Data collection, catalyst performance testing

The STAR fuel processor represents a culmination of three years of intensive R D and design efforts. Prior to their use in the integrated fuel processor, all components were tested in the MPR. Figure 4 compares the expected and obtained performance of the water-gas-shift catalyst in the MPR. Similarly, the MPR testing validates the desulfurizer performance data collected on the bench scale reactor (Table 2). The sulfur capacity was the same in both the MPR and the bench scale reactor. 

Fixed-bed reactors are used for testing commercial catalysts of larger particle sizes and to collect data for scale-up (validation of mathematical models, studying the influence of transport processes on overall reactor performance, etc.). Catalyst particles with a size ranging from 1 to 10 mm are tested using reactors of 20 to 100 mm ID. The reactor diameter can be decreased if the catalyst is diluted by fine inert particles the ratio of the reactor diameter to the size of catalyst particles then can be decreased to 3 1 (instead of the 10 to 20 recommended for fixed-bed catalytic reactors). This leads to a lower consumption of reactants. Very important for proper operation of fixed-bed reactors, both in cocurrent and countercurrent mode, is a uniform distribution of both phases over the entire cross-section of the reactor. If this is not the case, reactor performance will be significantly falsified by flow maldistribution. 

Most industrial reactors and high pressure laboratory equipment are built using metal alloys. Some of these same metals have been shown to be effective catalysts for a variety of organic reactions. In an effort to establish the influence of metal surfaces on the transesterification reactions of TGs, Suppes et collected data on the catalytic activity of two metals (nickel, palladium) and two alloys (cast iron and stainless steel) for the transesterification of soybean oil with methanol. These authors found that the nature of the reactor s surface does play a role in reaction performance. Even though all metallic materials were tested without pretreatment, they showed substantial activity at conditions normally used to study transesterification reactions with solid catalysts. Nickel and palladium were particularly reactive, with nickel showing the highest activity. The authors concluded that academic studies on transesterification reactions must be conducted with reactor vessels where there is no metallic surface exposed. Otherwise, results about catalyst reactivity could be misleading. 

In the present study, a small scale test plant with a methanol production capacity of 50 kg/day has been designed and constructed in order to examine the performance of catalysts developed under practical reaction conditions, and to collect experimental data useful for designing a pilot plant in the future. 

On a practical level, the heuristic approach includes first collecting all the possible data during the experiments as a function of the parameters which are deemed to be important, i.e. concentrations, temperature, pressures, pH, catalyst concentration, volume, etc. Then the rate constants are estimated by regression analysis and the adequacy of the model is judged based on some criteria (like residual sums and parameter significance, which will be discussed further). If a researcher is not satisfied, then additional experiments are performed, followed by parameter estimation and sometimes simulations outside the studied parameter domain. The latter procedure provides the possibility to test the predictive power of a kinetic model. The kinetic model is then gradually improved and the experimental plan is modified, if needed. This process continues until the researcher is satisfied with the kinetic model. 

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