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Multiphase Reactor Engineering for Clean and Low-Carbon Energy Applications

1. Aufl.

von: Yi Cheng, Fei Wei, Yong Jin
171,99 €
Verlag:	Wiley
Format:	PDF
Veröffentl.:	21.02.2017
ISBN/EAN:	9781119251064
Sprache:	englisch
Anzahl Seiten:	432

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Titelbeschreibung

Provides a comprehensive review on the brand-new development of several multiphase reactor techniques applied in energy-related processes <ul> <li>Explains the fundamentals of multiphase reactors as well as the sophisticated applications</li> <li>Helps the reader to understand the key problems and solutions of clean coal conversion techniques</li> <li>Details the emerging processes for novel refining technology, clean coal conversion techniques, low-cost hydrogen productions and CO2 capture and storage</li> <li>Introduces current energy-related processes and links the basic principles of emerging processes to the features of multiphase reactors providing an overview of energy conversion in combination with multiphase reactor engineering</li> <li>Includes case studies of novel reactors to illustrate the special features of these reactors</li> </ul>

Inhaltsverzeichnis

Preface xiii List of Contributors Xv 1 Novel Fluid Catalytic Cracking Processes 1 Jinsen Gao, Chunming Xu, Chunxi Lu Chaohe Yang, Gang Wang, Xingying Lan and Yongmin Zhang 1.1 FCC Process Description 1 1.2 Reaction Process Regulation for the Heavy Oil FCC 3 1.2.1 Technology Background 3 1.2.2 Principle of the Technology 3 1.2.3 Key Fundamental Research 4 1.2.4 Industrial Validation 7 1.3 Advanced Riser Termination Devices for the FCC Processes 10 1.3.1 Introduction 10 1.3.2 General Idea of the Advanced RTD System 11 1.3.3 Development of the External‐Riser FCC RTD Systems 12 1.3.4 Development of the Internal‐Riser FCC RTDs 15 1.3.5 Conclusions and Perspectives 18 1.4 An MZCC FCC Process 19 1.4.1 Technology Background 19 1.4.2 Reaction Principle for MZCC 19 1.4.3 Design Principle of MZCC Reactor 20 1.4.4 Key Basic Study 23 1.4.5 The Industry Application of MZCC 23 1.4.6 Prospectives 26 1.5 Two‐Stage Riser Fluid Catalytic Cracking Process 28 1.5.1 Preface 28 1.5.2 Reaction Mechanism of Heavy Oil in the Riser Reactor 29 1.5.3 The Proposed TSR FCC Process 32 1.5.4 The Industrial Application of the TSR FCC Technology 33 1.5.5 The Development of the TSR FCC Process 33 1.6 FCC Gasoline Upgrading by Reducing Olefins Content Using SRFCC Process 36 1.6.1 Research Background 36 1.6.2 Reaction Principle of Gasoline Upgrading 37 1.6.3 Design and Optimization on the Subsidiary Riser 38 1.6.4 Key Fundamental Researches 38 1.6.5 Industrial Applications of the SRFCC Process 42 1.6.6 Outlook 43 1.7 FCC Process Perspectives 44 References 45 2 Coal Combustion 49 Guangxi Yue, Junfu Lv and Hairui Yang 2.1 Fuel and Combustion Products 49 2.1.1 Composition and Properties of Fuel 49 2.1.2 Analysis of Compositions in the Fuel 50 2.1.3 Calorific Value of Fuel 50 2.1.4 Classifications of Coal 50 2.1.5 Combustion Products and Enthalpy of Flue Gas 51 2.2 Device and Combustion Theory of Gaseous Fuels 52 2.2.1 Ignition of the Gaseous Fuels 52 2.2.2 Diffusion Gas Burner 52 2.2.3 Fully Premixed‐Type Gas Burner 53 2.3 Combustion Theory of Solid Fuel 53 2.3.1 The Chemical Reaction Mechanism of Carbon Combustion 54 2.3.2 Carbon Combustion Reaction