Optimization of inlet temperature for deactivating LTWGS reactor performance
J. L. Ayastuy
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Search for more papers by this authorM. A. Gutiérrez-Ortiz
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Search for more papers by this authorJ. A. González-Marcos
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Search for more papers by this authorA. Aranzabal
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Search for more papers by this authorCorresponding Author
J. R. González-Velasco
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, SpainSearch for more papers by this authorJ. L. Ayastuy
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Search for more papers by this authorM. A. Gutiérrez-Ortiz
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Search for more papers by this authorJ. A. González-Marcos
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Search for more papers by this authorA. Aranzabal
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Search for more papers by this authorCorresponding Author
J. R. González-Velasco
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, Spain
Group of Chemical Technologies for Environmental Sustainability, Dept. of Chemical Engineering, Faculty of Science and Technology, Universidad del País Vasco/Euskal Herriko Unibertsitatea, 48080 Bilbao, SpainSearch for more papers by this authorAbstract
An industrial Cu-based low-temperature water-gas shift (LTWGS) reactor, subject to deactivation by irreversible chlorine adsorption, has been modeled and optimized. Both the chlorine adsorption kinetics and deactivation kinetics were assumed first order to chlorine partial pressure, and the rate constants were considered independent of temperature. The Efficient Production (EP) method has been used to compute the reactor production until the outlet CO conversion decays below a permissible minimum level. Two alternative strategies for the inlet temperature have been used to maximize the EP: constant and time-variable. Compared to the EP obtained for the optimum constant inlet temperatures, EP resulting from the use of the optimum time-variable inlet temperature sequence were higher, affording important energy savings. Furthermore, a sensitivity study with respect to most influential operational variables, such as inlet total flow rate, steam-to-gas ratio, pressure, and concentrations of chlorine, hydrogen, carbon monoxide, and inert content, was carried out. © 2005 American Institute of Chemical Engineers AIChE J, 2005
Literature Cited
- 1 Tanaka Y, Utaka T, Kikuchi R, Sasaki K, Eguchi K. Water gas shift reaction over Cu-based mixed oxides for CO removal from the reformed fuels. Appl Catal A: Gen. 2002; 6395: 1–9.
- 2 Zalc JM, Löffler DG. Fuel processing for PEM fuel cells: Transport and kinetic issues of system design. J Power Sources. 2002; 111: 58–64.
- 3 Chunshan S. Fuel processing for low-temperature and high-temperature fuel cells. Challenges and opportunities for sustainable development in the 21st century. Catal Today. 2002; 77: 17–49.
- 4 Newsome DS. The water–gas shift reaction. Catal Rev Sci Eng. 1980; 21: 275–318.
- 5 Hawker PN. Shift CO plus steam to H2. Hydrocarbon Process. 1982; 61: 183–187.
- 6 Ettouney HM, Shaban HI, Nayfeh LJ. Theoretical analysis of high and low temperature shift converters: Process and product development. Chem Eng Res Des. 1993; 71: 189–195.
- 7 Singh CPP, Saraf DN. Simulation of high-temperature water–gas shift reactors. Ind Eng Chem Process Des Dev. 1977; 16: 313–319.
- 8 Bohlbro H. The kinetics of the water gas conversion at atmospheric pressure. Acta Chem Scand. 1961; 15: 502–520.
- 9 Chinchen GC, Logan RH, Spencer MS. Water–gas shift reaction over an iron oxide/chromium oxide catalyst. III. Kinet React Appl Catal. 1984; 12: 97–103.
- 10 Ferretti OA, González JC, Laborde MA, Moreno N. Kinetic study of the water gas shift reaction at high temperatures. Lat Am J Chem Eng Appl Chem. 1986; 16: 75–83.
- 11 Gutmann WR, Johnson RE. Low Temperature Shift Reactions Using Copper–Zinc Oxide Catalysts. U.S. Patent Number 3 546 140; 1970.
- 12 Ghiotti G, Boccuzzi F. Chemical and physical properties of copper-based catalysts for CO shift reaction and methanol synthesis. Catal Rev Sci Eng. 1987; 29: 151–182.
- 13 Hadden RA, Lambert PJ, Ranson C. Relationship between the copper surface area and the activity of CuO/ZnO/Al2O3 water–gas shift catalysts. Appl Catal A: Gen. 1995; 122: L1–L4.
- 14 Amadeo NE, Laborde MA. Low temperature water gas shift reaction: Catalyst, kinetics and reactor design and optimisation. Trends Chem Eng. 1996; 3: 159–183.
- 15 Young PW, Clark CB. Why shift catalysts de-activate. Chem Eng Prog. 1973; 69: 69–74.
- 16 Ray N, Roy SK, Ganguli NC, Sen SP. Factor affecting the activity and life of industrial low-temperature shift catalyst. Technology 1973; 10: 216–219.
