A comprehensive approach for designing different configurations of isothermal reactors with fast catalyst deactivation

A methodology for simulating the performance of different reactor configurations for processes with complex reaction networks and fast catalyst deactivation has been proposed. These reaction configurations are: packed bed, moving bed and fluidized bed reactors with and without catalyst circulation. From kinetic parameters collected in a packed bed reactor and a rigorous consideration of the activity, modifications in the convection-dispersion-reaction equation have led to the prediction of the catalyst performance in each reactor configuration. The circulating fluidized bed reactor has been simulated with an original model of parallel compartments, which allows for determining its performance in the steady state from the evolution of the transitory period. The methodology has been used for simulating the dynamics of SAPO-34 fast deactivation during the methanol-to-olefins (MTO) process. For each reactor configuration, concentration profiles and their evolution with time have been simulated, thus predicting the effect of reaction conditions and water content (formed and/or co-fed) on the activity profile or the activity distribution function (in the case of circulating fluidized bed reactor). The olefin yield and distribution have also been compared for each reactor configuration.