Presentation on Fluidized Bed Reactor

4. Topics to be discussed
 Introduction
 Principle
 Hydrodynamics
 Kinetics Mechanism
 Catalyst Requirement
 Advantage
 Disadvantage
 Suppliers
 Further Challanges

6. Introduction
 History
 Exxon Mobil, 1942
 Increase in Demand
 Thermal Catalytic Reactor

9. Applications
Petroleum Industry
Fluidized Catalytic Cracking
Fluidized Bed Coking

11. Other Applications
 PetroChemical Industry
 Polymers, rubber, Polyethylenes, styrene
 Coal Industry i.e. Gasification
 WasteWater Treatment
 Nuclear Industry

12. U.SA Catalytic Cracking Unit
Ref: U.S.A Energy Information Administration
http://tonto.eia.doe.gov/dnav/pet/hist/mcrccus2A.htm

13. Principle
 MultiplePhases
 Solid Catalyst
 Gas distributors
 Liquid Feed
 Complex Reactions within same
unit

18. Hydrodynamics

19. Hydrodynaimcs
 Incipient Fluidization
 Minimum Fluidization Velocity
 Superficial Velocity
 Settling Velocity

21. Minimum Fluid Velocity
 Definition
 Role
 Calculation

22. Settling Velocity
 Definition
 Role
 Calculation

24. Fluidization regimes
Umf Umb Uch
U U
Solids Return
Solids Return
Solids Return
Gas
Fixed Particulate Bubbling Slug Flow Turbulent Fast Pneumatic
Bed Regime Regime Regime Regime Fluidization Conveying
Increasing Gas Velocity
24

26. Kinetic Mechanism
Catalyst Modification
Flow Regime
Reaction Rates calculation
Side Reactions

27. Kinetic Mechanism
 Kinetic equation can be presented as:

28. Kinetic Mechanism
 Reaction rates can be presented as:

29. Catalyst

31. Catalyst Properties Requirement
 Good stability to high temperature and to
steam
 High activity
 Large pore sizes

32. Catalyst Properties Requirement
 Good resistance to attrition
 Low coke production

33. Examples of Catalyst
 Zeolites
 Faujasite
 Mixtures of aluminium oxide and silicon dioxide.

34. Economics News
 Global Demand for catalyst used in the
refining industry is set to grow about $3.7
billion dollars in 2011
 Under new infiationary economic pressures
and environmental demands the market
may reach up to $4.8 billion dollars
Ref:http://www.nanomarkets.net/

35. Major Drivers/Suppliers
 Albemarle Cooperation
 W.R.Grace Company
 BASF Catalysts

37. Advantage

38. Advantage
 Uniform Particle Mixing
 Uniform Temperature Gradient

39. Advantage
 High Valued Products
 High Efficiency

40. Advantage
 Enhancement of Heat Transfer
 Enhancement of Mass Transfer
 Continuous State

41. Disadvantage

42. Disadvantage
Size of Reactor
Energy Requirement

43. Disadvantage
 Particle Entrainment
 Erosion of Internal Components

44. Disadvantage
 Attrition
 Understanding of Kinetics

45. Before Operation

46. After Operation

47. Erosion

48. Major Driver and Supplier
 ABB Lummus Global
 ExxonMobil Research and Engineering
 Shell Global Solutions
 Stone and Webster Engineering Corporation

49. Major Driver and Supplier
 Universal Oil Products
 Honeywell
 Kellogg Brown and Root
 World Largest Reactor

52. Challenges/Research Areas
 Design of Catalyst
 Understanding the complex kinetics
 Modelling of the Process
 Scale up issues

53. Conclusion
 Operation and Understanding of the reactor
mechanism is very complex
 Each type of reactor has its own merits and
demerits and its limitations
 Catalyst design plays an important role in
operation of reactors

54. Conclusion
 Trickle bed reactor modeling seem to be
complex and challenging
 Bubble column reactor efficiently work for slow
reaction
 Moving bed reactor work can efficiently for
catalytic cracking

55. Conclusion
 Membrane reactors are most important
due to their unique applications
 Fluidized bed reactors are integral and
most important in catalytic cracking

56. References
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 Hansen, J.A. & Cooper,B.H. (1992).’ Process simulation of refinery units including chemical reactors’.Computers & Chemical Engi
 Han, I.S, Chung, B.C. & Riggs, J.B. ( 2000). ‘Modeling of a fluidized catalytic cracking process’. Computers and Chemical Engineering, vol.
24, pp. 1681-1687
 Elnashaie, S.S.E.H & Elshishini, S.S. (1993).’Modelling, simulation and optimization of industrial fixed bed catalytic reactor
 Pedernera, M., Borio, D.O & Porras, J.A. (1996).’ A new cocurrent reactor for ammonia synthesis’. Chemical Engineering Science, vol. 51,
pp. 2927-2932
 Villamil, F.D.V., Marroquin, J.O., Paz, C.d.l.P. & Rodriguez, E. (2004). ‘A catalytic distillation process for light gas oil hydrodesulfurization’.
Chemical Engineering and ProcessingI, vol. 43,pp. 1309-1316
 Speight, J. & Ancheyta, J. (). Hydroprocessing of heavy oils and residuals.
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 Mederos, F.S., Ancheyta, J. & Chen, J. (2009).’ Review on criteria to ensure ideal behaviors in trickle-bed reactors’. Applied Catalysis,vol.
355, pp. 1-19
 Herk, D.V., Kreutzer, M.T., Makkee, M. & Moulijn, J.A. ( 2005).’ Scaling down trickle bed reactors’.Catalysis Today, vol. 106, pp. 227-232
 Urseanu, M.I., Boelhouwer, J.G., Bosman, H.J.M., Schroijen,J.C. & Kwant, G. (2005).’ Estimation of trickle-to-pulse flow regime transition
and pressure drop in high-pressure trickle bed reactors with organic liquids’. Chemical Engineering Journal, vol. 111, pp. 5-11