Process 54 2.4 Grate Firing of Coal 55 2.4.1 Coal Grate Firing Facilities 56 2.5 Coal Combustion in CFB Boiler 57 2.5.1 The Characteristic of Fluidized Bed 57 2.5.2 Combustion Characteristic of CFB Boiler 58 2.5.3 Development of Circulating Fluidized Bed Combustion Technology 58 2.5.4 Comparison Between Bubbling Fluidized bed and Circulating Fluidized Bed 59 2.6 Pulverized Coal Combustion 60 2.6.1 Furnace Type of Pulverized Coal Combustion 61 2.6.2 Circulation Mode of Water Wall 62 2.6.3 Modern Large‐Scale Pulverized Coal Combustion Technology 62 2.6.4 The International Development of the Supercritical Pressure Boiler 62 References 63 3 Coal Gasification 65 Qiang Li and Jiansheng Zhang 3.1 Coal Water Slurry 65 3.1.1 The Advantage of CWS 65 3.1.2 The Production of CWS 66 3.1.3 The Atomization of CWS 67 3.2 The Theory of Coal Gasification 70 3.2.1 Overview of Coal Gasification 70 3.2.2 The Main Reaction Processes of Coal Gasification 72 3.2.3 Kinetics of Coal Gasification Reaction 73 3.2.4 The Influencing Factors of Coal Gasification Reaction 77 3.3 Fixed Bed Gasification of Coal 79 3.3.1 The Principle of Fixed Bed Gasification 79 3.3.2 The Classification of Fixed Bed Gasification Technology 81 3.3.3 Typical Fixed Bed Gasification Technologies 81 3.3.4 The Key Equipment for Pressurized Fixed Bed Gasifier 85 3.3.5 The Application and Improvement of Pressurized Fixed Bed Gasifier in China 89 3.4 Fluid Bed Gasification of Coal 90 3.4.1 The Basic Principles of Fluidized Bed Gasification 90 3.4.2 Typical Technology and Structure of Fluidized Bed Gasification 91 3.5 Entrained Flow Gasification of Coal 98 3.5.1 The Principle of Entrained Flow Gasification Technology 98 3.5.2 Typical Entrained Gas Gasification Technologies 101 3.6 Introduction to the Numerical Simulation of Coal Gasification 112 3.6.1 The Numerical Simulation Method of Coal Gasification 112 3.6.2 Coal Gasification Numerical Simulation (CFD) Method 113 References 116 4 New Development in Coal Pyrolysis Reactor 119 Guangwen Xu, Xi Zeng, Jiangze Han and Chuigang Fan 4.1 Introduction 119 4.2 Moving Bed with Internals 121 4.2.1 Laboratory Tests at Kilogram Scale 122 4.2.2 Verification Tests at 100‐kg Scale 125 4.2.3 Continuous Pilot Verification 127 4.3 Solid Carrier FB Pyrolysis 129 4.3.1 Fundamental Study 130 4.3.2 Pilot Verification with Air Gasification 136 4.4 Multistage Fluidized Bed Pyrolysis 139 4.4.1 Experimental Apparatus and Method 139 4.4.2 Results and Discussion 141 4.5 Solid Carrier Downer Pyrolysis 145 4.5.1 Experimental Apparatus and Method 146 4.5.2 Results and Discussion 147 4.6 Other Pyrolysis Reactors 149 4.6.1 Solid Heat Carrier Fixed Bed 149 4.6.2 A Few Other New Pyrolysis Reactors 150 4.7 Concluding Remarks 153 Acknowledgments 153 References 153 5 Coal Pyrolysis to Acetylene in Plasma Reactor 155 Binhang Yan and Yi Cheng 5.1 Introduction 155 5.1.1 Background 155 5.1.2 Principles and Features of Thermal Plasma 156 5.1.3 Basic Principles of Coal Pyrolysis in Thermal Plasma 157 5.1.4 Development of Coal Pyrolysis to Acetylene Process 158 5.2 Experimental Study of Coal Pyrolysis to Acetylene 159 5.2.1 Experimental Setup 159 5.2.2 Typical Experimental Results 161 5.3 Thermodynamic Analysis of Coal Pyrolysis to Acetylene 164 5.3.1 Equilibrium Composition with/without Consideration of Solid Carbon 164 5.3.2 Validation of Thermodynamic Equilibrium Predictions 164 