Numerical modeling of chemical looping oxidative dehydrogenation of ethane in parallel packed beds

Abstract

Chemical looping oxidative dehydrogenation (CL-ODH) of ethane has the potential to be a highly efficient alternative to steam cracking for ethylene production. Accurate reactor modeling is of critical importance to efficiently scale up and optimize this new technology. This study reports a one-dimensional, heterogeneous packed bed model to simulate the CL-ODH of ethane to ethylene with a Na2MoO4-promoted CaTi0.1Mn0.9O3 redox catalyst. The overall reaction kinetics was well-described by coupling the gas-phase steam cracking of ethane with the reduction kinetics of the redox catalyst by H2 and C2H4. The impact of H2 on the formation rate of CO2 byproduct from C2H4 conversion was also thoroughly investigated to validate the applicability of the kinetic model under operational environments. The temperature variation within the different CL-ODH steps and the temperature distribution along the bed were also carefully considered. The accuracy of the model was validated by experiments conducted in a large lab-scale packed bed reactor (200 g catalyst loading), with an average deviation of 2.8% in terms of ethane conversion and ethylene yield. The model was subsequently used to optimize the operating parameters of the CL-ODH reactor, indicating that up to 63.7% single-pass C2 + olefin yield can be achieved with the current redox catalyst bed whereas further optimization of the redox catalyst to inhibit C2H4 activation can result in 69.4% single-pass C2 + yield while maintaining low CO2 selectivity.