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Energy 173 (2019) 1130e1140

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Energy
journal homepage: www.elsevier.com/locate/energy

Process simulation of hydrogen rich gas production from producer gas


using HTS catalysis
Tapas Kumar Patra, Sudeep Mukherjee, Pratik N. Sheth*
Chemical Engineering Department, Birla Institute of Technology and Science-Pilani, India

a r t i c l e i n f o a b s t r a c t

Article history: In the present article, ASPEN Plus is used to develop a process model of the hydrogen-rich gas production
Received 2 January 2019 through cleaning and catalytic conditioning of producer gas. The process includes producer gas cleaning
Received in revised form using venturi scrubber and sand bed filter followed by compression of the gas to 0.6 MPa using
16 February 2019
compressor. The clean producer gas along with steam undergoes high temperature water gas shift re-
Accepted 18 February 2019
action to produce hydrogen-rich gas. The power law kinetic model for commercial HTS catalysts reported
Available online 19 February 2019
in the literature is used in the model. Experimental results from our previous study and those reported in
the literature are used to validate the developed model for the compositions of CO & H2 in the product
Keywords:
Producer gas
gas. The validated model is further simulated to study the effects of parameters such as reactor tem-
Water gas shift reaction perature, catalyst bed length and steam to CO ratio on the product gas composition. The optimum
Hydrogen operating conditions for maximizing CO conversion are found and reported. The maximum H2
Process model composition and CO conversion predicted by the model are 27.029% 97.5479% respectively and the
ASPEN corresponding operating conditions are reactor; temperature of 350  C, S/CO of 8 and GHSV 1000 h1.
© 2019 Elsevier Ltd. All rights reserved.

1. Introduction were able achieve continuous high purity hydrogen production by


integrating oxidation, steam reforming, water gas shift and in-situ
Many industrial processes require hydrogen as a prime raw CO2 capture in an alternating fixed bed reactor. Biomass gasifica-
material or as a utility. In recent years, hydrogen has also been used tion is the process to convert of solid biomass into a combustible
for the electricity generation using fuel cells [1]. Currently, up to gaseous mixture via partial oxidation known as producer gas. The
96% of the hydrogen production processes are based on non composition of the gas mixture depends on the composition of
renewable sources like natural gas and oil reforming and coal biomass, type of gasifier, gasifying agent used and temperature
gasification followed by water gas shift reaction [2]. Several new profile inside the gasifier. In general, the raw producer gas consists
technologies like electrolysis of water, biomass thermochemical of hydrogen (H2), carbon monoxide (CO), carbon dioxide (CO2),
conversion, biological methods and solar photochemical conver- methane (CH4), nitrogen (N2), moisture (H2O), tar and suspended
sion methods are being adopted for renewable hydrogen produc- particles [6e10]. In order to utilize the raw producer gas for further
tion. Thermochemical conversion of biomass is one of the most downstream processes, it needs proper cleaning [11]. The presence
preferred methods for clean, efficient hydrogen production. of impurities such as tar and suspended particulate matter (SPM) in
Recently, Dou et al. [3] reported a detailed review on issues, chal- the producer gas may lead to practical problems such as coking,
lenges and advances in biomass thermochemical hydrogen pro- catalyst poisoning, tar deposition etc. The quality of the producer
duction methods. The authors recommended chemical looping gas in terms of tar and SPM content present in it needs to be kept as
technologies for sustainable hydrogen production. Dou et al. [4,5] low as possible in order to meet the industry standards [12]. Hence,
reported the process of chemical looping steam reforming of in general the gasifier is coupled with a gas cleaning system, which
ethanol with in-situ CO2 removal for hydrogen production. CaO was reduces the tar and suspended particulate matter (SPM) contents
used as sorbent and NiO as oxygen carrier for the study. The authors present in it [13]. There are different techniques available for
cleaning syngas generated from biomass gasification. The processes
broadly classified into hot gas clean up and cold gas clean up
technologies. Hot gases clean up techniques include cyclones,
* Corresponding author. Pilani Campus, Pilani, 333 031, Rajasthan, India.
barrier filters and electrostatic precipitators. In case of cold gas
E-mail address: pratik@pilani.bits-pilani.ac.in (P.N. Sheth).

https://doi.org/10.1016/j.energy.2019.02.136
0360-5442/© 2019 Elsevier Ltd. All rights reserved.
T.K. Patra et al. / Energy 173 (2019) 1130e1140 1131