5.3.3 Effect of Additional Chemicals on Thermodynamic Equilibrium 165 5.3.4 Key Factors to Determine the Reactor Performance 166 5.3.5 Key Factors to Determine the Reactor Performance 168 5.4 Computational Fluid Dynamics‐Assisted Process Analysis and Reactor Design 171 5.4.1 Kinetic Models of Coal Devolatilization 171 5.4.2 Generalized Model of Heat Transfer and Volatiles Evolution Inside Particles 176 5.4.3 Cross‐Scale Modeling and Simulation of Coal Pyrolysis to Acetylene 180 5.5 Conclusion and Outlook 183 References 186 6 Multiphase Flow Reactors for Methanol and Dimethyl Ether Production 189 Tiefeng Wang and Jinfu Wang 6.1 Introduction 189 6.1.1 Methanol 189 6.1.2 Dimethyl Ether 189 6.2 Process Description 191 6.2.1 Methanol Synthesis 191 6.2.2 DME Synthesis 192 6.2.3 Reaction Kinetics 195 6.3 Reactor Selection 197 6.3.1 Fixed Bed Reactor 197 6.3.2 Slurry Reactor 198 6.4 Industrial Design and Scale‐Up of Fixed Bed Reactor 200 6.4.1 Types of Fixed Bed Reactors 200 6.4.2 Design of Large‐Scale Fixed Bed Reactor 201 6.5 Industrial Design and Scale‐Up of Slurry Bed Reactor 202 6.5.1 Flow Regime of the Slurry Reactor 202 6.5.2 Hydrodynamics of Slurry Bed Reactor 203 6.5.3 Process Intensification with Internals 203 6.5.4 Scale‐Up of Slurry Reactor 206 6.6 Demonstration of Slurry Reactors 213 6.7 Conclusions and Remarks 214 References 215 7 Fischer–Tropsch Processes and Reactors 219 Li Weng and Zhuowu Men 7.1 Introduction to Fischer–Tropsch Processes and Reactors 219 7.1.1 Introduction to Fischer–Tropsch Processes 219 7.1.2 Commercial FT Processes 219 7.1.3 FT Reactors 220 7.1.4 Historical Development of FT SBCR 221 7.1.5 Challenges for FT SBCR 222 7.2 SBCR Transport Phenomena 222 7.2.1 Hydrodynamics Characteristics 222 7.2.2 Mass Transfer 226 7.2.3 Heat Transfer 229 7.3 SBCR Experiment Setup and Results 231 7.3.1 Introduction to SBCR Experiments 231 7.3.2 Cold Mode and Instrumentation 234 7.3.3 Hot Model and Operation 247 7.4 Modeling of SBCR for FT Synthesis Process 249 7.4.1 Introduction 249 7.4.2 Model Discussion 250 7.4.3 Multiscale Analysis 256 7.4.4 Conclusion 258 7.5 Reactor Scale‐Up and Engineering Design 259 7.5.1 General Structures of SBCR 259 7.5.2 Internal Equipment 259 7.5.3 Design and Scale‐Up Strategies of SBCR 261 Nomenclature 262 References 263 8 Methanol to Lower Olefins and Methanol to Propylene 271 Yao Wang and Fei Wei 8.1 Background 271 8.2 Catalysts 272 8.3 Catalytic Reaction Mechanism 273 8.3.1 HP Mechanism 274 8.3.2 Dual‐Cycle Mechanism 274 8.3.3 Complex Reactions 275 8.4 Features of the Catalytic Process 275 8.4.1 Autocatalytic Reactions 275 8.4.2 Deactivation and Regeneration 276 8.4.3 Exothermic Reactions 278 8.5 Multiphase Reactors 278 8.5.1 Fixed Bed Reactor 279 8.5.2 Moving Bed Reactor 280 8.5.3 Fluidized Bed Reactor 281 8.5.4 Parallel or Series Connection Reactors 284 8.6 Industrial Development 286 8.6.1 Commercialization of MTO 286 8.6.2 Commercialization of MTP 288 References 292 9 Rector Technology for Methanol to Aromatics 295 Weizhong Qian and Fei Wei 9.1 Background and Development History 295 9.1.1 The Purpose of Developing Methanol to Aromatics Technology 295 9.1.2 Comparison of MTA with Other Technologies Using Methanol as Feedstock 297 9.2 Chemistry Bases of MTA 298 9.3 Effect of Operating Conditions 300 9.3.1 Effect of Temperature 300 9.3.2 Partial Pressure 302 9.3.3 Space Velocity of Methanol 