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Olens via catalytic partial oxidation of light alkanes over Pt/LaMnO3 monoliths
L. Basini a, S. Cimino b,, A. Guarinoni a, G. Russo b, V. Arca c
a
h i g h l i g h t s
" CPO of ethane and n-butane to olens was studied on PtSn/LaMnO3 honeycombs.
" Bench scale testing showed high single pass yields of C2H4 + C3H6 around 55 wt.%.
" Stable reactivity demonstrated for 500 h.o.s. with ethane feed and sacricial H2.
" PtSn/LaMnO3 catalyst guaranteed a net hydrogen production across CPO reactor.
" Products quenching & catalyst overheating issues were identied during scale-up.
a r t i c l e
i n f o
Article history:
Available online 13 July 2012
Keywords:
Olens production
Catalytic partial oxidation
Light alkanes
Pt perovskite
Structured catalyst
Long-term stability
a b s t r a c t
The reactivity of a multi-layered monolith catalyst containing Pt and Sn over LaMnO3/La-c-Al2O3/cordierite, previously studied in a lab-scale plant for producing ethylene via Short Contact Time Catalytic
Partial Oxidation of ethane, has been further and extensively investigated in a bench-scale plant with
higher production capacity. Ethylene yields exceeding 55 wt.% have been achieved and the reactivity performances have been maintained for more than 500 h.o.s. The experiments, while conrming the potential of the technology, have pointed out some weakness in catalyst stability and reactor design. The
bench-scale experimental study has also addressed the reactivity features of n-butane indicating that
ethylene + propylene yields approach 54 wt.% in a wide range of experimental conditions.
2012 Elsevier B.V. All rights reserved.
1. Introduction
Light olens are the most important building blocks for the
polymers and variety of intermediates industry. World demand
of ethylene and propylene is exceeding now 180 MTA (about 2/3
related to ethylene production), with an annual growth of 45%
in the next decade [1,2].
Steam cracking of hydrocarbons has been and still is the main
industrial technology for producing light olens [14]. However,
despite the technological improvements occurred in more than
50 years, steam cracking remains the most energy-consuming process in the petrochemical industry.
It is expected that the possibility to perform oxidative dehydrogenation (ODH) or oxy-cracking of light alkanes through Short
Contact Time Catalytic Partial Oxidation (SCTCPO) would lead
to a novel technology with low capital investment, improved
energy efciency [26] and reduced NOx and CO2 emissions. In particular, it has been shown that monolithic Pt-based catalysts, operated under autothermal conditions i.e. wherein the feed is
partially combusted to drive the endothermic cracking processcan efciently convert ethane to ethylene, propane and n-butane
to ethylene and propylene, isobutane to propylene, isobutene and
ethylene [320].
Recent experiments performed at laboratory scale utilizing ethane and a patented Pt(Sn)/LaMnO3 catalysts [10,11], have produced olens with yields exceeding 61 wt.% and selectivity above
75 wt.% per pass. It has been estimated that these reactivity features could result in reduced production cost of ethylene with respect to steam cracking [10]. Indeed the advantages resulting from
the high olen yields and the compact reactor system [46,9] could
more than compensate the additional oxygen consumption costs,
not to mention the benet of reducing the CO2 and NOx emissions
by avoiding large heating furnaces.
However, from a technical standpoint, a better denition of several key operating issues is required, including: catalyst activity
and stability as well as reactor design [5,8,9,12,13,16]. In fact, most
of the available experimental results were obtained with small
474
Monolith catalysts with identical nominal composition were employed in the CPO of ethane or n-butane.
2.2. Bench-scale CPO plant
The tests were performed in a bench-scale plant with ethane
capacity of 1000 Nl/h (roughly 15 times larger than previous lab
scale [10,11]) and n-butane capacity of 390 Nl/h, composed by ve
main zones:
1.
2.
3.
4.
5.
The reactants ethane, nitrogen, oxygen and hydrogen were supplied by cylinders and their owrates controlled by mass ow controllers (Brooks, Bronkhorst). n-Butane owrate was measured and
controlled by a mass ow meter specic for liquids (Bronkhorst
mini CORI-FLOW).
