Modeling and optimization of methane tri-reforming reactor under different side-feeding strategies with the aim of maximizing hydrogen yield

Document Type : Research Article

Authors

Department of Chemical Engineering, College of Engineering, University of Isfahan, P.O. Box 81746-73441, Isfahan, Iran

Abstract

The use of membrane reactors to distribute one or more components through the membrane (also known as side-feeding strategy) is an efficient method for controlling reactions pathways and achieving the highest performance. In this study, an optimization of three types of membrane reactor and a conventional tri-reformer was carried out to maximize H2 yield subject to produce the proper syngas for the next common processes, including methanol, Fischer-Tropsch, and dimethyl ether (DME) direct synthesis. In this regard, a sensitivity analysis was performed to identify significant parameters affecting H2 yield in O2, CO2, and H2O membrane reactors. A comparison between these configurations under optimal conditions shows that O2 side-feeding strategy was the most favorable strategy in terms of CH4 conversion, H2 yield, and catalyst lifetime due to no formation of hot spot temperature. Also in this strategy, the H2 yield was increased by 8% and 10% compared to the conventional tri-reformer to produce suitable syngas for the methanol and DME direct synthesis processes, respectively.

Keywords

Main Subjects


[2] Akbari-Emadabadi S., Rahimpour M.R., Hafizi A., Keshavarz P., Production of Hydrogen-rich Syngas Using Zr Modified Ca-Co Bifunctional Catalyst-sorbent in Chemical Looping Steam Methane Reforming, Applied Energy, 206: 51-62 (2017).
[3] Singha R.K., Shukla A., Yadav A., Adak S., Iqbal Z., Siddiqui N., Bal R., Energy Efficient Methane Tri-reforming for Synthesis Gas Production over Highly Coke Resistant Nanocrystalline Ni–ZrO2 Catalyst, Applied Energy, 178: 110-125 (2016).
[4] Matar M., Mirbach M.J., Tayim H.A., "Catalysis in Petrochemical Processes" Kluwer Academic Publishers, Springer, Netherlands (1988).
[5] Özkara-Aydınoğlu Ş., Thermodynamic Equilibrium Analysis of Combined Carbon Dioxide Reforming with Steam Reforming of Methane to Synthesis Gas, International Journal of Hydrogen Energy, 35(23): 12821-12828 (2010).
[6] Cho W., Song T., Mitsos A., McKinnon J.T., Ko G.H., Tolsma J.E., Denholm D., Park T., Optimal Design and Operation of a Natural Gas Tri-reforming Reactor for DME Synthesis, Catalysis Today, 139(4): 261-267 (2009).
[7] Song C. Tri-reforming: A New Process for Reducing CO2 Emissions. Chemical Innovation, 31(1): 21-26 (2001).
[8] Rahimpour M.R., Aboosadi Z.A., Jahanmiri A., Synthesis Gas Production in a Novel Hydrogen and Oxygen Perm-selective Membranes Tri-reformer for Methanol Production. Journal of Natural Gas Science and Engineering, 9: 149-159 (2012).
[9] García-Vargas J.M., Valverde J.L., de Lucas-Consuegra A., Gómez-Monedero B., Dorado F., Sánchez P., Methane Tri-reforming over a Ni/β-SiC-based Catalyst: Optimizing the Feedstock Composition, International Journal of Hydrogen Energy, 38(11): 4524-4532 (2013).
[10] Chein R-Y., Wang C-Y., Yu C-T., Parametric Study on Catalytic Tri-reforming of Methane for Syngas Production, Energy, 118: 1-17 (2017).
[12] Arab Aboosadi Z., Jahanmiri A., Rahimpour M.R., Optimization of Tri-reformer Reactor to Produce Synthesis Gas for Methanol Production using Differential Evolution (DE) Method, Applied Energy, 88(8): 2691-2701 (2011).
[13] Khajeh S., Arab Aboosadi Z., Honarvar B., A Comparative Study Between Operability of Fluidized-bed and Fixed-bed Reactors to Produce Synthesis Gas through Tri-reforming, Journal of Natural Gas Science and Engineering, 19: 152-160 (2014).
[14] Farniaei M., Abbasi M., Rahnama H., Rahimpour M.R., Shariati A., Syngas Production in a Novel Methane Dry Reformer by Utilizing of Tri-reforming Process for Energy Supplying: Modeling and Simulation, Journal of Natural Gas Science and Engineering, 20: 132-146 (2014).
[15] Rahnama H., Farniaei M., Abbasi M., Rahimpour M.R, Modeling of Synthesis Gas and Hydrogen Production in a Thermally Coupling of Steam and Tri-reforming of Methane with Membranes, Journal of Industrial and Engineering Chemistry, 20(4): 1779-1792 (2014).