302 9.3.4 Pressure 302 9.3.5 Deactivation of the Catalyst 303 9.4 Reactor Technology of MTA 304 9.4.1 Choice of MTA Reactor: Fixed Bed or Fluidized Bed 304 9.4.2 MTA in Lab‐Scale Fluidized Bed Reactor and the Comparison in Reactors with Different Stages 305 9.4.3 20 kt/a CFB Apparatus for MTA 306 9.4.4 Pilot Plant Test of 30 kt/a FMTA System 306 9.5 Comparison of MTA Reaction Technology with FCC and MTO System 310 References 311 10 Natural Gas Conversion 313 Wisarn Yenjaichon, Farzam Fotovat and John R. Grace 10.1 Introduction 313 10.2 Reforming Reactions 313 10.3 Sulfur and Chloride Removal 314 10.4 Catalysts 314 10.5 Chemical Kinetics 315 10.6 Fixed Bed Reforming Reactors 316 10.7 Shift Conversion Reactors 317 10.7.1 High‐Temperature WGS 317 10.7.2 Low‐Temperature WGS 317 10.8 Pressure Swing Adsorption 317 10.9 Steam Reforming of Higher Hydrocarbons 318 10.10 Dry (Carbon Dioxide) Reforming 318 10.11 Partial Oxidation (POX) 320 10.11.1 Homogeneous POX 321 10.11.2 Catalytic Partial Oxidation 321 10.12 Autothermal Reforming (ATR) 321 10.13 Tri‐Reforming 321 10.14 Other Efforts to Improve SMR 322 10.14.1 Fluidized Beds 323 10.14.2 Permselective Membranes 323 10.14.3 Sorbent‐Enhanced Reforming 325 10.15 Conclusions 326 References 326 11 Multiphase Reactors for Biomass Processing and Thermochemical Conversions 331 Xiaotao T. Bi and Mohammad S. Masnadi 11.1 Introduction 331 11.2 Biomass Feedstock Preparation 332 11.2.1 Biomass Drying 332 11.2.2 Biomass Torrefaction Treatment 333 11.3 Biomass Pyrolysis 336 11.3.1 Pyrolysis Principles and Reaction Kinetics 336 11.3.2 Multiphase Reactors for Slow and Fast Pyrolysis 338 11.3.3 Catalytic Pyrolysis of Biomass 342 11.3.4 Biomass‐to‐Liquid Via Fast Pyrolysis 342 11.4 Biomass Gasification 343 11.4.1 Principles of Biomass Gasification 343 11.4.2 Gasification Reactions Mechanisms and Models 344 11.4.3 Catalytic Gasification of Biomass 347 11.4.4 Multiphase Reactors for Gasification 349 11.4.5 Biomass Gasification Reactor Modeling 355 11.4.6 Downstream Gas Processing 356 11.4.7 Technology Roadmap and Recent Market Developments 357 11.5 Biomass Combustion 359 11.5.1 Principles of Biomass Combustion 359 11.5.2 Reaction Mechanisms and Kinetics 360 11.5.3 Multiphase Reactors for Combustion 361 11.5.4 Advanced Combustion Systems 363 11.5.5 Agglomeration, Fouling, and Corrosion 365 11.5.6 Future Technology Developments 365 11.6 Challenges of Multiphase Reactors for Biomass Processing 366 11.6.1 Fluidization of Irregular Biomass Particles 366 11.6.2 Feeding, Conveying of Biomass 366 11.6.3 Reactor Modeling, Simulation, and Scale‐Up 367 11.6.4 Economics of Commercial Biomass Conversion Systems 368 References 369 12 Chemical Looping Technology for Fossil Fuel Conversion with In Situ CO2 Control 377 Liang‐Shih Fan, Andrew Tong and Liang Zeng 12.1 Introduction 377 12.1.1 Chemical Looping Concept 377 12.1.2 Historical Development 379 12.2 Oxygen Carrier Material 381 12.2.1 Primary Material Selection 381 12.2.2 Iron‐Based Oxygen Carrier Development 382 12.3 Chemical Looping Reactor System Design 384 12.3.1 Thermodynamic Analysis 385 12.3.2 Kinetic Analysis 388 12.3.3 Hydrodynamic Analysis 392 12.4 Chemical Looping Technology Platform 396 12.4.1 Syngas Chemical Looping Process 397 12.4.2 Coal Direct Chemical Looping Process 398 12.4.3 Shale Gas-to-Syngas Process 399 12.5 Conclusion 400 References 401 Index 405

