Multiphase Reactor Engineering for Clean and Low-Carbon Energy Applications

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.

• Preface xiiiList of Contributors Xv1 Novel Fluid Catalytic Cracking Processes 1Jinsen Gao, Chunming Xu, Chunxi Lu Chaohe Yang, Gang Wang, Xingying Lan and Yongmin Zhang1.1 FCC Process Description 11.2 Reaction Process Regulation for the Heavy Oil FCC 31.2.1 Technology Background 31.2.2 Principle of the Technology 31.2.3 Key Fundamental Research 41.2.4 Industrial Validation 71.3 Advanced Riser Termination Devices for the FCC Processes 101.3.1 Introduction 101.3.2 General Idea of the Advanced RTD System 111.3.3 Development of the External‐Riser FCC RTD Systems 121.3.4 Development of the Internal‐Riser FCC RTDs 151.3.5 Conclusions and Perspectives 181.4 An MZCC FCC Process 191.4.1 Technology Background 191.4.2 Reaction Principle for MZCC 191.4.3 Design Principle of MZCC Reactor 201.4.4 Key Basic Study 231.4.5 The Industry Application of MZCC 231.4.6 Prospectives 261.5 Two‐Stage Riser Fluid Catalytic Cracking Process 281.5.1 Preface 281.5.2 Reaction Mechanism of Heavy Oil in the Riser Reactor 291.5.3 The Proposed TSR FCC Process 321.5.4 The Industrial Application of the TSR FCC Technology 331.5.5 The Development of the TSR FCC Process 331.6 FCC Gasoline Upgrading by Reducing Olefins Content Using SRFCC Process 361.6.1 Research Background 361.6.2 Reaction Principle of Gasoline Upgrading 371.6.3 Design and Optimization on the Subsidiary Riser 381.6.4 Key Fundamental Researches 381.6.5 Industrial Applications of the SRFCC Process 421.6.6 Outlook 431.7 FCC Process Perspectives 44References 452 Coal Combustion 49Guangxi Yue, Junfu Lv and Hairui Yang2.1 Fuel and Combustion Products 492.1.1 Composition and Properties of Fuel 492.1.2 Analysis of Compositions in the Fuel 502.1.3 Calorific Value of Fuel 502.1.4 Classifications of Coal 502.1.5 Combustion Products and Enthalpy of Flue Gas 512.2 Device and Combustion Theory of Gaseous Fuels 522.2.1 Ignition of the Gaseous Fuels 522.2.2 Diffusion Gas Burner 522.2.3 Fully Premixed‐Type Gas Burner 532.3 Combustion Theory of Solid Fuel 532.3.1 The Chemical Reaction Mechanism of Carbon Combustion 542.3.2 Carbon Combustion Reaction Process 542.4 Grate Firing of Coal 552.4.1 Coal Grate Firing Facilities 562.5 Coal Combustion in CFB Boiler 572.5.1 The Characteristic of Fluidized Bed 572.5.2 Combustion Characteristic of CFB Boiler 582.5.3 Development of Circulating Fluidized Bed Combustion Technology 582.5.4 Comparison Between Bubbling Fluidized bed and Circulating Fluidized Bed 592.6 Pulverized Coal Combustion 602.6.1 Furnace Type of Pulverized Coal Combustion 612.6.2 Circulation Mode of Water Wall 622.6.3 Modern Large‐Scale Pulverized Coal Combustion Technology 622.6.4 The International Development of the Supercritical Pressure Boiler 62References 633 Coal Gasification 65Qiang Li and Jiansheng Zhang3.1 Coal Water Slurry 653.1.1 The Advantage of CWS 653.1.2 The Production of CWS 663.1.3 The Atomization of CWS 673.2 The Theory of Coal Gasification 703.2.1 Overview of Coal Gasification 703.2.2 The Main Reaction Processes of Coal Gasification 723.2.3 Kinetics of Coal Gasification Reaction 733.2.4 The Influencing Factors of Coal Gasification Reaction 773.3 Fixed Bed Gasification of Coal 793.3.1 The Principle of Fixed Bed Gasification 793.3.2 The Classification of Fixed Bed Gasification Technology 813.3.3 Typical Fixed Bed Gasification Technologies 813.3.4 The Key Equipment for Pressurized Fixed Bed Gasifier 853.3.5 The Application and Improvement of Pressurized Fixed Bed Gasifier in China 893.4 Fluid Bed Gasification of Coal 903.4.1 The Basic Principles of Fluidized Bed Gasification 903.4.2 Typical Technology and Structure of Fluidized Bed Gasification 913.5 Entrained Flow Gasification of Coal 983.5.1 The Principle of Entrained Flow Gasification Technology 983.5.2 Typical Entrained Gas Gasification Technologies 1013.6 Introduction to the Numerical Simulation of Coal Gasification 1123.6.1 The Numerical Simulation Method of