clean up, water or liquid absorbents are use to remove contami- balance, water gas shift reaction and the methanation reaction. The
nants. Wet scrubbers such as spray scrubbers, wet dynamic model predicts the syngas composition and its heating value, char
scrubbers, cyclonic spray scrubbers, impactor scrubbers, venturi and tar yield during the process. The developed model was vali-
scrubbers, and electrostatic scrubbers are the most common and dated with experimental results of two different agricultural resi-
effective method to remove both particulate matter and tar from dues at different moisture contents and process operating
the contaminated gas stream [14]. This clean producer gas can be conditions.
directly used in gas engines, turbines and as a feedstock to produce The prime objective of the present study is to model and study
liquid fuels and electricity. Apart from the quality of the gas in the downstream section of the H2 rich gas production unit, which
terms of tar and SPM content, the composition of the producer gas comprises of the gas cleaning system and the fixed bed water gas
mixture also plays a vital role in deciding its application in various shift reactor. The study also aimed at finding the optimum oper-
processes [15]. The producer gas generated from the biomass ating conditions for maximization of H2 composition in the product
gasification process is a potential source of hydrogen-rich gas gas. The model development and simulation have been carried out
production provided a proper quality and composition are main- using ASPEN Plus software. The simulated model predictions are
tained. In this process, the raw producer gas generated undergoes validated for CO conversion and H2 composition with experimental
water gas shift reaction for hydrogen enrichment. It is a highly data from the previous experimental study and also the experi-
economical and efficient process which uses one of the most mental results reported by Marono et al. [30]. Apart from this,
important reactions in the process industry. The reaction equilib- various parameters affecting the composition of the final product
rium depends significantly on the temperature and also requires gas are also studied using the sensitivity analysis tool. Various
the presence of the catalyst [16]. The Arrhenius law states that the operating parameters such as the steam/CO ratio (S/CO) and gas
rate of reaction increases with the increase in temperature, at the hourly space velocity (GHSV) are incorporated in the model using
same time according to Le Chatelier's principle, the equilibrium the design specification tool. Power law kinetic model is chosen
moves in a forward direction with a decrease in temperature, for an and the reaction kinetics of commercial high temperature shift
exothermic reaction and vice versa for endothermic reaction [17]. catalyst reported in literature is used for the simulation. An opti-
Thus, operating condition for the reaction under consideration is mization study is also carried out to find out the optimum oper-
decided by the trade-off between the kinetics and the thermody- ating conditions for the hydrogen production process. The results of
namics of this reaction. In an industry, the water gas shift reaction is the present study can be used for process design and scale up of
carried out at two different temperature ranges, low temperature various syngas to methanol and hydrogen production processes. It
shift (LTS) from 150  C to 250  C and high temperature shift (HTS) will also help is deciding the optimum range for variation of
from 350  C to 500  C [17,18]. A numerous studies are reported for operating parameters to get maximum conversion.
the kinetic simulation of downdraft biomass gasification [19e23]
however, a few researches have used Aspen Plus to develop a model 2. Process description
for the downdraft gasification process. Ramzan et al. [24] devel-
oped a steady state simulation model for a hybrid biomass gasifier. The raw producer gas from the gasification process contains
The model developed was based on Gibbs free energy minimization impurities such as tar, SPM, soot and dust particles which need to
method and chemical equilibrium in the reactions. The authors also be removed from it for its utilization in different industrial appli-
carried out a sensitivity analysis of the gasification process and cations such as power production, production of fuels and chem-
reported the effects of gasifier temperature, Equivalence ratio (ER), icals. Cleaning is necessary as because these impurities cause
moisture content and steam/biomass on syngas composition, HHV various problems in further downstream processes such as clog-
of the syngas, Cold gas efficiency (CGE) and hydrogen production. ging of the engine, corrosion, environmental pollution etc. The
Begum et al. [25] developed a model for fixed bed gasification of experimental setup used for model development is shown in Fig. 1.
Municipal solid waste (MSW) using Aspen Plus. The model calcu- The producer gas cleaning unit basically consists of two equip-
lations were based on Gibbs free energy minimization method to ments: venturi scrubber and sand bed filter. Venturi scrubber
predict the product gas composition, was validated with experi- effectively eliminates the impurities comprising of tar and SPM. The
mental data reported in literature. Kuo et al. [26] carried out a solvent passes through the venturi scrubber in a co-current fashion
comparative thermodynamic analysis for gasification of raw and and impurities from the gas phase get transferred to the liquid
torrified bamboo in a downdraft gasifier using Aspen Plus. The phase. Water is used as a solvent in the present system. The venturi
authors used two operating parameters modified equivalence ratio scrubber consists of a converging section, throat, diverging section
and steam supply ratio to study the gasification performance by and a cyclonic chamber. Water and gas enter separately from the
cold gas efficiency and carbon conversion. Formica et al. [27] re- top of the converging section and their velocity increases. The high
ported a zero dimensional steady state model for a downdraft velocity liquid gets atomized upon discharge into the throat section
biomass gasification plant. The model also included all the plant and comes in contact with gas phase. When the fluid passes
equipments such as gasifier, cyclone, heat exchangers and piping through the diverging section, its velocity decreases and the tiny
and validated with the experimental results. The authors have liquid droplets get mixed with the gas stream. The increased sur-
carried out simulations using various operating parameters such as face area of the solvent molecules enhances the mass transfer and
equivalence ratio, biomass moisture content and gasifying air thus the separation of impurities takes place efficiently [31]. In the
temperature. Tapasvi et al. [28] proposed a two stage gasification cyclonic chamber, the clean gas goes out of the top and the dirty
model for comparing torrified and non torrified biomass gasifica- water gets collected from the bottom. A sand bed filter is used to
tion. The authors reported a better model predictions by incorpo- remove the moisture and remaining impurities in the product gas.
rating tar, biomass decomposition products and char composition In the sand bed filter, the gas passes through a bed of thin wood
data in the model. Three process parameters i.e. steam to biomass shavings followed by of coarse and fine sands. The wood shavings
ratio, Gibbs reactor temperature and equivalence ratio were varied and sand bed collectively remove the moisture and remaining tar
and the model was validated with CeHeO ternary diagrams and particles. The outlet gas from the cleaning system is compressed
other reported experimental results. Recently Gagliano et al. [29] and sent to the fixed bed catalytic reactor. In this reactor water gas
proposed an equilibrium based model for co-current gasification of shift reaction is carried out to enhance the hydrogen content in the
agricultural residues. The model incorporates mass and energy producer gas. The water gas shift reaction involves the reaction of
1132 T.K. Patra et al. / Energy 173 (2019) 1130e1140

LEGEND:

1. r 9. Gas cylinder 17. Gas liquid separator

2. Rotameter 10. Mass flow controller

n 11. Water tank Water

n 12. HPLC Pump Steam

5. Pump 13. Temperature controller Compressed air

6. Cyclone separator 14. Pre-heater Syngas

7. Sand bed filter 15. HTS reactor

8. Compressor 16. Condenser

Fig. 1. Schematic diagram of the experimental setup.