The hydrocarbon feedstock, nitrogen and hydrogen were conveyed into a single line. Oxygen ew into a second, independent
line. Each line was equipped with an electric pre-heater. Mixing
of feedstock and oxidant streams was performed in a tube in
tube device, located on the top of the vertical steel vessel, featuring a thick internal refractory lining (tight t concentric ceramic
tubes) to limit heat loss in the reaction zone, whose inner diameter
was 26 mm (Fig. 1a). Three electrical resistances surrounded the
reaction zone and were switched on only during the light-off of
the self-sustained SCTCPO reactions.
The hot efuent from the catalytic reactor was transferred
through a water cooled line to heat exchangers and lters before
owing downstream through a back-pressure valve and being
ared.
A side-stream of the efuent was collected and analyzed by an
online GC (HP 7890, equipped with FID and TCD detectors) and a
microGC (Agilent Quad), calibrated to measure CO, CO2, N2, O2,
H2 and hydrocarbons up to C6.
Fig. 1. (a) Schematic of the bench scale SCTCPO mixing, reaction and cooling zones. (b) Optical microscopy and SEM-BSE images of the structured catalyst with PtSn/
LaMnO3/Al2O3 active washcoat layer on a cordierite honeycomb (600 cpsi).
v j F out
j
Sj
in
n F C n Hm F out
C n Hm
where vj is the number of C atoms in species j, F out
its outlet molar
j
in
out
ow, F Cn Hm F Cn Hm is the difference between inlet and outlet molar ows of the specic feedstock CnHm containing n atoms of C.
2.3. Operating conditions
Catalytic tests were generally performed at the operating pressure of 1.5 bara; in a few tests this was set at 2 bara. According to
previous reports [5,915,2325] hydrogen was fed to the reactor as
a sacricial fuel in order to maximize the selectivity to olens. The
inlet temperature of the pre-mixed stream was set at 250270 C
with ethane and 200250 C with n-butane, i.e. the maximum temperatures allowed by our experimental apparatus. Nitrogen was
used as an internal standard: its content in the feed stream (ca.
8 vol.% with ethane and 5 vol.% with n-butane) was kept as low
as possible according to the minimum stable ow rate of N2
achievable with the specic mass ow controllers employed in
each set of experiments.
Oxygen conversion in the CPO reactor was almost complete;
since in industrial units the presence of oxygen in the efuent cannot be tolerated, we performed specic tests to ascertain that the
eventual presence of residual O2 was caused by some lateral bypass between the honeycomb catalyst and the reaction tube. This
is a common issue with bench-scale CPO reactors, which has a direct negative impact on feed conversion and selectivity to olens.
The experimental campaign with ethane was performed with a
single catalyst sample that was on stream for a total of 550 h. During the rst 220 h the operating conditions were widely changed in
order to optimize the yield in C2 + C3 olens while minimizing the
consumption of reactants:
O2 =C ratio
H2 =O2 ratio
0:200:25 v=v
1:003:10 v=v
Nl=h:
O2 =C
0:150:27 v=v
H2 =O2
02:50
v=v
Nl=h:
475
476
(a)
100
60 %
50 %
80 %
70 %
Pt/Perovskite
Pt-Sn/Perovskite
Pt-Sn/Perov. ENI
90
40 %
80
C2H4
70
60
C2H2
5
0
50
60
70
80
90
100
C 2 H 6 conversion (%)
(c)
25
20
15
CO
10
CO2
5
0
50
60
70
80
90
100
(b)
15
CH4
10
C2H2
0
50
60
70
80
90
100
Fig. 2. Process selectivity to (a) C2H4 and C2H2, (b) CO and CO2, (c) CH4 and C2H2 as a function of ethane conversion during the CPO reaction over PtSn/LaMnO3 catalyst in the
bench scale reactor (eni) as compared to previous results at lab scale [10,11]. Dashed lines represent iso-yield curves.
