scholarly journals Ammonia synthesis fundamentals for a model-based HAZOP study

2015 ◽  
Vol 8 (1) ◽  
pp. 5-10 ◽  
Author(s):  
Ján Janošovský ◽  
Juraj Labovský ◽  
Ľudovít Jelemenský
Keyword(s):  
Process Model ◽  
Ammonia Synthesis ◽  
Fixed Bed ◽  
Steady States ◽  
Hazard Identification ◽  
Fixed Bed Reactor ◽  
Multiple Steady States ◽  
Nonlinear Behaviour ◽  
Model Based ◽  
Operation Conditions

Abstract Hazard and operability (HAZOP) analysis is a highly disciplined process hazard analysis (PHA) technique based on the exploration of the effects of process variables deviations. Inconveniences of a conventional HAZOP study are its time-consuming character and high cost. The principal objective of this paper is to present a new methodology for hazard identification of a selected chemical production process. Model-based HAZOP study is a very robust tool for predicting a systems response to deviations from design or operation conditions. An approach based on the mathematical modelling of a process can help to identify sources of hazard that could be overlooked by conventional PHA techniques. A case study focused on the multiple steady states phenomenon in an ammonia synthesis reactor is presented. The process simulation was performed using the Aspen HYSYS v8.4 process modelling environment. Nonlinear behaviour of the investigated fixed-bed reactor system was confirmed by an accident in an industrial ammonia synthesis reactor. The analysed system exhibited the feed temperature and pressure dependence of various operation parameters. This fact indicates the presence of multiple steady states. From the safety analysis point of view, switching between steady states can lead to process hazards.

scholarly journals Solution Combustion Synthesis of Fe2O3-Based Catalyst for Ammonia Synthesis

Catalysts ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1027
Author(s):  
Binxiang Cai ◽  
Huazhang Liu ◽  
Wenfeng Han
Keyword(s):  
Combustion Synthesis ◽  
Reaction Rate ◽  
Ammonia Synthesis ◽  
Fixed Bed ◽  
Solution Combustion Synthesis ◽  
Fixed Bed Reactor ◽  
High Dispersion ◽  
Synthesis Reaction ◽  
Solution Combustion ◽  
Metal Nitrates

Fe2O3-based catalysts were prepared by solution combustion synthesis (SCS) with metal nitrates (Fe, K, Al, Ca) as the precursors and glycine as the fuel. The activities of catalysts were evaluated in terms of ammonia synthesis reaction rate in a fixed bed reactor similar to the industrial reactors. The results indicate that the precursor of catalyst prepared by SCS is Fe2O3 which facilitates the high dispersion of promoters to provide high activity. The catalysts exhibit higher activity for ammonia synthesis than that of traditional catalysts, and the reaction rate reaches 138.5 mmol g−1 h−1. Fe2O3 prepared by SCS could be favorable precursor for ammonia synthesis catalyst. The present study provides a pathway to prepare catalyst for ammonia synthesis.

scholarly journals Analysis and Model-Based Description of the Total Process of Periodic Deactivation and Regeneration of a VOx Catalyst for Selective Dehydrogenation of Propane

Catalysts ◽  
2020 ◽  
Vol 10 (12) ◽  
pp. 1374
Author(s):  
Andreas Brune ◽  
Andreas Seidel-Morgenstern ◽  
Christof Hamel
Keyword(s):  
Catalyst Deactivation ◽  
Process Development ◽  
Coke Formation ◽  
Fixed Bed ◽  
Reaction Network ◽  
Fixed Bed Reactor ◽  
Side Reactions ◽  
Model Based ◽  
Total Process

This study intends to provide insights into various aspects related to the reaction kinetics of the VOx catalyzed propane dehydrogenation including main and side reactions and, in particular, catalyst deactivation and regeneration, which can be hardly found in combination in current literature. To kinetically describe the complex reaction network, a reduced model was fitted to lab scale experiments performed in a fixed bed reactor. Additionally, thermogravimetric analysis (TGA) was applied to investigate the coking behavior of the catalyst under defined conditions considering propane and propene as precursors for coke formation. Propene was identified to be the main coke precursor, which agrees with results of experiments using a segmented fixed bed reactor (FBR). A mechanistic multilayer-monolayer coke growth model was developed to mathematically describe the catalyst coking. Samples from long-term deactivation experiments in an FBR were used for regeneration experiments with oxygen to gasify the coke deposits in a TGA. A power law approach was able to describe the regeneration behavior well. Finally, the results of periodic experiments consisting of several deactivation and regeneration cycles verified the long-term stability of the catalyst and confirmed the validity of the derived and parametrized kinetic models for deactivation and regeneration, which will allow model-based process development and optimization.