steam with carbon monoxide. The heating coils are wrapped over a represent raw syngas, which is an impure producer gas; four
stainless steel pipe and temperature is controlled by using PID streams are mixed viz. GASIFIED, TAR, CSPM and FINESPM in a
controller (Make: Selec, Model: TC 513). The water is pumped mixer block (MIXER). The enthalpy of mixing is considered to be
through stainless steel pipe using HPLC pump (Make: Lab Alliance, zero as in reality, only one producer gas stream exists. The
Model: series II) which gets converted to steam at saturated con- PRODGAS (impure producer gas leaving the mixer) enters the
ditions. The flow rate of the gas is based on S/CO ratio. The steam venturi scrubber (VSCRUB). Another stream which is entering in the
generated is mixed with the feed gas in a mixer to preheat the venturi scrubber is the WATER. The outlet streams are DIRWATER
reactants. The mixed gas is then passed to a preheater, where the (water þ impurities) and GAS þ SPM. VScrub is a solid separator
feed mixture is further heated to 200  C. The preheated feed gas is block used for cleaning impurities from gaseous streams. Many
then passed through a catalyst bed in a tubular reactor. The outlet theoretical models are available to predict the particle collection
gas from the reactor is at a high temperature ranging from 300  C to efficiency of venturi scrubber such as Calvert, Yung, Boll etc. For the
450  C. This gas passes through a condenser to cool down the hot present study, CALVERT calculation method is chosen and the grade
hydrogen-rich gas. When the hot outlet gas is passed through the efficiency parameter (f) is chosen as 0.31. For predicting particle
condenser, the excess steam gets condensed and gets separated collection efficiency Calvert assumed that venturi scrubber consists
from the product gas in a gas-liquid separator. entirely a throat and the gas droplets accelerates in the throat to
achieve highest gas velocity. f is a correlative parameter used to
3. Model development calculate the penetration and its value lies in the range between 0.2
and 0.7 [35]. GAS þ SPM stream goes into the solid separator, where
3.1. Assumptions most of the SPM is separated on the basis of the parametric values.
It is a cyclone type solid separator block. The solid fraction of solid
Tar is a mixture of various hydrocarbons and represented as a outlet is chosen as 1 and the separation sharpness as 0.85. The
mixture of four different chemicals, i.e. 25% Toluene, 58% Phenol, classification characteristic for the separation is based on particle
15% Naphthalene and 2% Pyrene [32,33]. SPM is generally size. The GAS stream from the solid separator goes into the
comprised of unconverted carbon and ash. In the present simula- SNDBFLT (sand bed filter), where further separation is done. A Sep2
tion study, SPM is assumed to contain 100% of Ash [34].The system block is used to model the sand bed filter unit. The efficiency of
is assumed to be ideal and at steady state without any disturbances. separation for the sand bed filter is taken from literature as 97%
The loss of material from the system is negligible. Pressure and heat [36]. So the sand bed filter removes the remaining tar and the
loss have been incorporated in the model. The shift reactor is moisture present in the product gas with an outlet gas split fraction
assumed to remain at a constant temperature. of 0.03 for tar components and H2O. The pure gas, represented by
CLEANGAS is compressed in COMPRSOR. A compressor model
3.2. Model description which is available in the ASPEN Plus simulator was used. In order to
incorporate the heat loss during the compression process, a heat
Fig. 2 describes the complete process flow diagram of the pro- exchanger (Heater model) denoted by HEATLOSS is used. The heat
posed system developed using ASPEN Plus. Table 1 lists all the exchanger block is used to reduce the temperature of compressed
streams and blocks used in the ASPEN PLUS simulation. In order to product gas stream from 294.308 C to 40 C. The pressure of the inlet
T.K. Patra et al. / Energy 173 (2019) 1130e1140 1133

Fig. 2. Process flow sheet diagram (PFD) in ASPEN PLUS.

