
component i
j
reaction j
Appendix
It can be considered that the gas velocity at any point
has two components: an axial (u ) and a radial (u )
X
P
component. In a "rst approach the change in molar
number due to reaction is neglected. This is reasonable
(A.1)
du /dz"2u /R.
(A.2)
X
U
A mass balance over a cylindrical volume element with
radius equal to r gives
(nr)(du /dz)"u (2nr).
(A.3)
X
P
Combining Eqs. (A.2) and (A.3), the following relationship is obtained:
u "u (r/R).
(A.4)
P
U
Therefore, in this system the radial component of the gas
velocity varies linearly with the radius.
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