Generation of Catalytic Films of Zeolite Y and ZSM-5 on FeCrAlloy Metal

This work details the generation of thin films of structured zeolite catalysts (ZSM–5 and Y) onto the surface of a metal substrate (FeCrAlloy) using in-situ hydrothermal synthesis. In addition, the zeolite Y is post-synthetically modified by acidified ammonium ion exchange to generate US-Y. Finally the catalytic activity of the structured ZSM-5 catalyst films (Si/Al = 11, thickness 146 µm) and structured US–Y catalyst film (Si/Al = 8, thickness 23µm) were compared with the pelleted powder form of ZSM–5 and USY catalysts of similar Si/Al ratios. The structured catalyst films have been characterised using a range of techniques, including X-ray diffraction (XRD), Electron microscopy (SEM), Energy Dispersive X–ray analysis (EDX) and Thermogravimetric Analysis (TGA). The transition from oxide-on-alloy wires to hydrothermally synthesised uniformly zeolite coated surfaces was followed using SEM and XRD. In addition, the robustness of the prepared coating was confirmed by subjecting these to thermal cycling (ambient to 550°C). The cracking of n–heptane over the pellets and structured catalysts for both ZSM–5 and Y zeolite showed very similar product selectivities for similar amounts of catalyst with an apparent activation energy of around 60 kJ mol-1. This paper demonstrates that structured catalysts can be manufactured with excellent zeolite adherence and when suitably activated/modified give comparable cracking results to the pelleted powder forms. These structured catalysts will improve temperature distribution in highly exothermic and endothermic catalysed processes

Hydroisomerization of alkanes over metal-loaded zeolite catalysts

Zeolite catalysis plays an important role in many industrial applications due to their unique properties and has become widely used in the area of oil refining. Of particular interest is Zeolite Y, which can be hydrothermally treated into its ultrastable form, USY. USY offers a superior practicality, especially when dealuminated and metal-loaded. The importance of alkanes hydroisomerization arises from the continuingly stricter regulations imposed on the utilization of gasoline as an automotive fuel. The requirements to reduce the aromatics content in gasoline present a need to find an alternative way to maintain its research octane number (RON). An alternative to gasoline's high-octane aromatic content is to increase the RON for the paraffinic content of gasoline, which can be accomplished through hydroisomerization. Commercially, bifunctional metal-loaded zeolites are used to hydroisomerize the light naphtha stream produced at overheads of atmospheric distillation towers. However, no such process exists for the low-value heavy naphtha cut. This targeted process would, if successful, greatly improve refiner's profitability.In this work, bifunctional USY zeolite catalysts are studied in the hydroisomerization of a normal alkane (nC7, RON = 0). This nC7, found in heavy naphtha, has been used as the 'model' compound. The impact of different reaction conditions and catalyst properties on catalyst activity and stability, in addition to the catalyst selectivity to high octane isomers is one step towards determining optimum conditions and preferential catalyst formulations that favour octane maximization. Six platinum-loaded USY zeolite catalysts, four in-house and two commercial, were tested in an atmospheric glass fixed-bed reactor and a stainless steel reactor purpose-built during the course of this thesis. Reaction temperatures ranged from 170 to 250oC at pressures between 1 and 15 bar. The hydrogen to hydrocarbon molar ratio was fixed at 9, with feed space time ranging from 35.14 to 140.6 kg.s/mol. In-house catalysts were hydrothermally treated at different severities, while commercial ones were originally dealuminated through acid-leaching treatments.Results have shown commercial catalyst CBV-712 gave the best performance and highest octane values for product isomers (>30). In addition, there was no coke generation. The next best catalyst was the most severely steamed in-house catalyst (USY-D) that has shown a remarkable performance at high pressures, almost eclipsing the performance of CBV-712, yet produced higher levels of coke. Other USY catalysts tested were less robust during reactions, probably due to imbalance in their acidic to metallic functions, or diffusion limitations arising from their pore structures. The best catalysts were, nonetheless, highly sensitive to sulfur presence in the feed, which severely impacted their activity, especially their metallic functions, and thus require sulfur-free feeds in order to demonstrate their full capacities. Simple kinetic modelling of experimental data was performed using the initial rates method and estimation of kinetic parameters, whose values were in good agreement with previous literature.EThOS - Electronic Theses Online ServiceSaudi AramcoGBUnited Kingdo

Multiple use of waste catalysts with and without regeneration for waste polymer cracking

Waste plastics contain a substantial number of valuable chemicals. The wastes from post-consumer as well as from industrial production can be recycled to valuable chemical feedstock, which can be used in refineries and/or petrochemical industries. This chemical recycling process is an ideal approach in recycling the waste for a better environment. Polymer cracking using a laboratory fluidised bed reactor concentrated on the used highly contaminated catalyst, E-Cat 2. Even though E-Cat 2 had low activity due to fewer acid sites, the products yielded were similar with amorphous ASA and were far better than thermal cracking. The high levels of heavy metals, namely nickel and vanadium, deposited during their lifetime as an FCC catalyst, did not greatly affect on the catalyst activity. It was also shown that E-Cat 2 could be used with and without regeneration. Although there was more deactivation when there was no regeneration step, the yield of gases (C2–C7) remained fairly constant. For the first time, these results indicate that “waste” FCC catalyst (E-Cat) is a good candidate for future feedstock recycling of polymer waste. The major benefits of using E-Cat are a low market price, the ability to tolerate reuse and regeneration capacity

Kinetics of methylcyclohexane dehydrogenation and reactor simulation for 'on-board' hydrogen storage