[16] Khajeh S., Arab Aboosadi Z., Honarvar B., Optimizing the Fluidized-bed Reactor for Synthesis Gas Production by Tri-reforming, Chemical Engineering Research and Design, 94: 407-416 (2015).
[17] Fekri Lari M., Farsi M., Rahimpour M.R., Modification of a Tri-reforming Reactor based on the Feeding Policy to Couple with Methanol and GTL Units, Chemical Engineering Research and Design, 144: 107-114 (2019).
[18] Farsi M., Fekri Lari M., Rahimpour M.R., Development of a Green Process for DME Production based on the Methane Tri-reforming, Journal of the Taiwan Institute of Chemical Engineers, 106: 9-19 (2020).
[19] Lu Y., Dixon A.G., Moser W.R., Ma Y.H., Analysis and Optimization of Cross-flow Reactors with Distributed Reactant Feed and Product Removal, Catalysis Today, 35(4): 443-450 (1997).
[20] Alipour-Dehkordi A., Khademi M.H., Use of a Micro-porous Membrane Multi-tubular Fixed-bed Reactor for Tri-reforming of Methane to Syngas: CO2, H2O or O2 Side-feeding, International Journal of Hydrogen Energy, 44(60): 32066-32079 (2019).
[21] Alipour-Dehkordi A., Khademi. M.H., O2, H2O or CO2 Side-feeding Policy in Methane Tri-reforming Reactor: The Role of Influencing Parameters, International Journal of Hydrogen Energy, 45: 15239-15253 (2020).
[23] Xu J., Froment G.F., Methane Steam Reforming, Methanation and Water-gas Shift: I. Intrinsic Kinetics, AIChE Journal, 35(1): 88-96 (1989).
[24] Trimm D.L., Lam C-W., The Combustion of Methane on Platinum—alumina Fibre Catalysts—I: Kinetics and Mechanism, Chemical Engineering Science, 35(1): 88-96 (1989).
[25] De Smet C., De Croon M., Berger R., Marin G., Schouten J., Design of Adiabatic Fixed-bed Reactors for the Partial Oxidation of Methane to Synthesis Gas. Application to Production of Methanol and Hydrogen-for-fuel-cells, Chemical Engineering Science, 56(16):4849-4861 (2001).
[26] Weigand B., "Analytical Methods for Heat Transfer and Fluid Flow Problems", Springer, Berlin, Heidelberg (2004).
[27] Holman J.P., "Heat Transfer", McGraw-Hill, United States of America (2010).
[29] Fogler H.S., "Elements of chemical reaction engineering", Prentice Hall, London (1999).
[30] Rodriguez M.L., Ardissone D.E., Heracleous E., Lemonidou A.A., López E., Pedernera M.N., Borio D.O., Oxidative Dehydrogenation of Ethane to Ethylene in a Membrane Reactor:
A Theoretical Study
, Catalyst Today, 157: 303-309 (2010).
[31] Uchytil P., Schramm O., Seidel-Morgenstern A., Influence of the Transport Direction on Gas Permeation in Two-layer Ceramic Membranes, Journal of Membrane Science, 170(2): 215-224 (2000).
[32] Babu B., Angira R., Optimal Design of an Auto-thermal Ammonia Synthesis Reactor, Computers & Chemical Engineering, 29(5): 1041-1045 (2005).
[33] Babu B., Angira R., Modified Differential Evolution (MDE) for Optimization of Non-linear Chemical Processes, Computers & Chemical Engineering, 30(6-7): 989-1002 (2006).
[34] Saad J.M., Williams P.T., Manipulating the H2/CO Ratio from Dry Reforming of Simulated Mixed Waste Plastics by the Addition of Steam, Fuel Processing Technology, 156: 331-338 (2017).
[35] Zhang Y., Zhang S., Benson T., A Conceptual Design by Integrating Dimethyl Ether (DME) Production with Tri-reforming Process for CO2 Emission Reduction, Fuel Processing Technology, 131: 7-13 (2015).
[36] Munro M., Evaluated Material Properties for a Sintered Alpha-alumina, Journal of the American Ceramic Society, 80(8): 1919-1928 (2005).
[37] Hussain A., Seidel-Morgenstern A., Tsotsas E., Heat and Mass Transfer in Tubular Ceramic Membranes for Membrane Reactors, International Journal of Heat and Mass Transfer, 49(13-14): 2239-2253 (2006).
[38] Darvishi A., Bakhtyari A., Rahimpour M.R., A Sensitivity Analysis and Multi-objective Optimization to Enhance Ethylene Production by Oxidative Dehydrogenation of Ethane in a Membrane-assisted Reactor, Chinese Journal of Chemical Engineering, 26: 1879-1895 (2018).
[39] Kang J.S., Kim D.H., Lee S.D., Hong S.I., Moon D.J., Nickel-Based Tri-reforming Catalyst for the Production of Synthesis Gas, Applied Catalysis A: General, 332(1): 153-158 (2007).
[40] Dahl P.J., Christensen T.S., Winter-Madsen S., King S.M., Proven Autothermal Reforming Technology for Modem Large-scale Methanol Plants, Nitrogen + Syngas International Conference & Exhibition, Haldor Topsoe Website, 1-12 (2014).