Experimental Quantification of Gas Dispersion in 3D-Printed Logpile Structures Using a Noninvasive Infrared Transmission Technique.

3D-printed catalyst structures have the potential to broaden reactor operating windows. However, the hydrodynamic aspects associated with these novel catalyst structures have not yet been quantified in detail. This work applies a recently introduced noninvasive, instantaneous, whole-field concentration measurement technique based on infrared transmission to quantify the rate of transverse gas dispersion in 3D-printed logpile structures. Twenty-two structural variations have been investigated at various operating conditions, and the measured transverse gas dispersion has been correlated to the Péclet number and the structures' porosity and feature size. It is shown that staggered configurations of these logpile structures offer significantly more tunability of the dispersion behavior compared to straight structures. The proposed correlations can be used to facilitate considerations of reactor design and operating windows.

On the Potential of Gallium- and Indium-Based Liquid Metal Membranes for Hydrogen Separation.

The concept of liquid metal membranes for hydrogen separation, based on gallium or indium, was recently introduced as an alternative to conventional palladium-based membranes. The potential of this class of gas separation materials was mainly attributed to the promise of higher hydrogen diffusivity. The postulated improvements are only beneficial to the flux if diffusion through the membrane is the rate-determining step in the permeation sequence. Whilst this is a valid assumption for hydrogen transport through palladium-based membranes, the relatively low adsorption energy of hydrogen on both liquid metals suggests that other phenomena may be relevant. In the current study, a microkinetic modeling approach is used to enable simulations based on a five-step permeation mechanism. The calculation results show that for the liquid metal membranes, the flux is limited by the dissociative adsorption over a large temperature range, and that the membrane flux is expected to be orders of magnitude lower compared to the membrane flux through pure palladium membranes. Even when accounting for the lower cost of the liquid metals compared to palladium, the latter still outperforms both gallium and indium in all realistic scenarios, in part due to the practical difficulties associated with making liquid metal thin films.

Experimental validation of pressure swing regeneration for faster cycling in sorption enhanced dimethyl ether synthesis.

Sorption enhanced dimethyl ether synthesis (SEDMES) is a novel DME production route from CO2-rich feedstocks. In situ water removal by adsorption results in high single-pass conversions, thereby circumventing the disadvantages of conventional routes, such as low carbon efficiency, energy intensive downstream separation and large recycling. The first-time demonstration of pressure swing regeneration with 80% single-pass carbon selectivity to DME allows for an enormous increase in productivity. Already a factor four increase compared to temperature swing regeneration is achieved, unlocking the potential of SEDMES as a carbon utilisation technology.

Effect of Superficial Gas Velocity on the Solid Temperature Distribution in Gas Fluidized Beds with Heat Production.

The hydrodynamics and heat transfer of cylindrical gas-solid fluidized beds for polyolefin production was investigated with the two-fluid model (TFM) based on the kinetic theory of granular flow (KTGF). It was found that the fluidized bed becomes more isothermal with increasing superficial gas velocity. This is mainly due to the increase of solids circulation and improvement in gas solid contact. It was also found that the average Nusselt number weakly depends on the gas velocity. The TFM results were qualitatively compared with simulation results of computational fluid dynamics combined with the discrete element model (CFD-DEM). The TFM results were in very good agreement with the CFD-DEM outcomes, so the TFM can be a reliable source for further investigations of fluidized beds especially large lab-scale reactors.

Selective separation of furfural and hydroxymethylfurfural from an aqueous solution using a supported hydrophobic deep eutectic solvent liquid membrane.

For the first time, 12 different supported deep eutectic solvent (DES) liquid membranes were prepared and characterized. These membranes consist of a polymeric support impregnated with a hydrophobic DES. First, the different membranes were characterized and their stability in water and air was determined. Subsequently, the supported DES liquid membranes were applied for the recovery of furfural (FF) and hydroxymethylfurfural (HMF) from aqueous solutions. The effects of substrate properties (e.g. pore size), DES properties (e.g. viscosity) and concentrations of FF and HMF in the feed phase on the observed diffusivities and permeabilities were assessed. It was found that the addition of DES enhances the transport of FF and HMF through the polymeric membrane support. In particular, the use of the DES consisting of thymol + lidocaine (in the molar ratio 2 : 1) impregnated in a polyethylene support resulted in enhanced transport for both FF and HMF, and is most interesting for (in situ) isolation of FF and HMF from aqueous solutions, e.g. in biorefinery processes.

Recent Advances in Pd-Based Membranes for Membrane Reactors.