- 17 Ray N, Rastogi VK, Chhabra DS, Dutta S, Sen SP. Deactivation of low temperature shift catalyst. II. Poisoning by chloride. J Res Inst Catal Hokkaido Univ 1982; 30: 25–38.
- 18 Mertzsch N, Joedicke G, Wolf F, Renger P. The effect of chloride poisoning of the ternary cupric oxide-zinc oxide-aluminum oxide catalyst for low-temperature carbon monoxide conversion. Chem Tech (Leipzig). 1984; 36: 245–247.
- 19 Grant AW, Ranney JT, Campbell CT, Evans T, Thorton G. The influence of chlorine on the dispersion of Cu particles on Cu/ZnO(0001) model catalysts. Catal Lett. 2000; 65: 159–168.
- 20 Twigg MV, Spencer MS. Deactivation of supported copper metal catalysts for hydrogenation reactions. Appl Catal A: Gen. 2001; 212: 161–174.
- 21 Lovik L, Hillestad M, Hertzberg T. Long term dynamic optimization of a catalytic reactor system. Comput Chem Eng. 1998; 22: S707–S710.
- 22 Lovik I, Hillstad M, Hertzberg T. Sensitivity in optimisation of a reactor system with deactivating catalyst. Comput-Aided Chem Eng. 2000; 8: 517–522.
- 23 Ajinkya MB, Ray WH. The optimization of axially dispersed packed bed reactors experiencing catalyst decay. Chem Eng Sci.. 1973; 28: 1719–1729.
- 24 González-Velasco JR, Gutiérrez-Ortiz MA, Gutiérrez-Ortiz JI, González-Marcos JA. Analysis of the lumped and distributed optimal temperature trajectories for packed bed reactors with concentration dependent catalysts reactivation. Can J Chem Eng. 1990; 68: 860–866.
- 25 Pommersheim JM, Chandra K. Optimal batch reactor temperature policy for reactions with concentration dependent catalyst decay. AIChE J. 1975; 21: 1029–1032.
- 26 Cuthrell JE, Biegler LT. Simultaneous optimisation and solution methods for batch reactor control profiles. Comput Chem Eng. 1989; 13: 49–62.
- 27 Grubecki I, Wojcik M. Comparison between isothermal and optimal temperature policy for batch reactor. Chem Eng Sci. 2000; 55: 5161–5163.
- 28 Sadana A. On optimum temperature operations in deactivating fixed-bed reactors. Chem Eng Commun. 1980; 4: 51–55.
- 29 Romero A, Gonzalez-Velasco JR, Bilbao J. Anales deq uímica. Quím Fís Ing Quím Ser A. 1981; 77: 253–258.
- 30 Hong JC, Lee HH. Stepwise temperature set-point optimisation for isothermal fixed-bed reactor subject to catalyst deactivation. J Chin Inst Chem Eng. 1990; 21: 21–26.
- 31 Barreto GF, Ferretti OA, Farina IH, Lemcoff NO. Optimization of the operating conditions of CO converters. Ind Eng Chem Process Des Dev. 1981; 20: 594–603.
- 32 Faqir NM, Attarakih MM. Optimal temperature policy for immobilized enzyme packed bed reactor performing reversible Michaelis–Menten kinetics using the disjoint policy. Biotechnol Bioeng. 2002; 77: 163–173.
- 33 González-Velasco JR, Gutiérrez-Ortiz MA, González-Marcos JA, Amadeo N, Laborde MA, Paz M. Optimal inlet temperature trajectories for adiabatic packed reactors with catalyst decay. Chem Eng Sci. 1992; 47: 1495–1501.
- 34 Ayastuy JL. Conversión de Monóxido de Carbono a baja temperatura: Cinética del Proceso y Optimación de la operación industrial PhD Thesis. Bilbao, Spain: Universidad del País Vasco/EHU; 2002.
- 35 Rosen O, Luss R. Evaluation of gradients for piecewise constant optimal control. Comput Chem Eng. 1991; 15: 273–281.
- 36 Hicks GA, Ray WH. Approximation methods for optimal control synthesis. Can J Chem Eng. 1971; 49: 522–528.
- 37 Buzzi-Ferraris G, Facchi E, Forzatti P, Tronconi E. Control optimization of tubular catalytic reactors with catalyst decay. Ind Eng Chem Process Des Dev. 1984; 23: 126–131.
- 38 González-Velasco JR, Gutiérrez-Ortiz MA, Romero-Salvador A. Optimization by lumped control of reactors with Langmuir–Hinshelwood catalyst deactivation. Can J Chem Eng. 1985; 63: 314–321.
- 39 Sen B, Ray N, Bhattachariya NB. Shift reaction on iron-chromia and copper based catalysts. Chem Age India. 1981; 32: 321–331.