and outlet streams remains constant at 6 bars, the vapour fraction is stream (COLD) goes into the gas liquid separator (GLS), a Flash2
taken as 1 and the net het duty for the heat exchanger is 363.513 block is chosen.
Cal/sec. The outlet gas of the cleaning system going into the tank is To model it. The final outlet stream coming out from GLS is
represented by COMPGAS stream. A Splitter model (SPLITTER) is represented as FINALGAS. Table 2 describes the various model pa-
used which splits the COMPGAS stream into two fractions, one that rameters used for different blocks in the process flow diagram.
goes into the shift reactor system (CLNGASIN) and the other that An optimization study for the water gas shift reactor has been
remains in the tank. The amount of the gas going into the reactor carried out. The operating parameters such as reactor temperature,
system is decided by split fraction. The Split fraction is the fraction steam to CO ratio and GHSV are considered for the study and the
of inlet stream going into the outlet stream.. The split fraction for output parameter chosen is CO conversion. Three different levels
the CLNGAS stream is set as 0.1 i.e. only a small fraction of the clean for all the input parameters are taken and a full factorial design
producer gas has been fed into the water gas shift reactor. In our method is adopted to consider all possible combination of the
case, this split fraction is based on the steam/CO ratio. This is ach- operating conditions.
ieved by using the design specification tool. A small FORTRAN code
is written, the ratio variable was defined as:
3.3. Model parameters
R ¼ H2 O=CO (1)
A bimodal particle size distribution (PSD) of the particulate
Where, H2O and CO are variables representing the mole flow
matter with a peak diameter of 0.155 mm reported by Jimenez and
rates of H2O and CO in the FEED stream respectively. Here, the split
Ballester [38] is used in this model. According to Laurence and
fraction parameter of SPLITTER block is varied to achieve the
Ashenafi [39] sand bed filter has a particle removal efficiency from
desired value of R.
70% to 99%, while the tar removal efficiency is about 50%e97%.
Before developing the model of the shift reactor system, the
Pathak et al. [36] reported the cleaning efficiency of the filter in the
reactions scheme and kinetic model are defined. A kinetic scheme
range of 83%e97%. In the present ASPEN model, the parametric
is defined for the water gas shift reaction. The reaction model
values of separation efficiencies of the sand bed filter have been
chosen is the reversible general type and the reaction class selected
considered to be 97%. Laurence and Ashenafi [39] reported the
is power law. The pre-exponential factor, activation energy and the
separation efficiency in the range of 85%e90%. In the present
exponent values reported by Hla et al. [37] are used. One of the raw
model, the parametric value of separation sharpness of solid
materials of the shift process is water (H2O stream). This goes into
separator has been considered to be 85%. The kinetic model for the
the steam generator (STEAMGEN) which is modeled using the
commercial water gas shift catalysts i.e. High Temperature Catalyst
heater block. STEAM is then mixed with the CLNGASIN stream in
(HTC) represented by equations (2) and (3) are reported in Hla et al.
MIXER2 (mixer block), the MIXED stream is then preheated by a
[37] is chosen in the present study. The equilibrium constant is
preheater (PREHEAT). The preheated stream (FEED) goes into the
calculated using the correlation given in equation (5).
REACTOR which is a Rplug reactor. The dimensions and other
specifications such as the reactor temperature and catalyst loading  
88±2:18 0:9±0:041 0:31±0:056
are entered. For a particular simulation, the reaction kinetic model r ¼ 100:659±0:0125 exp P CO P H2 O
has been chosen accordingly. The outlet of the reactor (H2RICH) is
RT (2)
then condensed in a condenser (CONDENS) which is modeled using P 0:156±0:078
CO2 P 0:05±0:006
H2 ð1  bÞ
a HeatX block. The minimum temperature approach is set at 10  F
and the hot stream outlet temperature is 40  C. The condensed where b is the approach to equilibrium and is defined as:
1134 T.K. Patra et al. / Energy 173 (2019) 1130e1140

Table 1 Table 2
Description of steams and blocks in the ASPEN model. Various model input parameters used for simulation.

S Stream/Block Description Component Parameter value


No. name
Producer gas Flow rate (m3/sec) 0.0005
1 CLEANGAS Clean gas exiting the sand bed filter Temperature(C) 500
2 COLD Cooled hydrogen rich gas Pressure (Pa) 130,000
3 COMPRSOR Compressor block Composition (%), dry basis
4 CONDENS Condenser block CO 15
5 CSPM Supermicron mode of SPM H2 15
6 DIRWATER Dirty water collected from the venturi scrubber CO2 13
7 FEED Preheated producer gas and steam mixture CH4 2
8 FINALGAS Final dry hydrogen rich gas N2 55
9 FINESPM Fine mode of SPM Venturi Scrubber Throat diameter (m) 0.025
10 GAS Clean gas exiting the solid separator Water
11 GAS þ SPM Mixture of producer gas and SPM coming out from Flow rate (m3/sec) 1.96e-5
venturi scrubber Temperature (C) 25
12 GASIFIED Producer gas without impurities Pressure (Pa) 150,000
13 GLS Gas- liquid separator block Compressor Discharge pressure (Pa) 600,000
14 H2O Water supplied to the steam generator Steam generator Water
15 H2RICH Hydrogen rich producer gas mixture Flow rate (mL/min) 1
16 HEATLOSS Heat exchanger for cooling the high pressure producer Temperature (C) 25
gas Pressure(bar) 500,000
17 HOTWAT Hot water from the condenser Pre heater Outlet temperature (C) 200
18 HPPROGAS High pressure producer gas Reactor Internal diameter (m) 0.01575
19 LIQUID Excess water drained out Length (m) 0.4
20 MIXED Mixture of producer gas and steam Temperature (C) 350
21 MIXER Mixture block Catalyst loading (kg) 0.00774
22 MIXER2 Mixing of producer gas with steam Catalyst bed length (m) 0.040
23 PREHEAT Preheater block Porosity ̊ 0.565
24 PRODGAS Mixture of producer gas with tar and SPM Catalyst pellet Diameter (m) 0.006
25 REACTOR Water gas shift catalytic reactor block Length (m) 0.006
26 SAND þ DIR Dirty sand collected from the sand bed filter after Condenser Gas outlet temperature (C) 40
cleaning Water
27 SNDBFILT Sand bed filter block Inlet temperature (C) 25
28 SOLID SPM collected from solid separator Pressure (Pa) 100,000
29 SOLIDSEP Solid separator block Heat exchanger Outlet temperature(C) 40
30 STEAM Steam produced from steam generator Net heat duty (cal/sec) 363.514
31 STEAMGEN Steam generator block Vapour fraction 1
32 TANKGAS Part of producer gas that remains in the storage tank Splitter CLNGAS split fraction 0.1
33 COMPGAS Compressed and Cooled producer gas ̊
34 SPLITTER Storage tank block for high pressure producer gas
35 CLNGASIN Part of producer gas that is supplied to the water gas shift
reactor Table 3
36 TAPWAT Cold water for cooling Rplug Reactor and reaction kinetics Parameters.
37 TAR Tar ̊
Catalyst loading (gram) 7.74
38 VSCRUB Venturi scrubber block
Bed voidage 0.565̊
39 WATER Water circulated through the venturi scrubber
Reactor temperature (C) 300e500
Reactor length (cm) 2e10
Reactor diameter (mm) ̊ 15.75
Pre exponential factor (1/s) 4.56
Activation energy (kJ/mol) 88
PCO2 PH2 Concentration exponents (forward reaction) CO: 0.9, H2O: 0.31, CO2: -0.156,
b¼ (3) H2: -0.05
KPCO PH2 O Concentration exponents (backward CO: -0.1, H2O: -0.69, CO2: 0.844,
reaction) H2: 0.95 ̊
K is the equilibrium constant. Co-efficient for driving force constants A: 0, B: 0, C: 0, D: 0
Callaghan [40] reported the following correlation: (forward reaction) ̊
Co-efficient for driving force constants A: 5.5728, B: -5021.92, C: 0, D:-
2180:6 (backward reaction) 0.00088,780
̊
log10 K ¼ 2:1498 þ 0:0003855T þ (4)
T
The RPlug reactor in the model uses catalyst loading with
amount of catalyst, porosity of catalyst bed and temperature of the
4. Results and discussion
reactor for simulation. In the reaction section the power law kinetic
model is chosen. In this model the pre-exponential factor, activa-
4.1. Model validation
tion energy, exponent and the coefficients for the reactants and
products for forward and reverse reactions are entered. The details
In this section, the simulation results of the developed Aspen
of the data used are gin in Table 3.
Plus model is validated with the experimental results obtained
Power law kinetic expression: ̊
using the model producer gas mixture and also the experimental
results reported by Marono et al. [30]. The composition of model
R ¼ ½kinetic factor ½driving force
product gas, GHSV, steam to CO ratio, catalyst weight and the
catalyst composition data from the previous experimental study
Kinetic factor ¼ k eE=RT are used as the input parameters to the model. Details of the model
input parameters used from the model gas mixture experimental
T.K. Patra et al. / Energy 173 (2019) 1130e1140 1135