Model-Based Experimental Analysis of a Fixed-Bed Reactor for Catalytic SO2Oxidation

2009 ◽  
Vol 48 (11) ◽  
pp. 5165-5176 ◽  
Author(s):  
J. C. Schöneberger ◽  
H. Arellano-Garcia ◽  
G. Wozny ◽  
S. Körkel ◽  
H. Thielert
Keyword(s):  
Experimental Analysis ◽  
Fixed Bed ◽  
Fixed Bed Reactor ◽  
Model Based

scholarly journals Simulation and optimization of coupling reaction of methanol synthesis and isopropyl alcohol dehydrogenation

2018 ◽  
Vol 10 (3) ◽  
pp. 127
Author(s):  
Jenny Rizkiana ◽  
Yogi Wibisono Budhi ◽  
Azis Trianto
Keyword(s):  
Methanol Synthesis ◽  
Isopropyl Alcohol ◽  
Fixed Bed ◽  
Coupling Reaction ◽  
Fixed Bed Reactor ◽  
Inlet Temperature ◽  
Simulation And Optimization ◽  
Optimum Operation ◽  
Operation Conditions ◽  
Reaction Conversion

A study on simulation and optimization of coupling reaction between methanol synthesis and isopropyl alcohol (IPA) dehydrogenation was performed. The analysis is carried out theoretically to obtain the optimum operation conditions which give the best performance. The reactions are just interacting thermally. In this study, both reactions are held catalytically in a heat-exchanger type reactor. As a high pressure reaction, methanol synthesis is placed in the inner side of reactor tube while dehydrogenation of IPA is in the opposite. Tube wall acts as a heat transfer media. The reactor is modeled by a steady state heterogeneous equation for a fixed bed reactor. Optimization is done in order to find the optimum value of operation conditions, those are the inlet temperature of both side of reactor and the molar feed flow ratio between the exothermic side and the endothermic side. Sum of weighted reaction conversion is considered to be the objective function that is maximized. The simulation result shows that coupled reactor makes the reaction conversion higher than a conventional adiabatic reactor and the optimum operation conditions give the maximum value of the conversion. This study presents a theoretical proof that coupling reaction is feasible. Keywords: coupling reaction, IPA dehydrogenation, methanol synthesis, optimization, simulated annealingAbstrak Telaah mengenai simulasi dan optimisasi reaksi perangkaian (coupling reaction) antara sintesis metanol dengan dehidrogenasi isopropil alkohol (IPA) telah dilakukan. Analisis dilaksanakan secara teoretik guna mendapatkan kondisi optimum yang akan memberikan hasil terbaik. Pada penelitian ini, kedua reaksi dilaksanakan secara katalitik dalam reaktor bertipe buluh-cangkang. Karena bertekanan tinggi, sintesis metanol ditempatkan pada sisi buluh, sedangkan dehidrogenasi IPA ditempatkan pada sisi cangkang. Dinding buluh berperan sebagai media perpindahan panas. Reaktor dimodelkan dengan reaktor heterogen tunak unggun tetap. Optimisasi dilakukan dalam rangka mendapatkan nilai optimum dari kondisi operasi yang mencakup temperatur inlet sisi eksotermik dan endotermik serta rasio umpan molarnya. Jumlah total konversi reaksi terbobotkan dipilih sebagai nilai objectif yang akan dioptimumkan. Hasil simulasi menunjukkan bahwa reaktor perangkaian termal mampu meningkatkan konversi reaksi jika dibandingkan dengan reaktor adiabatik dan pada kondisi operasi yang optimum diperoleh konversi maksimal. Penelitian ini menunjukkan bahwa reaksi perangkaian layak untuk dilaksanakan.Kata kunci: reaksi perangkaian, dehidrogenasi IPA, sintesis methanol, optimisasi, simulated annealing

scholarly journals Pengaruh kondisi operasi pada kinerja reaksi dekomposisi katalitik metana dalam reaktor gauze

2018 ◽  
Vol 9 (2) ◽  
pp. 69
Author(s):  
Widodo W Purwanto ◽  
Yuswan Muharam ◽  
Dwi Yulianti
Keyword(s):  
Stainless Steel ◽  
Methane Conversion ◽  
Sol Gel ◽  
Fixed Bed ◽  
Dip Coating ◽  
Space Time ◽  
Methane Decomposition ◽  
Fixed Bed Reactor ◽  
Feed Ratio ◽  
Operation Conditions

