ATR - Modelling and Simulation
ATR - Modelling and Simulation
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Article in Latin American applied research Pesquisa aplicada latino americana = Investigación aplicada latinoamericana · October 2006
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Abstract - The steady–state operation of the auto- provides the heat required by the endothermic reforming
thermal reformer is simulated as two reactors in reactions to proceed. The ATR unit, illustrated in Fig. 1,
series by means of a detailed mathematical model. is a refractory-lined pressure vessel containing a burner,
An input-output model is selected to describe the a combustion chamber and a catalyst bed. The hydro-
upper combustion chamber. The possible occur- carbon feedstock is mixed with steam and pure oxygen,
rence of homogeneous steam reforming and water- enriched-air or air in a specially designed burner located
gas-shift (WGS) reactions is considered. The catalyst at the top of the reactor. In the combustion chamber
bed is represented through a one-dimensional het- (upper part), the partial combustion reactions take place.
erogeneous model, which allows calculating the axial In the lower section of the reactor, loaded with a high-
variations of composition, temperature and pressure temperature resistant reforming catalyst, the steam re-
of the process gas stream. The strong intraparticle forming and shift conversion reactions occur as the gas
diffusional limitations are taken into account by rig- passes through the fixed-bed.
orous solution of the mass balances inside the cata-
Oxygen/Air
lyst particle. The gas-solid heat-transfer resistances (or enriched-air)
are also evaluated. An intrinsic kinetics is used for
Feedstock
the steam reforming and WGS reactions. Heat losses and steam Burner
to the environment are considered. The influence of Combustion
the main operating variables on the reactor per- chamber
dxCO2
The CH4 combustion takes place through numerous = Ωρ B (η3 r3s + η 4 r4s )/FCH ,0 (6)
radical reactions, but it can be represented as a single dz 4
( ) ( )
molecular reaction, i.e. the highly exothermic combus- V dV
tion to CO and H2O (Eq. 1, Christensen and Primdahl, where: η i = ∫ ri p s , j ri p ss, j i = 2, 3, 4. (7)
0 V
1994). The excess CH4, after complete consumption of
the O2 in the combustion zone, is further converted by Energy balance
the homogeneous steam reforming (Eqs. 2 and 4) and dT 1 ⎡ Qloss ,bed ⎤
= ⎢h f av (Ts − T ) − ⎥ (8)
WGS reaction (Eq. 3) in the thermal zone, which is part dz c p ρ g u s ⎣ Ω ⎦
of the combustion chamber. Final methane conversion
occurs through heterogeneous catalytic reactions (Eq. 2 Momentum equation
to 4). The possible occurrence of carbon formation is dpt fρ g u s2
not considered. =− (9)
dz gd p
B. Model Equations
Boundary conditions
The steady-state operation of the ATR is simulated as
two reactors in series: combustion zone and catalyst z = 0 : xCH = xCH ,0 ; xCO = xCO ,0 ; T = T0 ; pt = pt,0 (10)
4 4 2 2
bed. The essential features of these models are de- Catalyst Particle
scribed in this section. The selected catalyst particle, Ni/MgAl2O4 spinel, is the
B.I. Combustion Chamber industrial Haldor Topsoe RKS-2-7H (tablet-shaped with
An input-output model, based on global mass and en- seven holes and convex ends). The complex geometry
ergy balances and equilibrium equations, is selected to of the real particle is represented by means of an equiva-
describe the upper combustion chamber. Complete oxy- lent annular model (Piña et al., 2001). The component
gen consumption is considered. The occurrence of the fluxes on the particle surface, required for the evalua-
homogeneous steam reforming and WGS reactions is tion of the effectiveness factors (Eq. 7) and the heat
taken into account. To this end, a given approach to the transferred to the catalyst surface from the bulk gas
equilibrium (ΔTe,SR) is assumed for reaction (2), while (first term of the right-hand side of Eq. 8), are obtained
the WGS-reaction (3) is supposed to be in equilibrium by the solution of the following model:
(ΔTe,WGS =0). The stoichiometric and equilibrium rela- Mass balances
tionships for reactions (1) to (3) are solved together with
the enthalpy balance equation to estimate the tempera- DCHe
4
1 d dps,CH4
r dr
(r
dr
[ ]
) = R T r2 ( ps, j ) + r4 ( ps, j ) ρ p (11)
ture and composition of the gas mixture that leaves the
combustion section. Heat losses to the environment
through the wall of the reactor are considered.