study are given in Table 4. The model is validated by comparing the 50


Hydrogen
CO and H2 composition in the product gas mixture obtained at Model Prediction
different reactor temperature for three different GHSV values of Experimental
1356, 2712 and 5425 h1 with the corresponding experimental 40 Carbon Monoxide

Product gas Composition(%)


results. Model Prediction
Figs. 3e5 shows the comparison of model predicted H2 and CO Experimemtal
30
composition with the respective experimental results obtained for
GHSV of 1356, 2712 and 5425 h1 respectively. Form the results
shown in Fig. 3 it is observed that, for GHSV of 1356 h1 the model
20
predicted H2 and CO composition of the product gas matches well
with the experimental results. Moreover, for the GHSVs of 2712 h1
and 5425 h1 as shown in Figs. 4 and 5, the model predicted CO and 10
H2 compositions values matches exactly with that of the corre-
sponding experimental results. The H2 composition for GHSV 2712
h1 and 5425 h1 matches exactly with the experimental data for 0
all reactor temperatures. In case of the CO composition in the
product gas for the GHSV of 1356 h1, the model predicted CO
300 325 350 375 400

composition value is less than that of the results obtained from the Reactor Temperature(deg C)
experimental study. However, at higher GHSVs of 2712 h1 and Fig. 4. Comparison of experimental data of the present study with the model pre-
5425 h1, the model predicted CO composition values and the dicted H2 and CO compositions in the product gas for GHSV 2712 h1..
corresponding experimental values matches well. In fact for lower
reactor temperatures it exactly matches with the experimental CO
composition for all GHSVs. 50
Hydrogen
The developed model is also validated with experimental results Model Prediction
reported by Marono et al. [30] for CO and H2 composition in the Experimental
40 Carbon Monoxide
product gas at different reactor temperatures. The composition of
Product gas Composition(%)

product gas, space velocity, steam to CO ratio, catalyst weight and Model Prediction
Experimemtal
catalyst composition reported by Marono et al. [30] are used as
30

Table 4 20
Experimental data from present study used for simulation.

Feed gas composition Component Composition (%


10
v/v)
CO 15.95
H2 15.74
CO2 12.41 0
CH4 5.00
N2 50.90 300 325 350 375 400
Space velocity (h1) 1356, 2712 & 5425 Reactor Temperature(deg C)
Steam/CO ratio 8
Catalyst weight (gm) 6 Fig. 5. Comparison of experimental data of the present study with the model pre-
Catalyst Composition (wt %) Fe2O3 Cr2O3 dicted H2 and CO compositions in the product gas for GHSV 5425 h1..
92 8

model input parameters and the values are given in Table 5.


50 Fig. 6 shows the comparison of model predicted CO and H2
Hydrogen
Model Prediction
compositions with the experimental values as reported by Marono
Experimental et al. [30] at different reactor temperatures for GHSV 2885 h1. The
40 Carbon Monoxide model predicted CO and H2 composition values match closely with
Product gas Composition(%)

Model Prediction the experimental values. The CO composition decreases rapidly


Experimemtal with the increase in reactor temperature up to 370  C and beyond
30 that the CO composition increases slightly with the increase in
reactor temperature up to 430  C, which is clearly captured by the
simulated model. At lower and higher reactor temperatures i.e.
20
300  C and 430  C, the model predicted CO composition values
matches closely with the experimental data. However, for inter-
mediate reactor temperatures i.e. 350  C and 380  C, the model
10
slightly over predicts the CO conversion and consequently, lower
values of CO composition is predicted in comparison to experi-
mental data. The model predicted CO compositions varies from
0
23.54% to a minimum value of 6.60%, which is achieved at a reactor
300 325 350 375 400 temperature of 370  C. From Fig. 6, it is also seen that the H2 pro-
Reactor Temperature(deg C) duction increases with the increase of reactor temperature. For all
reactor temperature values, i.e. from 300  C to 470  C, the model
Fig. 3. Comparison of experimental data of the present study with the model pre-
dicted H2 and CO compositions in the product gas for GHSV 1356 h1.. predicted values matches closely with the experimental results.
1136 T.K. Patra et al. / Energy 173 (2019) 1130e1140

