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Laboratory of Catalysis and Chemical Reaction Engin�eri�g, National Institute of Ch�mi�try, and
.
Department of Chemical Engineering, University of Ljubljana, P.O. Box 537, 61001 Ljubljana, Slovema
One-dimensional heterogeneous and pseudohomogeneous plug flow models were employed to model
an adiabatic fixed bed reactor for the catalytic dehydration of methanol to dimethyl ether.
Longitudinal temperature and methanol conversion profiles predicted by these mod�ls were compared
to those experimentally measured in a pilot reactor. The reactor was packed Wlth 3-mm 'Y-Al?Os
pellets and operated in a temperature range of 290-360°C and at a pressure of 2.1 bar. Intraparticle
mass transport was found to be the rate-controlling step.
Figure l. Schematic drawing of the experimental apparatus for catalytic dehydration of methanol: (1) gas cylinder (nitrogen), (2) methanol
reservoir, (3) mass flow controller, (4) metering pump, (5) evaporator, (6) ball valve, (7) preheater, (8) manometer, (9) needle valves, (10) tube
and shell heat exchanger, (11) phase separator, (12) coolers, (13) thermocouples, (14) calcium silicate insulation block, (15) glass wool, (16)
catalyst bed, (17) inert bed, (18) sampling valve.
Table I. Properties of Catalyst and Reactor and Operating Table II. One-Dimensional Plug Flow Models of the Fixed
Conditions Bed Reactor Used in This Study
where the overall effectiveness factor, 11o, accounts for the (6)
intraparticle as well as interparticle mass- and heat
transport limitations (model I). The overall effectiveness
factor is defined as a ratio of the actual (global) rate to the (7)
rate based on bulk conditions, thus
2480 Ind. Eng. Chern. Res., Vol. 32, No. 11, 1993
0.20
0.08 +10. ' +10. /
/ /
T=563 K T=5 9 3 K / /
/ /
0.16
/
/
/
-10.
/ -10.
/
�0.06
0
I...
AI 0.12
/
"'0
Cl) /� ,./
00.04 / // /
/
::J / ..q,. 0.08
() /
/ /
/
0
u
o.o2
// /
/
/
/
/
.. ooooo
66666
Rate eq. 1)
Rote eq. 12)
? 0.04
ooooo
66666
Rate eq. 1)
Rote eq. 12)
t
,
,
,.
/.
0.00
0.00 0.02 0.04 0.06 0.08 0.04 0.08 0.12 0.16 0.20
0.50
0.30 +10. .q. ... /
+10. .Q)
/
/
�
T=613 K / T=633 K """'(I)
/ /
Oil' 0.40 /
/
/
/ /L
/
Cl>/ -10.
/
/
-1 0.
/
Cl)
..... / ....,./ 10
� 0.20 /
/
0.30
"'0
/ 0/
/
Cl)
.....
/
0
::J 0.20
()
� �
0o.1o
u ooooo Rote eq. 1) ooooo Rote eq. 1)
66666 Rote eq. 12) 0.10 66666 Rote eq. 12)
0.00 ..______.__
____....___
.._ __J__J 0.00 "'----'L--'---_J
0.00 0.10 0.20 0.30 0.00 0.10 0.20 0.30 0.40 0.50
Measured rate Measured rate
Figure 2. Comparison between experimentally measured global reaction rates for 3-mm catalyst pellets and those calculated by eqs 1 and
12. Area marked corresponds to the pilot reactor operating conditions.
and the following boundary conditions Kutta method while the surface conditions (C8 and 'P) in
the heterogeneous model were determined by a Newton
iteration method. In these calculations, p, Cp and Mf,
at r = 0 (8)
were considered as a function of temperature. Nonlinear
equations (eqs 6 and 7), coupled through the concentration
at r = dp!2 (9) and temperature within the catalyst particle, had to be
solved in each node of the computational grid used in the
integration of the mass and heat balances. Due to the
dT
h(T'- ,.,�,
1 ·) = -x. - at r = dp/2 (10) complex rate equation, the solution is not so straightfor
edr ward. However, one can use either Bischoff's approximate
When the reaction rate is small compared to the external solution with a generalized Thiele modulus (Bischoff, 1965)
heat- and mass-transfer rates, the surface concentration or a numerical solution. In this study, the numerical
and temperature both approach those in the bulk gas approach was used; the boundary value problem (eqs 6-10)
phase, hence was first converted into an initial value problem by adding
an appropriate transient term to eqs 6 and 7 and then
�' = cb
' and T' = T>
integrated according to the initial conditions to the steady
and consequently state (Riggs, 1988; Hindmarsh, 1986).
To avoid a time-consuming numerical calculation of the
71/710 = 1
effectiveness factors, one can employ eq 1 with the intrinsic
This leads to the one-dimensional heterogeneous model rate coefficients replaced by apparent coefficients that
where only the intraparticle resistances have to be account for the intraparticle mass- and heat-transport
considered (model II). Equations 2 and 3 with initial limitations. For that purpose, the rate per catalyst particle
conditions (eq 5) still apply, but the overall effectiveness can be calculated from the relation
factor, T'/o, has to be replaced by the particle effectiveness
- - 2 2
factor, 71, defined as
v-1
k,/(M (XM - XwXFJK)
(TC.)dV= - ::...