Coal Gasification 1123.6.2 Coal Gasification Numerical Simulation (CFD) Method 113References 1164 New Development in Coal Pyrolysis Reactor 119Guangwen Xu, Xi Zeng, Jiangze Han and Chuigang Fan4.1 Introduction 1194.2 Moving Bed with Internals 1214.2.1 Laboratory Tests at Kilogram Scale 1224.2.2 Verification Tests at 100‐kg Scale 1254.2.3 Continuous Pilot Verification 1274.3 Solid Carrier FB Pyrolysis 1294.3.1 Fundamental Study 1304.3.2 Pilot Verification with Air Gasification 1364.4 Multistage Fluidized Bed Pyrolysis 1394.4.1 Experimental Apparatus and Method 1394.4.2 Results and Discussion 1414.5 Solid Carrier Downer Pyrolysis 1454.5.1 Experimental Apparatus and Method 1464.5.2 Results and Discussion 1474.6 Other Pyrolysis Reactors 1494.6.1 Solid Heat Carrier Fixed Bed 1494.6.2 A Few Other New Pyrolysis Reactors 1504.7 Concluding Remarks 153Acknowledgments 153References 1535 Coal Pyrolysis to Acetylene in Plasma Reactor 155Binhang Yan and Yi Cheng5.1 Introduction 1555.1.1 Background 1555.1.2 Principles and Features of Thermal Plasma 1565.1.3 Basic Principles of Coal Pyrolysis in Thermal Plasma 1575.1.4 Development of Coal Pyrolysis to Acetylene Process 1585.2 Experimental Study of Coal Pyrolysis to Acetylene 1595.2.1 Experimental Setup 1595.2.2 Typical Experimental Results 1615.3 Thermodynamic Analysis of Coal Pyrolysis to Acetylene 1645.3.1 Equilibrium Composition with/without Consideration of Solid Carbon 1645.3.2 Validation of Thermodynamic Equilibrium Predictions 1645.3.3 Effect of Additional Chemicals on Thermodynamic Equilibrium 1655.3.4 Key Factors to Determine the Reactor Performance 1665.3.5 Key Factors to Determine the Reactor Performance 1685.4 Computational Fluid Dynamics‐Assisted Process Analysis and Reactor Design 1715.4.1 Kinetic Models of Coal Devolatilization 1715.4.2 Generalized Model of Heat Transfer and Volatiles Evolution Inside Particles 1765.4.3 Cross‐Scale Modeling and Simulation of Coal Pyrolysis to Acetylene 1805.5 Conclusion and Outlook 183References 1866 Multiphase Flow Reactors for Methanol and Dimethyl Ether Production 189Tiefeng Wang and Jinfu Wang6.1 Introduction 1896.1.1 Methanol 1896.1.2 Dimethyl Ether 1896.2 Process Description 1916.2.1 Methanol Synthesis 1916.2.2 DME Synthesis 1926.2.3 Reaction Kinetics 1956.3 Reactor Selection 1976.3.1 Fixed Bed Reactor 1976.3.2 Slurry Reactor 1986.4 Industrial Design and Scale‐Up of Fixed Bed Reactor 2006.4.1 Types of Fixed Bed Reactors 2006.4.2 Design of Large‐Scale Fixed Bed Reactor 2016.5 Industrial Design and Scale‐Up of Slurry Bed Reactor 2026.5.1 Flow Regime of the Slurry Reactor 2026.5.2 Hydrodynamics of Slurry Bed Reactor 2036.5.3 Process Intensification with Internals 2036.5.4 Scale‐Up of Slurry Reactor 2066.6 Demonstration of Slurry Reactors 2136.7 Conclusions and Remarks 214References 2157 Fischer–Tropsch Processes and Reactors 219Li Weng and Zhuowu Men7.1 Introduction to Fischer–Tropsch Processes and Reactors 2197.1.1 Introduction to Fischer–Tropsch Processes 2197.1.2 Commercial FT Processes 2197.1.3 FT Reactors 2207.1.4 Historical Development of FT SBCR 2217.1.5 Challenges for FT SBCR 2227.2 SBCR Transport Phenomena 2227.2.1 Hydrodynamics Characteristics 2227.2.2 Mass Transfer 2267.2.3 Heat Transfer 2297.3 SBCR Experiment Setup and Results 2317.3.1 Introduction to SBCR Experiments 2317.3.2 Cold Mode and Instrumentation 2347.3.3 Hot Model and Operation 2477.4 Modeling of SBCR for FT Synthesis Process 2497.4.1 Introduction 2497.4.2 Model Discussion 2507.4.3 Multiscale Analysis 2567.4.4 Conclusion 2587.5 Reactor Scale‐Up and Engineering Design 2597.5.1 General Structures of SBCR 2597.5.2 Internal Equipment 2597.5.3 Design and Scale‐Up Strategies of SBCR 261Nomenclature 262References 2638 Methanol to Lower Olefins and Methanol to Propylene 271Yao Wang and Fei Wei8.1 Background 2718.2 Catalysts 2728.3 Catalytic Reaction Mechanism 2738.3.1 HP Mechanism 2748.3.2 Dual‐Cycle Mechanism 2748.3.3 Complex Reactions 2758.4 Features of the Catalytic Process 2758.4.1 Autocatalytic Reactions 2758.4.2 Deactivation