100
90
80
70
60
20
Pt-Sn/Perov. ENI
Pt-Sn/Perov. labscale
model 1000C
10
0
50
60
70
80
90
100
C2H6 conversion %
100
(a)
80
100
60
75
40
50
20
0
100
100
200
300
400
500
25
600
(b)
80
Selectivity %
125
60
15
10
5
0
100
200
300
400
500
600
time on stream, h
Fig. 4. Ethane CPO life test on PtSn/LaMnO3 catalyst: (a) fuel conversion and
pressure drops across the reactor and (b) process selectivities to main products as
function of time on stream at xed inlet conditions.
477
Fig. 5. Optical microscopy and SEM-BSE images of the PtSn/LaMnO3 monolith catalyst after the life test of ethane CPO. (a and b) Partially melted cordierite structure close to
the top inlet section and (c) loss/thinning of active washcoat. (d) Build-up of carbon overlayer above the active phase causing the partial occlusion of some channels in the
outlet section of the catalyst.
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
C2H6
n-C4H10
HCn>4
C4H10
C4H8
C3H6
C3H8
C2H2
C2H6
C2H4
CO2
CH4
CO
FS Conv.
C2H6
n-C4H10
80
50%
40%
C-Selectivity %
60%
70%
(a)
C2 + C3 Olefins
60
30%
C2H4
40
20%
C3H6
20
10%
0
50
10
molar ratios
478
CH4
C4H8
C2H2
60
70
80
90
100
C4H10 Conversion %
(b)
C2H4 / C3H6
6
4
2
0
50
CH4 / C3H6
60
70
80
90
100
C4H10 Conversion %
Fig. 7. Results of n-butane CPO over PtSn/LaMnO3 monolith catalyst. (a) C-atom
selectivities to C3H6, C2H4, C2H2 and CH4 (dashed lines represent iso-yield curves).
(b) C2H4/C3H6 and CH4/C3H6 molar ratios as a function of C4H10 conversion.
479
H2/O2=0.0
H2/O2=0.9
70
H2/O2=1.0
60
H2/O2=2.0
H2/O2=3.0
50
C-selectivity %
50
40
0.14
0.16
0.18
0.20
0.22
0.24
0.26
(b)
30
2
in
O2in
20
H2 /
10
Fig. 9. Moles of H2 in the outlet stream per mole of O2 fed vs. the feed H2/O2 ratio
during the CPO of ethane and n-butane over PtSn/LaMnO3 catalysts. Points below
the dashed line indicate a net consumption of H2 throughout the catalytic reactor.
0.14
0.16
0.18
20
C-selectivity %
O2/C
0
0.20
0.22
0.24
0.26
O2/C
(c)
15
10
5
0
0.14
C-selectivity %
3
in
80
/ O2
90
(a)
out
100
H2
n-C4H10 conv. %
14
12
10
8
6
4
2
0
0.16
0.18
0.22
0.24
0.26
0.22
0.24
0.26
O2/C
(d)
0.14
0.20
0.16
0.18
0.20
O2/C
Fig. 8. Effect of O2/C and H2/O2 feed ratios on fuel conversion and C-atom selectivity
to the main products during the CPO of n-butane over PtSn/LaMnO3 monolith
catalyst. Data at H2/O2 = 0.9 were obtained at P = 2 bara. Arrows indicate trends for
increasing H2/O2 values.
Regarding the effect of pressure on the catalytic features, moving from 1.5 to 2 bara (data set at H2/O2 = 0.9 in Fig. 8) we observed
a small reduction in the process selectivity to ethylene whereas
fuel conversion and selectivity to propylene were almost
unaffected.
A net hydrogen production was identied as a key condition to
achieve favorable overall economics of the process. As seen in
Fig. 9, for ethane to ethylene the process produces more H2 than
fed for all the operating condition explored with H2/O2 up to 3.
On the contrary, for n-butane to olens the CPO process produces
a H2 surplus only at low H2/O2 ratios, namely below 0.5 v/v. Similar
qualitative results were reported by Bodke et al. [29] but the crossover points depend strongly on the type of catalyst [21] as well as
on reactor design and process conditions such as the fuel to oxygen
ratio and preheat [29]. In fact, a further peculiar feature of the Pt/
LaMnO3 catalyst is the possibility to advantageously use CO or
mixtures of CO and H2 as sacricial fuels to avoid the eventual
H2 unbalance [11,23].
480