Table 5 100
Experimental data reported by Marono et al. [30] used for simulation. Hydrogen
90 Model Prediction
Feed gas composition Component Composition (%
Experimental
v/v, dry basis) 80

Product gas composition (%)


Carbon Monoxide
CO 44
70 Experimental
H2 40
CO2 15
Model Prediction
CH4 1 60
Space velocity (h1) 2885 & 10,000
50
Steam/CO ratio 2
Catalyst weight (gm) 5 40
Catalyst Composition (wt %) Fe2O3 Cr2O3
92 8 30

20

100 10
Hydrogen
90 Model Prediction 0
Experimental 280 300 320 340 360 380 400 420 440
80
Product gas composition (%)

Carbon Monoxide o
Reactor Temperature ( C)
70
Experimental
Model Prediction Fig. 7. Comparison of experimental data of Marono et al. [30] with the model pre-
60 dicted H2 and CO compositions in the product gas for GHSV 10,000 h1.

50

40 CO increases in the reactor outlet stream. This is justified by the


simple fact that an increase in the GHSV decreases the residence
30 time of the reactants, leading to reduced conversion. The maximum
20 amount of H2 and CO2 produced at a GHSV of 1000 h1 are 27.02%
and 21.81%. On the other side, the CO concentration at the reactor
10 outlet reaches a much lower value of 0.31% for a GHSV of 1000 h1.
0 From the results, it is inferred that GHSV of 1000 h1 is the opti-
280 300 320 340 360 380 400 420 440 460 480 mum value for the maximum H2 and CO2 production. It can be seen
Reactor Temperature ( C)
o in Fig. 8 that, at lower GHSV values the CO conversion is very high
and at higher values it is a much lower value. This may be due to the
Fig. 6. Comparison of experimental data of Marono et al. [30] with the model pre- decrease in residence time of producer gas mixture in the catalyst
dicted H2 and CO compositions in the product gas for GHSV 2885 h1.
bed at higher GHSV values. The maximum CO conversion achieved
at a GHSV of 1000 h1 for is 97.54%.The CO conversion varies from
97.54% at 1000 h1 to a Minimum of 81.78% at 20,000 h1 GHSV.
Beyond 415  C, H2 production almost starts to decrease slowly with
the further rise in reactor temperature, which is in line with the
experimental trend. The H2 composition value predicted by the 4.2.2. Effect of catalyst bed length
model varies from 44.08% at 300  C to a maximum of 56.13% at The catalyst bed length defines the amount of the catalyst used
415  C. In Fig. 7, the model predicted CO and H2 composition values in the reactor. This parameter affects the residence time of the re-
are compared with the experimentally obtained values reported by actants. For a given mass of catalyst, the bed length can be calcu-
Marono et al. [30] for GHSV 10,000 h1. The results are matching lated using the porosity, which in our case is 0.565. In this study, the
very well with the experimental data for GHSV of 10,000 h1 as bed length has been varied from 2 cm to 10 cm at reactor
well. The CO composition predicted by the model varies from
35.01% at 300  C to a minimum value of 5.91% at 415  C. The H2
40 100
composition value predicted by the model varies from 48.83% at CO
300  C to a maximum of 55.85% at 370  C. CO2
H2
CO conversion
80
30
4.2. Simulation results
Product gas composition(%)

CO conversion (%)

4.2.1. Effects of GHSV 60


20
The GHSV is defined as the ratio of total flow rate of reactants
into the reactor to the catalyst bed volume used in the reactor. This
parameter affects the residence time of the reactants. In the present 40

study, the GHSV is varied from 1000 h1 to 20,000 h1 at reactor 10

temperature of 350  C and S/CO ratio of 8. The GHSV is varied over


20
this wide range by changing the flow rate of the reactants and by
keeping the catalyst length constant at 4 cm. The volumetric flow 0
rate of the water in the pre-heater is kept constant at 1 ml/min. The
0
compositions of CO, CO2 and H2 (dry basis) is studied along with the -5000 0 5000 10000 15000 20000 25000 30000
CO conversion (XCO) for various GHSVs. -1
GHSV (h )
Fig. 8 the effects of GHSV on the product gas composition and CO
conversion at S/CO ratio of 8. It has been observed that as the GHSV Fig. 8. Variation of product gas composition (CO, CO2 and H2) and CO conversion with
increases, the amount of H2 and CO2 decreases, while the amount of GHSV.
T.K. Patra et al. / Energy 173 (2019) 1130e1140 1137

temperature of 350  C, S/CO ratio of 8. The volumetric flow rate of 40 100


CO
the water in the pre-heater is kept constant at 1 ml/min. The CO2
H2
compositions of CO, CO2 and H2 (dry basis) have been studied along COconversion

with the CO conversion (XCO) for various catalyst bed lengths. A 80


30

Product gas composition (%)


FORTRAN script is used to define the conversion and the compo-
sition variables.