and Regeneration 2768.4.3 Exothermic Reactions 2788.5 Multiphase Reactors 2788.5.1 Fixed Bed Reactor 2798.5.2 Moving Bed Reactor 2808.5.3 Fluidized Bed Reactor 2818.5.4 Parallel or Series Connection Reactors 2848.6 Industrial Development 2868.6.1 Commercialization of MTO 2868.6.2 Commercialization of MTP 288References 2929 Rector Technology for Methanol to Aromatics 295Weizhong Qian and Fei Wei9.1 Background and Development History 2959.1.1 The Purpose of Developing Methanol to Aromatics Technology 2959.1.2 Comparison of MTA with Other Technologies Using Methanol as Feedstock 2979.2 Chemistry Bases of MTA 2989.3 Effect of Operating Conditions 3009.3.1 Effect of Temperature 3009.3.2 Partial Pressure 3029.3.3 Space Velocity of Methanol 3029.3.4 Pressure 3029.3.5 Deactivation of the Catalyst 3039.4 Reactor Technology of MTA 3049.4.1 Choice of MTA Reactor: Fixed Bed or Fluidized Bed 3049.4.2 MTA in Lab‐Scale Fluidized Bed Reactor and the Comparison in Reactors with Different Stages 3059.4.3 20 kt/a CFB Apparatus for MTA 3069.4.4 Pilot Plant Test of 30 kt/a FMTA System 3069.5 Comparison of MTA Reaction Technology with FCC and MTO System 310References 31110 Natural Gas Conversion 313Wisarn Yenjaichon, Farzam Fotovat and John R. Grace10.1 Introduction 31310.2 Reforming Reactions 31310.3 Sulfur and Chloride Removal 31410.4 Catalysts 31410.5 Chemical Kinetics 31510.6 Fixed Bed Reforming Reactors 31610.7 Shift Conversion Reactors 31710.7.1 High‐Temperature WGS 31710.7.2 Low‐Temperature WGS 31710.8 Pressure Swing Adsorption 31710.9 Steam Reforming of Higher Hydrocarbons 31810.10 Dry (Carbon Dioxide) Reforming 31810.11 Partial Oxidation (POX) 32010.11.1 Homogeneous POX 32110.11.2 Catalytic Partial Oxidation 32110.12 Autothermal Reforming (ATR) 32110.13 Tri‐Reforming 32110.14 Other Efforts to Improve SMR 32210.14.1 Fluidized Beds 32310.14.2 Permselective Membranes 32310.14.3 Sorbent‐Enhanced Reforming 32510.15 Conclusions 326References 32611 Multiphase Reactors for Biomass Processing and Thermochemical Conversions 331Xiaotao T. Bi and Mohammad S. Masnadi11.1 Introduction 33111.2 Biomass Feedstock Preparation 33211.2.1 Biomass Drying 33211.2.2 Biomass Torrefaction Treatment 33311.3 Biomass Pyrolysis 33611.3.1 Pyrolysis Principles and Reaction Kinetics 33611.3.2 Multiphase Reactors for Slow and Fast Pyrolysis 33811.3.3 Catalytic Pyrolysis of Biomass 34211.3.4 Biomass‐to‐Liquid Via Fast Pyrolysis 34211.4 Biomass Gasification 34311.4.1 Principles of Biomass Gasification 34311.4.2 Gasification Reactions Mechanisms and Models 34411.4.3 Catalytic Gasification of Biomass 34711.4.4 Multiphase Reactors for Gasification 34911.4.5 Biomass Gasification Reactor Modeling 35511.4.6 Downstream Gas Processing 35611.4.7 Technology Roadmap and Recent Market Developments 35711.5 Biomass Combustion 35911.5.1 Principles of Biomass Combustion 35911.5.2 Reaction Mechanisms and Kinetics 36011.5.3 Multiphase Reactors for Combustion 36111.5.4 Advanced Combustion Systems 36311.5.5 Agglomeration, Fouling, and Corrosion 36511.5.6 Future Technology Developments 36511.6 Challenges of Multiphase Reactors for Biomass Processing 36611.6.1 Fluidization of Irregular Biomass Particles 36611.6.2 Feeding, Conveying of Biomass 36611.6.3 Reactor Modeling, Simulation, and Scale‐Up 36711.6.4 Economics of Commercial Biomass Conversion Systems 368References 36912 Chemical Looping Technology for Fossil Fuel Conversion with In Situ CO2 Control 377Liang‐Shih Fan, Andrew Tong and Liang Zeng12.1 Introduction 37712.1.1 Chemical Looping Concept 37712.1.2 Historical Development 37912.2 Oxygen Carrier Material 38112.2.1 Primary Material Selection 38112.2.2 Iron‐Based Oxygen Carrier Development 38212.3 Chemical Looping Reactor System Design 38412.3.1 Thermodynamic Analysis 38512.3.2 Kinetic Analysis 38812.3.3 Hydrodynamic Analysis 39212.4 Chemical Looping Technology Platform 39612.4.1 Syngas Chemical Looping Process 39712.4.2 Coal Direct Chemical Looping Process 39812.4.3 Shale Gas-to-Syngas Process 39912.5 Conclusion 400References 401Index 405