Ethylene Production
Ethylene Production
Ethylene Production
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Abdulrahman A. Al-Rabiah
King Saud University
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Received 27 July 2004; received in revised form 4 October 2004; accepted 21 February 2005
Available online 31 May 2005
Abstract
A rigorous two-dimensional mathematical model is used to simulate a bench-scale membrane reactor for ethane dehydrogenation to ethylene
using a palladium-based membrane. Since the reaction is equilibrium limited the removal of the product hydrogen by the membrane shifts
the thermodynamic equilibrium. For further displacement of the thermodynamic equilibrium, auxiliary hydrogenation reaction of benzene
to cyclohexane over nickel catalyst is used to remove part of hydrogen. The two catalysts are loaded together in a well-mixed pattern
configuration. Optimal conditions are observed and explanations offered. An effective length criterion for the optimal conditions is presented.
The results show that the well-mixed pattern strategy has substantial improvement in the reactor performance in terms of high conversions,
low temperatures and reduced mass of the catalyst used. The investigation, although is restricted to two catalyst, has uncovered a part of the
rich characteristics of this system.
© 2005 Elsevier B.V. All rights reserved.
0255-2701/$ – see front matter © 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.cep.2005.02.004
M.E.E. Abashar, A.A. Al-Rabiah / Chemical Engineering and Processing 44 (2005) 1188–1196 1189
Recently, several studies have shown that the performance where I at temperature (T0 ) is given by
of the fixed bed catalytic reactors (FBRs) and fixed bed cat-
H ◦ a b c 2 d 3
alytic membrane reactors (FBMRs) has improved signifi- I= − ln T0 − T0 − T − T
cantly by introduction of the dual-functionality via structured RT0 R 2R 6R 0 12R 0
pattern (either mixed or layered configuration) of the catalyst e 4 G◦
− T − (5)
bed [5–7,16]. The purpose of these patterns is to couple the 20R 0 RT0
reactions in different ways to achieve certain degree of inte-
gration of heat, further shift of thermodynamic equilibrium 2.2. Auxiliary reaction
and simultaneous production of more than one product.
Ethane dehydrogenation to ethylene is endothermic and The purpose of the auxiliary reaction is to remove hy-
thermodynamically limited reaction. The membrane reactor drogen for further displacement of the dehydrogenation ther-
technology is very attractive field to be implemented in this modynamic equilibrium. This may be accomplished through
respect, however very little research work has been done so hydrogenation of benzene on nickel catalysts to cyclohexane.
far [9,10,12]. The authors [9,10,12] have shown experimen- The kinetics is given by [19]:
tally that the conversion of ethane to ethylene has improved
C6 H6 + 3H2 → C6 H12 (6)
substantially by implementing the membrane reactors, how-
ever high conversions still require high temperatures. The P C 6 H6 P H2
R2 = k2 KB (7)
objective of this investigation is to explore the potential ap- (1 + KB PC6 H6 )(PC6 H6 + PH2 )
plication of integrated catalytic membrane reactors for simul-
taneous production of ethylene and cyclohexane at relatively the rate constant is given by
low temperatures. The concept of the dual-functionality of the 6038.65
catalyst bed is implemented in an experimental co-current k2 = 121.11 × exp − (8)
T
composite membrane reactor. The thermodynamic equilib-
rium is shifted by the membrane and auxiliary reaction. A and the adsorption equilibrium constant of benzene is given
rigorous mathematical model is utilized to study the influ- by
ence of various parameters and to identify the key parame-
3019.32
ters that are likely to affect the catalyst pattern strategies and KB = 788.0 × exp − (9)
T
the performance of the membrane reactors. This preliminary
investigation is restricted to two types of catalysts.