e
DCO 2
1 d dps,CO2
r dr
(r
dr
[ ]
) = −R T r3 ( ps, j ) + r4 ( ps, j ) ρ p (12)
B.II. Catalyst Bed Energy balance
The catalyst bed is represented through a one- 4
ρ B ∑ (−ΔH i )risη i = h f av (Ts − T ) (13)
dimensional heterogeneous model. The axial dispersion i=2
of mass and heat is neglected because of the high gas Boundary Conditions:
space velocities. Since the reactor operates under near r = rin : p s ,CH 4 = p CH 4 , p s ,CO2 = p CO2
adiabatic conditions (small heat losses), the radial gradi-
ents of temperature and composition are ignored. Due to r = req : dp s ,CH 4 dr = dp s ,CO2 dr = 0 (14)
the high reaction rates on the catalyst surface caused by
C. Numerical Solution
the high temperature levels, the gas-solid heat-transfer
resistance is included in the model (Rostrup-Nielsen, The non-linear algebraic equations that constitute the
1993). The strong intraparticle diffusional limitations combustion chamber model are solved by means of a
(Christensen and Primdahl, 1994) are taken into account Broyden routine. The differential equations for the gas
by rigorous solution of the mass balances inside the phase are integrated via a Gear method. The differential
catalyst particle, which is assumed isothermal (Raghu- equations for the particle are discretized by means of
nandanan and Reddy, 1994). Fresh catalyst conditions second order finite differences, using an adaptive grid of
are considered. The intrinsic kinetic expressions derived two elements with variable width. Thirty and ten grid
by Xu and Froment (1989) for reactions (2) to (4) are points are assigned to the first (near the catalyst surface)
adopted. and the second element, respectively. For each axial
Thus, the governing equations for the bulk phase are: position, the resultant 89 non-linear algebraic equations
are solved through the Broyden algorithm.
290
J. PIÑA, D. O. BORIO
operations.
1150
III. RESULTS AND DISCUSSION T
To evaluate the capabilities of the proposed model, 1100
typical ATRs operating conditions are used (Table 1). Ts
T (ºC)
1050
Table 1. Industrial ATR – Reference conditions.
Parameter Reported Values*
1000
Catalyst Zone
Internal diameter (m) 1.0 950
Height (m) 0.74
Feed 900
NG feed (Nm3/h) 3500 0 0.2 0.4 0.6 0.8 1
H2O/C 1.4 Z/L
Figure 2: Axial profiles of the gas and solid temperatures in
CO2/C 0.02
the catalyst bed.
O2/C 0.54
Preheat Temperatures Figures 3 and 4 present the composition distributions
(gas-phase) and observed reaction rates (2) to (4) along
NG+H2O (ºC) 525
the catalyst bed, respectively.
O2+H2O (ºC) 230 0.2
0.48
Reported Calculated
Parameter
Values* Values CO
Product Gas 0.44 0.16
yi
yi
291
Latin American Applied Research 36:289-294 (2006)
0.56 5
tive at the bed inlet due to the inversion of the WGS-
reaction inside the catalyst particle (Fig. 5). For Z/L>
0.1, r3obs becomes positive as a consequence of the tem-
4
perature decrease (Fig. 4). For all the axial positions, the
Product Ratios
reactions occur in a narrow zone close to the catalyst H2/CO
surface with effectiveness factors in the order of 10-3. 3
This phenomenon is illustrated in Fig. 5 for a particle
located at the catalyst bed entrance. 0.52
0.07 CO/CO2
2
r2obs
0.05
0.5 1
ri obs ( kmol/ kg cat s)
1100
ri ( kmol/ kg cat s)
T (ºC )
2.5
r4 1050
1.5
1000
0.5
950
r3
-0.5
0 0.2 0.4 0.6 0.8 1
0 0.04 0.08 0.12 0.16 Z/L
r* Figure 7: Gas temperature axial profiles for different S/C.