�==-
.:. .. --- (12)
VM ' '
f, VfiM .I\. M+KWXW)4
(1+2-lj{}(
(11)
where the apparent coefficients (h8, KM , kw) are evaluated
from the experiments performed with particles employed
in the pilot reactor. However, eq 12 also represents an
Results and Discussion
approximate solution of the integral in eqs 4 and 11,
Integration of the reactor mass and heat balances (eqs respectively, for the concentration range investigated.
2 and 3) was performed by using a fourth-order Runge- Employing eq 12 in the heterogeneous models, they can
Ind. Eng. Chem. Res., Vol. 32, No. 11, 1993 2481
Table III. Intrinsic and Apparent Coefficient Valuations 700 r-----
for 3-mm -y-AlzOa Catalyst Pellets <l>w=4.34 1/h
P = 2.1 b ar
680
parameter intrinsic (eq 1) apparent (eq 12)•
{;.
k, 5.35 X 1013 exp(-17280/T} 6.60 X 10Sexp(-10800/T} � 660 0
KM 5.39 X 104 exp(8487/T} 0.72 X 1Q-2 exp(830/T}
K., 8.47 X 1Q-2 exp(5070/T} 0.45 X 1Q-2 exp(l130/T} Q)
I... 640
:::J
• Component concentrations are expressed by mole fraction. -
Constants k; are dimensionless in this case. � 620
Q)
C..soo
670
<l>w=6.74
P=2.1
1/h
bar
E
Q)
points (T0=551.15 K)
I-
580 (T0=561.15 K)
T0=551.15 K
'-...o.eo 650
-- Ts � 56
I...
0
Ts
630 Q)
' I... 540
0.10 0.20
+-
0 0.60
(.)
' ::l 0.00 0.30
� ' 0
+-
- ' 610
700
' h I... <l>w=6.74 l�h
Vl " Q)
Vl
P = 2.1 ar
Q. 680
Q) 0.40 8 \
59o --
c
8 � E � ..,:..--
{;.
0
Q) � /
...-:
> h 660
+- 7J f- ,-
(.) 570
7Jo ,'l
Q)
� 0.20 I... 640
:::J /,::
- -
w 550
� 620
Q)
0.00 c______j______.J._____j_____J 530 C.. soo
0.00 0.1 0 0.20 0.30 0.40
Reactor length, m E
Q)
I-
580
��
Figure 3. Particle and overall effectiveness factors and temperature
as a function of the longitudinal reactor coordinate. 56
1.00 ,-------,
T0 = 551.15 K 41w=6.74 1/h
0
P = 2.1 bar 660 P = 2.1 b ar
- -.. ---- 0
T0=551.15 K
0.80 6. �
-..... ....: :>·,_;.... �640
/ a.>
�
/ fr
' !.....
c 0 . 60
0 ::J 620
/ �/ -+-
Vl 0
!..... / �/ !.....
/�/ a.> 600
� 0.40 a..
c /�/
0 1,1/ E ClOCXX)
Experimental points
u
1 / ClOCXX)Exp. points 41w=4.34 1/h a.> 58o -- Model Ill
,'I ,'}"' � Exp. points 41w=6.74 1/h 1--
'/ 0'
h' 1.2 • h
0.20 -- Model
,
�/ '� - - Model II 560
h' 0.8 • h
- - h' = 5.0 • h
--- Model Ill -------- h' = 0.2 • h
------ Model IV
0.00 f!F------'---_j_---L---' 540 �--�---L-----'--'---�
0.00 0.10 0.20 0.30 0.40 0.00 0.10 0.20 0.30 0.40 0.50
1.00 r------, 680 ,------,
To = 561.15 K 41w=6.74 1/h ---(j
0
••
Figure 5. Comparison between experimentally measured conversion Figure 7. Effect of the heat- and mass-transfer coefficients on
profiles and those predicted by the models at two different inlet temperature profile predicted by the heterogeneous model III.
temperatures.
illustrated in Figure 7, where the temperature profiles are
680 r------,
--·o plotted for different values of the mass and heat transport
41w=6.74 1/h ,. --
P = 2.1 bar 0 coefficients, respectively. These two physically relevant
660 T0=551.15 K / ,'
Q)
E s8o (model II) or in the form of eq 12 with the apparent rate
1- ocx::x:x:J
Experimental points parameters (model IV). The apparent rate parameters
-- Model ll can be easily determined by experiments in a differential
- - o.,· = 1.2 1 o •.•
----- o.:,· = o.8 1 o•.• reactor employing particles of the same size that are going
540 �-----L----�- to be used in a commercial reactor.
0.00 0.10 0.20 0.30 0.40 0.50
Acknowledgment
Reactor length, m
We acknowledge support from the Ministry of Science
Figure 8. Effect of the effective diffusivity on temperature profile and Technology of Slovenia under Grant No. C2-0541-
predicted by the heterogeneous model II.
104 and from Nafta-Lendava for making it possible to run
680 .-------, a pilot reactor at their facilities for more than 2 months.