Autorenportrait

Yi Cheng is currently a Professor in the Department of Chemical Engineering at Tsinghua University. He has received several awards such as the first prize of Natural Science Award by the Ministry of Education of China and the first prize of Science and Technology Progress Award by China Petroleum and Chemical Industry Federation. He has written numerous articles and presented papers at many conferences. Fei Wei is currently a Professor in the Department of Chemical Engineering at Tsinghua University. He has been the head of Fluidization Lab of Tsinghua University (FLOTU) for 20 years, and received several top-level national awards in China. He has written numerous articles, book chapters and book chapters and presented papers at many conferences. Yong Jin is currently a Professor in the Department of Chemical Engineering at Tsinghua University and a Member of the Chinese Academy of Engineering. He has authored more than 300 published articles, numerous books and book chapters and presented papers at approximately 50 conferences.

Back cover copy

Provides a comprehensive review on the brand-new development of several multiphase reactor techniques applied in energy-related processes Almost all of the fuels, chemicals, and materials used by modern society are produced through chemical transformations, where multiphase reactors play the core role in these industrial chemical transformations. Multiphase Reactor Engineering for Clean and Low-Carbon Energy Applications covers the applications of multiphase reactors in the energy-related processes, especially to the emerging processes of clean, highly efficient conversion of fossil fuels to chemical products. The book provides a comprehensive review on the development and characteristics of conventional and non-conventional multiphase reactors, with topics on the state of the art of applications of multiphase reactors. Each chapter is led by a process description starting with the basic chemical reaction principles followed by the analysis of reactors for the appropriate reactor selection and concluding with industrial development of multiphase reactors. Multiphase Reactor Engineering for Clean and Low-Carbon Energy Applications features: <ul> <li>Emerging processes for novel refining technology, clean coal conversion techniques, hydrogen production and CO2 capture and storage</li> <li>Current energy-related processes and links the basic principles of emerging processes to the features of multiphase reactors to provide an overview of energy conversion in combination with multiphase reactor engineering</li> <li>Case studies of novel reactors with illustration of the special features of these reactors</li> </ul> Multiphase systems are found in a number of diverse areas of applications, including the manufacture of petroleum-based products and fuels, the production of commodity and specialty chemicals, pharmaceuticals, herbicides and pesticides, refining of ores, production of polymers and other materials, and so on. Multiphase reactor engineering will continue to play a key role in industrial developments.