Methane decomposition is an alternative way to produce high quality carbon nanotubes (CNTs) and hydrogen simultaneously. The use of gauze reactor for methane decomposition had proven in solving pressure drop problem in fixed bed reactor. This experiment was carried out to study the effects of operation conditions (space time, temperature, and feed ratio) to gauze rector performance. Ni-Cu-Al catalyst which is prepared by sol-gel method with atomic ratio 2:1:1, was coated to Stainless Steel gauze by dip coating method. The reaction was done by flowing methane into the reactor at atmospheric pressure and varying space time (0.0006; 0.0032; 0.006 g×kat×min/mL), temperature (700, 750, and 800°C), and feed ratio CH4:H2 (1:0, 4:1, 1:1). An online gas chromatograph is used to detect the gas products. Reactor performances were observed from methane conversion, hydrogen purity, carbon yield and quality of nanocarbon that have been produced. Experiment result showed that the highest reactor performance (except nanocarbon quality) occurred at space time 0.006 gr cat min/mL, temperature 700 °C, and with pure methane as feed which give methane conversion, hydrogen purity, and yield carbon results are 90.66%, 90.16%, and 37 g carbon/g catalyt, respectively. Based on SEM analysis indicated that the best nanocarbon morphology can be gained at CH4:H2 ratio of 1:1.Keyword : methane decompotition, gauze reactor, carbon nanotube Abstrak Dekomposisi katalitik metana adalah salah satu alternatif untuk memproduksi hidrogen dan nanokarbon bermutu tinggi secara simultan. Penggunaan reaktor gauze untuk dekomposisi metana terbukti dapat mengatasi permasalahan penyumbatan pada reaktor unggun diam. Penelitian ini dilakukan untuk mengetahui pengaruh kondisi operasi (space time, temperatur, dan rasio umpan) terhadap kinerja reaktor gauze. Katalis Ni-Cu-Al disiapkan dengan menggunakan metode sol-gel dengan perbandingan atomik 2:1:1 dilapiskan pada gauze Stainless Steel dengan metode dip-coating. Reaksi dilakukan dengan mengalirkan metana ke dalam reaktor pada tekanan atmosferik dan dengan memvariasikan space time (0,0006; 0,0032; 0,006 g×kat×min/mL), temperatur (700, 750, dan 800 °C), dan rasio umpan CH4:H2 (1:0, 4:1, 1:1). Produk gas dianalisis dengan menggunakan gas chromatography yang terpasang secara online. Kinerja reaktor pada penelitian ini ditinjau dari konversi metana, kemurnian hidrogen, perolehan dan kualitas nanokarbon yang dihasilkan. Berdasarkan hasil eksperimen diketahui bahwa kinerja reaktor paling tinggi (kecuali kualitas nanokarbon) terjadi pada space time 0,006 g×kat×min/mL, temperatur 700 °C, dan dengan menggunakan metana murni yang memberikan hasil konversi metana, kemurnian hidrogen, serta perolehan karbon secara berturut-turut 90,66%, 90,16%, dan 37 gram karbon/gram katalis. Hasil analisis menggunakan SEM menunjukkan bahwa morfologi nanokarbon paling baik didapat pada komposisi reaktan CH4: H2 = 1:1.Kata Kunci : dekomposisi metana, reaktor gauze, karbon nanotube

scholarly journals Process simulation of dimethyl ether synthesis via methanol vapor phase dehydration

2013 ◽  
Vol 15 (2) ◽  
pp. 122-127 ◽  
Author(s):  
Ziyang Bai ◽  
Hongfang Ma ◽  
Haitao Zhang ◽  
Weiyong Ying ◽  
Dingye Fang
Keyword(s):  
Dimethyl Ether ◽  
Vapor Phase ◽  
Process Simulation ◽  
Fixed Bed ◽  
Fixed Bed Reactor ◽  
Reflux Ratio ◽  
Methanol Vapor ◽  
Operation Conditions ◽  
Dimethyl Ether Synthesis ◽  
Simulation Results

The production processes included catalytic dehydration of methanol in an adiabatic fixed-bed reactor and two columns product separations. In this study, the technological process for dimethyl ether (DME) synthesis is built on PRO/II platform based on the combined parameters of the reaction dynamic model for methanol dehydration reaction, the improved NRTL model of the liquid phase, the PR model of vapor phase. In order to validate the proposed model, the simulation results have been compared with the available data from a set of industrial production equipment with a production capacity of 200 000 tonnes per annum. A comparison between the calculated and measured results has proved that these results are satisfactory. The bed height and the volume of the catalytic bed are calculated aim at one million t/a DME yields and while taking account of high-purity DME production. After discussing the influence of feed stage location and reflux ratio for DME product purity, the suitable unit operation conditions are chosen. Accordingly, accurate process simulation results provide the basis and guidance for an improvement and development of the similar industrial device.

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