•• = 6.74 1/h -----------------: .. - We also thank Bayer, A. G., Germany, for the catalyst
/. �-'6 0 supply.
P = 2.1 bar ""
/. ,"
660 T0= 551.15 K
� d•= 3.0 mm '' Nomenclature
' /
�640 I/ / C; =concentration in fluid phase, kmol/ms
Q) , /
I... I /
cp =specific heat of fluid, kJ/(kg·K)
..2 620 I /
/ De,i = effective diffusion coefficient, m2/s
c
I... I. / dp = particle diameter, m
/
Q) 600 / Mi. =heat of reaction, kJ/kmol
c.. / h =heat-transfer coefficient, W/(m2·K)
/
E s8o
/ ocx::x:x:J Experimental points K = thermodynamic equilibrium constant
K; =adsorption constant, mS/kmol
Q) --Model li
1- - - P' = 1. 9 • P
----- P' = 3.8 I p K; = apparent adsorption constant
- - dp' = 2.0 • dp k; =mass-transfer coefficient, m/s
-------- dp' = 0.5 • dp
k. =reaction rate constant, kmol/(kg·h)
540 �-----L----�--�L---�
0.00 0.10 0.20 0.30 0.40 0.50 k. = apparent reaction rate constant, kmol/(kg·h)
M; = molecular weight, kg/kmol
Reactor length, m
P =pressure, bar
Figure 9. Effect of the particle size and operating pressure on R =reactor radius, m
temperature profile predicted by the heterogeneous model II. r =particle radial coordinate, m
i' =reactor radial coordinate, m
0. 10 ..------,
rM =rate of methanol disappearance, kmol/(kg·h)
T =temperature, K
..s:: 0.08 f- ¢ ¢
u =superficial velocity, m/s
......
¢ 8 V = particle volume, ms
C'l C) z=reactor longitudinal coordinate, m
...... 0.06
0 0
X; =mole fraction
0
Greek Letters
E 0.04 Mixture composition
MeOH:DME:H20:N2 4>M =methanol feed rate, L/h
....... ocx::x:x:J 35 9 : 9 : 47 71 =effectiveness factor
:::::E 00000 41 13: 13: 33
I... 0.02 ¢¢¢¢¢ 50 : 9 : 9 : 32 T/o = global effectiveness factor
I Ae = particle effective thermal conductivity, kJ/(ms·K)
......
0.00 L____j_ __ _L__..J.___L____j____L__...l_.__ L___J____ v;=stoichiometric coefficient
0 2 3 4 5 6 7 8 9 10 p =gas-phase density, kg/ms
Pressure, bar PB = catalyst bed density, kg/ms
Pp =catalyst particle density, kg/ms
Figure 10. Effect of the operating pressure on global reaction rate
for 3 mm -r·Al2 0a catalyst pellets. Subscripts and Superscripts
b = bulk conditions
and the operating pressure on the longitudinal temperature E =dimethyl ether
profile is depicted in Figure 9. It is obvious that the effect e =effective
of particle diameter is appreciable. It is somewhat i = ith component (methanol , DME, water)
M =methanol
surprising that the total pressure has almost no effect on
0 =inlet conditions
the predicted temperature profile. One can speculate that
s =surface conditions
the reduction of the intrinsic reaction rate due to the
W =water
pressure rise is compensated by the increase of the
effectiveness factor. The net result is, however, almost Literature Cited
the same global reaction rate. This conclusion is confirmed Bercic, G. Dehydration of Methanol over-y-Al20a. Kinetics of Reaction
with the experimental results obtained in a CSTR system and Mathematical Model of an Industrial Reactor. Ph.D. Thesis,
using the same catalyst pellets (Figure 10). The University of Ljubljana, 1990.
2484 Ind. Eng. Chem. Res., Vol. 32, No. 11, 1993
Bercic, G.; Levee, J. Intrinsic and Global Reaction Rate of Methanol Riggs, J. M. An Introduction to Numerical Methods for Chemical
Dehydration over "(-Al208 Pellets. Ind. Eng. Chem. Res. 1992, 31, Engineers; Texas Tech University Press: Lubbock, TX, 1986; p
1035-1040. 406.
Bischoff, K. B. Effectiveness Factors for General Reaction Rate Woodhouse, J. C. U.S. Patent 2,014,408, 1935.
Forms. AIChE J. 1965, 11, 351-355.
Brake, L. D. U.S. Patent 4,595,785, 1986.
Chang, C. D. Hydrocarbons from Methanol; Marcel Decker: New Received for review March 1, 1993
York, 1983; p 75. Revised manuscript received July 1, 1993
Hindmarsh, A. C. Solving Ordinary Differential Equations on an Accepted July 27, 1993•
IBM-PC Using LSODE. LLNL Tentacle Magazine; LLNL:
Livermore, CA, April 1986; Vol. 6, No.4.
Martin, H. Low Peclet Number Particle-to-Fluid Heat and Mass • Abstract published in Advance ACS Abstracts, October 1,
Transfer in Packed Beds. Chem Eng. Sci. 1978, 33, 913-919. 1993.