3. Hydrogen permeation rate
a co-current packed bed membrane reactor. A schematic di- The boundary conditions are
agram of the composite Pd–Ag membrane reactor is given
in Fig. 1. The following simplifying assumptions are used in ∂Cit
L = 0, Cit = Cift ; r1 = 0, = 0;
the derivation of the conservation equations of the model: ∂r1
1. The reactor operates at steady state conditions and isother- r1 = R1 , Cit = Cic ; i = 1–5 (13)
mally with negligible pressure drop.
2. The membrane has exclusive selectivity for hydrogen. The effective diffusivity coefficient is calculated from [22]:
This assumption is justified by the experimental evidence 1 − yi
of Gobina et al. [11]. Dei = (14)
n
3. The reactions are considered to take place only in the tube (yi /Dij )
side. j=1
j = i
4. Negligible diffusion resistances within the catalyst parti-
cles.
5. Axial diffusion is negligible. 4.2. Ceramic support
6. The ideal gas law is obeyed.
The differential mass balance equations on component i
is given by
4.1. Tube side
Deci ε2 ∂ ∂Cc
The differential mass balance equations on component i r2 i = 0, R1 < r2 < R2 , i = 1–5
r2 ∂r2 ∂r2
is given by (15)
∂Cit Det i ε1 L0 1 ∂ ∂Cit (1 − ε1 )L0
= r1 + The boundary conditions are
∂L ul r1 ∂r1 ∂r1 ul
n=2 ∂Cit
∂Cic
= Dei ε2
c
, i = 1–5;
where i = 1, 2, 3, 4 and 5 for C2 H6 , C2 H4 , H2 , C6 H6 and ∂r2
r2 =R1
C6 H12 , respectively, γ ij the stiochiometric coefficient of com-
∂Cic
for H2 are ignored due to the small particle used. Abashar [24] has
given special attention in his published article to the total dif-
∂C3c
Q
=
0
PHt 2 − PHs 2 (17) fusive fluxes in the catalyst pellet in the pilot plant reactor.
Fig. 2. Comparison of fixed bed (FBR) and fixed bed membrane (FBMR) re-
actors: (a) ethane conversion vs. dimensionless reactor length; (b) hydrogen
partial pressure vs. dimensionless reactor length. Fig. 4. Effect of sweep ratio (SR) on the exit ethane conversion for various
temperatures.
decrease of the membrane thickness increases the hydrogen effect of the decrease of the membrane thickness on the exit
permeation rate, then equilibration of the partial pressures ethane conversion.
on each side of the membrane occurs and the permeation Fig. 6 shows the effect of tube side total pressure (Pt )
rate drops accordingly. On the other hand, if the equilibrium on the exit ethane conversion. The dehydrogenation reac-
is approached too slowly the removal of hydrogen will not tion of ethane (Eq. (1)) shows that the total number of moles
affect the conversion in this small reaction volume. In fact, increases. Therefore, the reaction is thermodynamically fa-
the amount of hydrogen permeating per unit time through a vored at low pressure according to Le Châtelier’s [5] principle
specific membrane area must match the amount of hydrogen and at the same time the high pressure favors the hydrogen
produced by the reaction in the given volume of the reactor permeation driving force. As one can see clearly that the
per unit time at the existing driving force. The hydrogen pro- decrease of pressure has positive effect on the exit ethane
duction and removal should be at comparable rates. Neither conversion. This could be due to the fact that under these
the production rate nor removal rate of hydrogen are constant operating conditions the effect of decrease of pressure on
within this small reaction volume. This may explain the little the displacement of the thermodynamic equilibrium is more
M.E.E. Abashar, A.A. Al-Rabiah / Chemical Engineering and Processing 44 (2005) 1188–1196 1193
Fig. 8. Exit ethane conversion vs. catalyst 2 concentration for various tem-
peratures. Fig. 10. Effect of temperature on the dimensionless effective reactor
length.