Today's transportation system is contributing to increasing air pollution and lack of future fuel for a growing number of vehicles. Over the years, many alternate solutions have been proposed to replace or to assist conventional fuels in order to alleviate the environmental damage and future fuel shortage. One such solution is to use hydrogen gas as fuel in an internal combustion engine or a fuel cell. Hydrogen being light, flammable and having very low critical temperature has associated problems of storage, transportation and utilisation. The methylcyclohexane-toluene-hydrogen (MTH)-system is a safe and economical way of storage and 'on-board' hydrogen generation. The dehydrogenation reaction of MCH is highly endothermic and suffers from equilibrium limitations. Therefore, success of the MTH-system for 'on-board' applications lies in the development of a highly active, selective and stable catalyst as well as a reactor supplying high rates of heat transfer to the catalytic bed. A review of the literature has shown that there is a huge disagreement in describing the kinetic mechanism of the dehydrogenation reaction of MCH. There is no consensus on the rate-determining step and the inhibition offered by the products. Moreover, there is no detailed kinetic investigation over a wide range of operating conditions including experiments without H2 in the feed and under integral conditions.The present study is designed to conduct a detailed kinetic investigation over a wide range of operating conditions including experiments without hydrogen in the feed for the most promising catalyst developed to date. The reaction kinetics are incorporated into a two-dimensional pseudo-homogeneous model to predict observed longitudinal temperature profiles. Alternative configurations and schemes for 'on-board' hydrogen generation based on the MTH-system are compared and a prototype reactor, suitable for 'on-board' hydrogen generation, is designed and simulated in detail, exchanging heat with the engine exhaust gas. Kinetic experiments were performed in a laboratory fixed bed tubular reactor under integral conditions. A 1.0 wt% Pt/Al2O3 catalyst was prepared and a wide range of experimental conditions were studied. A number of kinetic models were applied based on the power law, Langmuir-Hinshelwood-Hougen-Watson (LHHW) and Horiuti-Polanyi (HP) mechanisms. A kinetic model based on LHHW single-site mechanism with loss of the first H2 molecule the rate rate-controlling step was found to best fit the data. Analyses of the products show that the dehydrogenation of MCH is very selective towards toluene. As well as the main product toluene, a number of condensable by-products were also identified. Benzene, cyclohexane and ring-closed products (ethylcyclopentane and dimethylcyclopentanes) are the major by-products.Laboratory experimental data for the 12 experimental runs made under varying conditions of pressure, space velocity and feed composition were simulated and good agreement between predicted and observed centreline temperatures was found. A hybrid MTH-gasoline-system is a viable option. Using titanium aluminide as the material of construction, the dynamic (start up) time requirement for the prototype reactor may be halved over that required for a stainless steel construction.EThOS - Electronic Theses Online ServiceHigher Education of PaksitanGBUnited Kingdo

Optimization of Fischer-Tropsch plant

Fischer-Tropsch synthesis is the technology for converting fuel feedstocks such as natural gas and coal into transportation fuels and heavy hydrocarbons. There is scope for research and development into integrated processes utilising synthesis gas for the production of a wide range of hydrocarbons. For this purpose there should be strategies for the development of Fischer-Tropsch processes, which consider both economic and technological feasibilities. The aim of this study was to optimize Fischer Tropsch Plants in order to produce gasoline and gas oil by investigating the benefits of recycling & co-feeding of unconverted gas, undesired compounds, and lighter hydrocarbons over iron-based catalysts in order to save on capital and operating costs. This involved development of FT models for both two-phase and three-phase reactors. The kinetic parameters for these models were estimated using optimization with MATLAB fitting to experimental data and these models were then applied to ASPEN HYSYS flowsheets in order to simulate nine different Fischer-Tropsch plant designs. The methodology employed involved qualitative modelling using Driving Force Analysis (DFA) which indicates the necessity of each compound for the Fischer-Tropsch reactions and mechanism. This also predicts each compounds influence on the selectivity of different products for both two-phase and three-phase reactors and for both pure feeding and co-feeding arrangements. In addition, the kinetic models for both two-phase and three-phase reactor were modified to account for parameters such as the size of catalyst particles, reactor diameter and the type of active sites used on the catalyst in order to understand and quantify their effects. The kinetic models developed can describe the hydrocarbon distributions consistently and accurately over large ranges of reaction conditions (480-710K, 0.5-2.5MPa, and H2/CO ratio: 0.5-2.5) over an iron-based catalyst for once-through processes. The effect of recycling and co-feeding on the iron-based catalyst was also investigated in the two reactor types. It was found that co-feeding unwanted compounds to synthesis gas increases the production of hydrocarbons. This recycling and co-feeding led to an increase in H2/CO feed ratio and increased selectivity towards C5+ products in addition to a slightly increased production of light hydrocarbons (C1-C4). Finally, the qualitative model is compared with the quantitative models for both two-phase and three-phase reactors and using both pure feeding and co-feeding with the same reactor conditions. According to the detailed quantitative models developed, in order to maximize hydrocarbon production pressures of 2MPa, temperatures of 450K and a H2/CO feed ratio of 2:1 are required. The ten different Fischer-Tropsch plant cases were based on Fischer-Tropsch process. FT reactor models were built in ASPEN HYSYS and validated with real FT plant data. The results of the simulation and optimization supported the proposed process plant changes suggested by qualitative analysis of the different components influence. The plants involving recycling and co-feeding were found to produce higher quantities of gasoline and gas oil. The proposed heuristic regarding the economic scale of the optimized model was also evaluated and the capital cost of the optimized FT plant reduced comparison with the real FT plant proposed by Gerard. Therefore, the recycling and co-feeding to FT reactor plant was the best efficiency to produce both gasoline and gas oil.EThOS - Electronic Theses Online ServiceGBUnited Kingdo