Ethane dehydrogenation in a catalytic membrane reactor coupled with a reactive sweep gas

Development and Intensification of the Ethylene Process Utilizing a Catalytic Membrane Reactor

Ethylene is considered the most important petrochemical constituent in the world today. It is currently produced via the thermal cracking process, which is generally expensive. Ethane dehydrogenation (EDH) is endothermic, and the thermodynamic equilibrium limits its conversion. The present study explores the viability of using a catalytic membrane reactor (MR) for ethylene production from EDH. The removal of hydrogen from the reaction zone using a palladium-silver (Pd-Ag) membrane has led to a high shift in the equilibrium conversion. The effects of operating conditions and reactor configurations on the ethane conversion were investigated. The ultimate ethane conversion was 22.2% when using the MR at 660 K and 300 kPa. The ethane conversion in the shell-side of the reactor increased to ∼99% when benzene hydrogenation was added as an auxiliary reaction in the tube-side of the reactor. Two new processes for ethylene production were developed for an annual capacity of 100,000 metric tons. Cryogenic distillation was required to separate ethylene from ethane if there is no auxiliary reaction. On the other hand, the ethylene process with cyclohexane as a byproduct does not require a refrigeration cycle system, and its economic analysis shows a return on investment of 34.4%, indicating that the process is a promising technology.

Theoretical Prediction of the Efficiency of Hydrogen Production via Alkane Dehydrogenation in Catalytic Membrane Reactor

The hydrogen economy is expected to dominate in the nearest future. Therefore, the most hydrogen-containing compounds are considered as potential pure hydrogen sources in order to achieve climate neutrality. On the other hand, alkanes are widely used to produce industrially important monomers via various routes, including dehydrogenation processes. Hydrogen is being produced as a by-product of these processes, so the application of efficient separation of hydrogen from the reaction mixture can give double benefits. Implementation of the dehydrogenation processes in the catalytic membrane reactor is that case. Since the use of dense metal membranes, which possess the highest perm-selectivity towards hydrogen, is complicated in practice, the present research is aimed at the optimization of the porous membrane characteristics. By means of a mathematical modeling approach, the effects of pore diameter on the hydrogen productivity and purity for the cases of ethane and propane dehydrogenation processes were analyzed. The pore size value of 0.45 nm was found to be crucial as far as the diffusion of both the alkane and alkene molecules through the membrane takes place.

Modeling and simulation of ammonia removal from purge gases of ammonia plants using a catalytic Pd-Ag membrane reactor

In this work, the removal of ammonia from synthesis purge gas of an ammonia plant has been investigated. Since the ammonia decomposition is thermodynamically limited, a membrane reactor is used for complete decomposition. A double pipe catalytic membrane reactor is used to remove ammonia from purge gas. The purge gas is flowing in the reaction side and is converted to hydrogen and nitrogen over nickel-alumina catalyst. The hydrogen is transferred through the Pd-Ag membrane of tube side to the shell side. A mathematical model including conservation of mass in the tube and shell side of reactor is proposed. The proposed model was solved numerically and the effects of different parameters on the rector performance were investigated. The effects of pressure, temperature, flow rate (sweep ratio), membrane thickness and reactor diameter have been investigated in the present study. Increasing ammonia conversion was observed by raising the temperature, sweep ratio and reducing membrane thickness. When the pressure increases, the decomposition is gone toward completion but, at low pressure the ammonia conversion in the outset of reactor is higher than other pressures, but complete destruction of the ammonia cannot be achieved. The proposed model can be used for design of an industrial catalytic membrane reactor for removal of ammonia from ammonia plant and reducing NO(x) emissions.