CO conversion (%)
60
20
L ¼ 4*W/7.74
V ¼ L*194.729*10
40
VFLOW ¼ MFLOW/DENSITY
10
VFLOW ¼ VFLOW*(P*273.15/T)
SPACEV ¼ VFLOW*1000/V
20
X ¼ (COIN-COOUT)*100/COIN
0
CO ¼ CO*100/ (1-H2O)
CO2 ¼ CO2*100/ (1-H2O) 0
H2 ¼ H2*100/ (1-H2O) 250 300 350 400 450 500 550 600
o
Reactor temperature ( C)
Fig. 9 shows the effect of catalyst bed length on the product gas
composition and CO conversion at S/CO ratio of 8. It is observed that Fig. 10. Variation of product gas composition (CO, CO2, and H2) with reactor
with the increase in catalyst bed length H2 and CO2 composition temperature.

increases and that of CO decreases in the reactor outlet stream. This


is justified by the simple fact that an increase in the catalyst amount
increases the residence time of the reactants, thus a better con-
version. The values of zero catalyst bed length show the inlet observed that a major change in the concentration of the compo-
producer gas composition. The maximum amount of H2 and CO2 nents occurs in the temperature range of 300  Ce400  C. The
produced at a catalyst bed length of 10 cm are 25.98% and 20.69%. concentrations of CO2, H2 increases with reactor temperature and
On the other side, the CO concentration at the reactor outlet rea- reached the maximum value at 400  C however, beyond this
ches a much lower value of 2.58 for a catalyst bed length of 8 cm. temperature further increase in temperature results in decrease of
From the results, it is inferred that catalyst bed length of 8 cm is the H2 and CO2 compositions. This may be due to the reaction achieves
optimum value for the maximum H2 and CO2 production, beyond equilibrium conversion. Hence in case of high temperature shift
this further rise in length, has a negligible effect on product gas the reaction favors backward reaction with increase in reactor
composition. It can be seen in Fig. 9 that, with the increase in temperature. The maximum concentration of H2 and CO2 pre-
catalyst bed length up to 8 cm the CO conversion increases sharply dicted at reactor temperatures of 450  C and 500  C are 26.64% &
and after that the conversion rate is steep. The maximum CO con- 21.40%. The outlet gas CO composition reaches the lowest value of
version achieved at a catalyst bed length of 10 cm is 86.51%.The CO 0.83% at 450  C and that of 1.21% at 500  C. Despite the fact that
conversion varies from 34.43% at 2 cm bed length to a maximum of water gas shift reaction is an exothermic reaction, at high tem-
86.51% at 10 cm bed length. peratures, a high conversion of CO and concentrations of the
products were observed. Thus, the high temperature shift reaction
(HTS) is highly sensitive towards the reaction temperature and is
4.2.3. Effect of reactor temperature controlled by chemical kinetics rather than its thermodynamics.
Fig. 10 shows the effect of reactor temperature on the outlet gas With the increase in reactor temperature, the CO conversion in-
composition and CO conversion at an S/CO ratio of 8. As the tem- creases exponentially up to 400  C. There is no substantial varia-
perature of the reactor was increased, the concentration of CO tion in CO conversion with the further increase in reactor
decreases while the CO2 and H2 concentration increases. It can be temperature. The maximum CO conversion of 93.48% is predicted
at reactor temperatures of 450  C. At lower values of reactor
temperature of 300  C the CO conversions reduced to the lowest
40 100
CO value of 17.75%.
CO2
H2
35 COconversion
80 4.2.4. Effect of steam to CO ratio
30 Fig. 11 shows the effect of S/CO ratio on the reactor outlet gas
Product gas composition (%)

composition of CO, CO2 and H2. From the figure it is seen that with
CO conversion (%)

25
60 the increase in S/CO ratio the composition H2 and CO2 increases and
that of CO decreases. At S/CO ratio of 8 the maximum amount of H2
20
and CO2 obtained in the product gas stream are 26.64% and 21.40%
40 respectively. The maximum amount of H2 and CO2 produced at S/
15
CO of 8 are 26.64% and 21.40%. Fig. 12 shows the effect of S/CO on CO
10 conversion at different reactor temperatures. It can be seen that
20 higher S/CO gives higher CO conversion. While increasing the S/CO
5 from 2 to 4, the CO conversion value goes up from 69.27% to 86.13%
and the further rise in S/CO to 8 results in increase in CO conversion
0 0
to a maximum value of 93.48%. By analyzing the outlet gas
0 2 4 6 8 10 12 14
composition profiles, the S/CO ratio of 8 is found to be the optimum
catalyst bed length (cm)
at all reactor temperatures for maximum CO conversion and H2
Fig. 9. Variation of product gas composition (CO, CO2 and H2) and CO conversion with production since there is no significant variation is observed in the
catalyst bed length. product gas composition beyond this value.
1138 T.K. Patra et al. / Energy 173 (2019) 1130e1140

Table 6
S/CO=2 List of different factors with their levels.
25 CO
Factor Level-1 Level-2 Level-3
CO2
H2 GHSV (h1) 1000 1500 2000
Product gas composition (%)

20 S/CO=4 S/CO 2 4 8
CO Reactor temperature (C) 300 350 400
CO2
15 H2
S/CO=6 has 3 levels. So, accordingly, the total number of experiments which
CO
is given by (level) factor becomes 27. The results of all the 27 ex-
10 CO2
H2
periments are shown in the following Table 7. The response variable
S/CO=8 considered in the experiment is the product gas composition and
5 CO CO conversion.
CO2 On examining the above results, it is observed that highest CO
H2 conversion of about 97.55% and H2 composition of 27.026% are
0 achieved for GHSV 1000 h1, S/CO ratio of 8 and temperature
250 300 350 400 450 500 550 600 350  C. The GHSV 2000 h1, S/CO ratio of 2 and the reactor tem-
Reactor temperature ( C)
0
perature of 300  C corresponds to the lowest CO conversion of
63.35% and the lowest H2 composition of 23.687%. Unlike the
Fig. 11. Effect of steam to CO ratio on outlet gas composition.
temperature dependence trend observed before, the conversion of
CO is not higher at temperatures as high as 400  C. For instance, the
100
conversion at a specific GHSV and S/CO ratio is higher at 350  C
S/CO 2 than at 400  C. From this it can be inferred that at low GHSVs,
S/CO 4 unlike in the previous study, the optimum temperature for the shift
80
S/CO 6 reaction is 350  C. ̊Note that the temperature dependence is still
S/CO 8
followed as the conversion at 300  C is lower than that at 400  C
and 350  C. The conversion of CO also increases with the S/CO ratio.
CO conversion (%)