It can be seen that the complete conversion of ethane is shown that the profile at all temperatures present a minimum
attained at different reactor lengths depending on the bed value at which the effective reactor length is optimal. The
compositions. Also, the exit ethane conversion increases and minima steadily decrease as the temperature increases and
decreases as the amount of catalyst 2 increases, i.e. there ex- the effective length regions shrink with the decrease of tem-
ist optimal conditions under which the complete conversion perature. It appears that the temperature has a pronounced
of ethane is achievable. In order to investigate the optimum effect on the effective reactor length and the position of the
conditions, we define an effective reactor length (Leff ) as the optimal conditions.
reactor length that gives 99.8% conversion of ethane. This The effect of the tube side pressure on the dimen-
criterion is fair enough to find the optimum conditions. sionless effective reactor length is shown in Fig. 11. The
Fig. 10 shows the dimensionless effective reactor length increase of the pressure has two opposing effects on the
versus the bed composition for different temperatures. It is thermodynamic equilibrium. The increase of the pressure
Fig. 9. Ethane conversion along the reactor for different concentrations of Fig. 11. Effect of tube side pressure on the dimensionless effective reactor
catalyst 2. length.
M.E.E. Abashar, A.A. Al-Rabiah / Chemical Engineering and Processing 44 (2005) 1188–1196 1195
has positive effect on the hydrogen permeation driving force k2 reaction rate constant of hydrogenation reaction
and the hydrogenation reaction of benzene due to the de- (kg mol/kg s)
crease in number of moles and negative effect on the de- KB adsorption constant for benzene (Pa−1 )
hydrogenation reaction of ethane due to the increase of the K1 equilibrium constant of dehydrogenation reaction
number of moles. The increase of the pressure has an over- (Pa)
all positive effect on the optimal value of the dimension- L dimensionless reactor length
less effective reactor length and its position. This result is L0 reactor length (m)
opposite to the negative result of increasing the pressure Pi partial pressure of component i (Pa)
in the fixed bed membrane reactor (FBMR) as shown in Pt pressure in tube side (Pa)
Fig. 6. Ps pressure of sweep gas (Pa)
QH2 hydrogen permeation rate (kg mol/s)
Q0 permeability constant (kg mol m/m2 s Pa0.5 )
7. Conclusions r1 radial dimension in catalyst bed (m)
r2 radial dimension in ceramic support (m)
The results presented in this paper show that the inte- R universal gas constant (kJ/kg mol K)
grated catalytic membrane reactor with catalyst pattern strat- R1 inner tube radius (m)
egy is an attractive application for production of ethylene R2 outer radius of composite tube (m)
and cyclohexane. The introduction of the concept of dual- R1 rate of dehydrogenation reaction (kg mol/kg s)
functionality of the well-mixed catalyst bed has appreciable R2 rate of hydrogenation reaction (kg mol/kg s)
improvement of the reactor performance in terms of high con- T temperature (K)
versions, low temperatures and reduced total reactor lengths. ul axial velocity (m2 /s)
The combined effect of the membrane and reaction cou- yi mole fraction of component i
pling is believed to enhance the ethane conversion to com-
pletion at relatively low temperatures (720–800 K). These Greeks symbols
are important results, since it is known that excessive tem- γ ij stiochiometric coefficient of component i in the jth
peratures have destructive effects on the catalysts, the me- reaction
chanical and chemical stability of the membranes and the δ membrane thickness (m)
reactors. ε1 porosity of catalyst bed
Effective operating regions with optimal conditions are ε2 porosity of ceramic support
observed and an effective reactor length criterion is used to θj volume fraction of catalyst j
evaluate the performance of the reactor. In light of the results ρj density of catalyst j (kg/m3 )
presented the optimal effective reactor length is favored by
high temperature and tube side pressure. It seems that the po- Subscript
tential application of coupling ethane and benzene reactions f feed
in fixed bed membrane reactors is promising. Future research
should focus on different catalyst layer configurations and Superscripts
rigorous optimization studies. Further improvements are still c ceramic support
to be expected both in scientific knowledge and industrial s shell side
practice in ethylene industry. t tube side
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