Figure 5: Reaction rate profiles for reactions (2) to (4) inside TL=950 ºC, ΔTe,SR =326 ºC and ΔTe,WGS =0 ºC.
a catalyst particle located at the bed entrance.
A.II. Carbon dioxide-to-carbon ratio (CO2/C)
A. Influence of the feed composition Different CO2/C ratios have been selected to study the
The steam-to-carbon ratio (S/C) and the CO2 content in effect of the feed composition on the ATR performance.
the hydrocarbon stream have been recognized as critical The feed gas molar flowrate (Fgas) has been kept con-
operating parameters (Christensen et al., 1998). stant by decreasing the S/C ratio. The CO2/C and O2/C
A.I. Steam-to-carbon ratio (S/C) ratios have been simultaneously varied to maintain the
To simulate situations where the S/C ratio is varied, the outlet gas temperature at 950 ºC (Fig. 8). As it can be
steam flowrate has been modified from the value of the seen in Fig. 8, higher CO2/C ratios lead to a product gas
reference case (Table 1). To keep constant the gas tem- with lower H2/CO and CO/CO2 ratios. The simulation
perature at the reactor outlet (TL=950 ºC), the oxygen- results are consistent with the pilot plant tests performed
to-carbon ratio (O2/C) has been simultaneously adapted by Christensen et al. (1998).
(Fig. 6). Figure 6 also shows that lower S/C ratios give a Figure 9 shows the WGS observed reaction rate for dif-
syngas with lower H2/CO and higher CO/CO2 ratios. ferent CO2/C ratios along the catalyst bed. Due to the
These trends are in agreement with the experimental higher CO2 contents, the WGS-reaction proceeds re-
data reported by Christensen and Primdahl (1994) and verse ( r3obs <0) in higher fractions of the total length.
Christensen et al. (1998).
292
J. PIÑA, D. O. BORIO
0.565 3.2
As expected, lower extents of the homogeneous reaction
(2) (i.e., higher ΔTe,SR values) lead to higher tempera-
0.56
tures and lower CH4 conversions in the combustion
2.8
chamber (T0 and xCH4,0 in Fig. 10 and 11, respectively).
O2/C (f eed stream)
0.555
The total methane conversion (xCH4,L) is almost un-
Product Ratios
changed due to the assumption of constant TL. However
0.55 CO/CO2 2.4
as ΔTe,SR is augmented, the H2/CO and CO/CO2 ratios in
the product decrease and increase respectively.
0.545
H2/CO 1300 6
2
0.54
1200
0.535 1.6
1100 T0 4
Qloss/Qcomb (%)
0 0.1 0.2 0.3 0.4
CO2/C
T (ºC)
1000
Figure 8: Effect of CO2/C on H2/CO and CO/CO2 product TL
ratios. Adjustment of O2/C to keep TL=950 ºC. Fgas=3500
Nm3/h, ΔTe,SR =326 ºC and ΔTe,WGS =0 ºC. 900
T e,SR
2
0.006
800
0.004 700 0
200 300 400 500
r3 obs ( kmol/ kg cat s)
ΔT e,SR (ºC)
Figure 10: Effect of ΔTe,SR on Te,SR, T0 and TL. Adjustment of
0.002
x CH 4,L
CO2/C=0.05
-0.002
CO2/C=0.2
CO2/C=0.4 0.9 H2/CO 2.8
Product Ratios
-0.004
x CH 4,0
x CH 4
293
Latin American Applied Research 36:289-294 (2006)
Product Ratios
2.8 us = superficial velocity, (mf3/mr2 s).
V =volume of the catalyst particle, (mcat3).
x CH 4
294