60 The majority of CO gets converted when the S/CO ratio is 8. At


300  C, and GHSVs 1500 h1 and 2000 h1, the conversion at S/CO
ratio of 8 is even lower than that for S/CO ratio of 4. Thus, if the
40 reaction temperature reaches up to 300  C, the trend of higher CO
conversion for high S/CO ratio may not fit well(except for those
with GHSV at 1000 h1).With respect to GHSV, the lower the value
20 of the GHSV, higher is the conversion. This can be explained by the
fact that GHSV is inversely related to the residence time of the
reactant. Lower is the GHSV, the more time the reactant spends in a
0 reactor and thus, the residence time is higher. So, we observe a very
250 300 350 400 450 500 550 600 high conversion at GHSV 1000 h1 followed by 1500 h1 and 2000
0
Reactor temprature ( C) h1. As discussed before, the minimum residence time for the re-
actants must be 0.09 s. In this simulation study, it varies from
Fig. 12. Effect of steam to CO ratio on CO conversion. around 2.23 se4.45 s which much more than the minimum
requirement. Therefore, using the results obtained in this simula-
tion, the experiments can be performed accordingly and be used to
4.3. Optimization study
verify your findings.
As seen earlier, the shift reaction process is affected by various
operating parameters such as catalyst bed length, reactor temper- 5. Conclusions
ature, Steam to CO ratio and GHSV. Thus, there is a need for opti-
mization of these parameters to find optimum operating In the present study, a steady state model was developed for
conditions. Out of various experimental design methods available biomass gasification based producer gas cleaning unit and water
full factorial design method is chosen in the present study. This gas shift catalytic reactor unit using ASPEN Plus. The gas coming out
method taken into account all the possible combinations of from the gasifier was represented as a mixture of producer gas, tar,
different operating parameters considered for the optimization CSPM and SPM. Two cleaning units used to clean the gas mixture
study. The Factorial experiment is an experiment which contains were venturi scrubber and sand bed filter. The clean gas was then
two or more parameters affecting it. It helps to study the effect of
fed to a water gas shift catalytic reactor for hydrogen-rich enrich-
the factors on a particular variable. The values of the factors are ment. A RPlug reactor was used to model the water gas shift cat-
discretized called ‘levels’. The total number of combinations equals
alytic reactor unit. The reaction scheme of the catalytic reactor was
to (level) factor. Hence, the number of factorial designs is defined. defined by a power law kinetic model for commercial higher
In the present study, a large number of levels are present, which
temperature shift catalyst. The model was validated with the
increases the number of factorial designs. It is difficult to perform so experimental data of our previous study and with the literature
many experiments and hence full factorial design of experiments is
data reported by Marono et al. [30] for CO conversion and H2
used in the present study for simulation. The number of factors is composition at different GHSVs. The model predictions were found
three with three levels for each. The levels are chosen based on the
to be matching well with the experimental results. A parametric
experimental constraints of the present experimental set up. The analysis was also carried out to study the effect of various operating
factors considered and their levels are given in Table 6. Every factor
parameters such as GHSV, catalyst bed length, water gas shift
T.K. Patra et al. / Energy 173 (2019) 1130e1140 1139

Table 7
Experimental matrix for factorial design study.

Run No. GHSV (h1) S/CO T ( C) CO conversion(%) H2 composition(vol %)

1 2000 2 300 63.35,134 23.68,704


2 2000 2 350 86.20,049 25.95,071
3 2000 2 400 79.59,864 25.31,058
4 1500 2 300 72.42,476 24.60,231
5 1500 2 350 86.47,895 25.97,746
6 1500 2 400 79.59,809 25.31,052
7 1000 2 300 82.99,626 25.64,132
8 1000 2 350 86.52,842 25.98,214
9 1000 2 400 79.59,936 25.31,054
10 2000 4 300 72.99,816 24.65,938
11 2000 4 350 94.41,920 26.73,243
12 2000 4 400 90.95,737 26.40,516
13 1500 4 300 82.01373 25.54,581
14 1500 4 350 94.52,343 26.74,213
15 1500 4 400 90.95,870 26.40,512
16 1000 4 300 91.39,887 26.44,708
17 1000 4 350 94.53,463 26.74,330
18 1000 4 400 90.95,726 26.40,517
19 2000 8 300 81.20,366 25.46,710
20 2000 8 350 97.52,744 27.02378
21 2000 8 400 95.81,570 26.86,359
22 1500 8 300 89.14,455 26.23,270
23 1500 8 350 97.54,345 27.02532
24 1500 8 400 95.81,739 26.86,382
25 1000 8 300 96.10,031 26.89,028
26 1000 8 350 97.54,790 27.02570
27 1000 8 400 95.81,789 26.86,381

reactor temperature, and steam to CO ratio on the product gas Funding


composition and CO conversion. The model performance evalua-
tion is reported in terms of CO conversion and H2 composition in This work was financially supported by Department of Science
the product gas. The maximum CO conversion and H2 production and Technology, Government of India, New Delhi, under the fast-
were achieved at GHSV of 1000 h1, catalyst bed length of 10 cm, track scheme for young scientists (Grant no.SB/FTP/ETA 213/2012).
the reactor temperature of 350  C and S/CO ratio value of 8. An
optimization study was also carried out using the factorial design References
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