Palladium-based membranes for hydrogen separation have been studied by several research groups during the last 40 years. Much effort has been dedicated to improving the hydrogen flux of these membranes employing different alloys, supports, deposition/production techniques, etc. High flux and cheap membranes, yet stable at different operating conditions are required for their exploitation at industrial scale. The integration of membranes in multifunctional reactors (membrane reactors) poses additional demands on the membranes as interactions at different levels between the catalyst and the membrane surface can occur. Particularly, when employing the membranes in fluidized bed reactors, the selective layer should be resistant to or protected against erosion. In this review we will also describe a novel kind of membranes, the pore-filled type membranes prepared by Pacheco Tanaka and coworkers that represent a possible solution to integrate thin selective membranes into membrane reactors while protecting the selective layer. This work is focused on recent advances on metallic supports, materials used as an intermetallic diffusion layer when metallic supports are used and the most recent advances on Pd-based composite membranes. Particular attention is paid to improvements on sulfur resistance of Pd based membranes, resistance to hydrogen embrittlement and stability at high temperature.

Advancement of an Infra-Red Technique for Whole-Field Concentration Measurements in Fluidized Beds.

For a better understanding and description of the mass transport phenomena in dense multiphase gas-solids systems such as fluidized bed reactors, detailed and quantitative experimental data on the concentration profiles is required, which demands advanced non-invasive concentration monitoring techniques with a high spatial and temporal resolution. A novel technique based on the selective detection of a gas component in a gas mixture using infra-red properties has been further developed. The first stage development was carried out using a very small sapphire reactor and CO2 as tracer gas. Although the measuring principle was demonstrated, the real application was hindered by the small reactor dimensions related to the high costs and difficult handling of large sapphire plates. In this study, a new system has been developed, that allows working at much larger scales and yet with higher resolution. In the new system, propane is used as tracer gas and quartz as reactor material. In this study, a thorough optimization and calibration of the technique is presented which is subsequently applied for whole-field measurements with high temporal resolution. The developed technique allows the use of a relatively inexpensive configuration for the measurement of detailed concentration fields and can be applied to a large variety of important chemical engineering topics.

Fluidized Bed Membrane Reactors for Ultra Pure H2 Production--A Step forward towards Commercialization.

In this research the performance of a fluidized bed membrane reactor for high temperature water gas shift and its long term stability was investigated to provide a proof-of-concept of the new system at lab scale. A demonstration unit with a capacity of 1 Nm³/h of ultra-pure H2 was designed, built and operated over 900 h of continuous work. Firstly, the performance of the membranes were investigated at different inlet gas compositions and at different temperatures and H2 partial pressure differences. The membranes showed very high H2 fluxes (3.89 × 10(-6) mol·m(-2)·Pa(-1)·s(-1) at 400 °C and 1 atm pressure difference) with a H2/N2 ideal perm-selectivity (up to 21,000 when integrating five membranes in the module) beyond the DOE 2015 targets. Monitoring the performance of the membranes and the reactor confirmed a very stable performance of the unit for continuous high temperature water gas shift under bubbling fluidization conditions. Several experiments were carried out at different temperatures, pressures and various inlet compositions to determine the optimum operating window for the reactor. The obtained results showed high hydrogen recovery factors, and very low CO concentrations at the permeate side (in average <10 ppm), so that the produced hydrogen can be directly fed to a low temperature PEM fuel cell.

Morphology and N2 Permeance of Sputtered Pd-Ag Ultra-Thin Film Membranes.

The influence of the temperature during the growth of Pd-Ag films by PVD magnetron sputtering onto polished silicon wafers was studied in order to avoid the effect of the support roughness on the layer growth. The surfaces of the Pd-Ag membrane films were analyzed by atomic force microscopy (AFM), and the results indicate an increase of the grain size from 120 to 250-270 nm and film surface roughness from 4-5 to 10-12 nm when increasing the temperature from around 360-510 K. After selecting the conditions for obtaining the smallest grain size onto silicon wafer, thin Pd-Ag (0.5-2-µm thick) films were deposited onto different types of porous supports to study the influence of the porous support, layer thickness and target power on the selective layer microstructure and membrane properties. The Pd-Ag layers deposited onto ZrO2 3-nm top layer supports (smallest pore size among all tested) present high N2 permeance in the order of 10(-6) mol·m(-2)·s(-1)·Pa(-1) at room temperature.

Auto-thermal reforming using mixed ion-electronic conducting ceramic membranes for a small-scale H2 production plant.

The integration of mixed ionic electronic conducting (MIEC) membranes for air separation in a small-to-medium scale unit for H2 production (in the range of 650-850 Nm3/h) via auto-thermal reforming of methane has been investigated in the present study. Membranes based on mixed ionic electronic conducting oxides such as Ba0.5Sr0.5Co0.8Fe0.2O3-δ (BSCF) give sufficiently high oxygen fluxes at temperatures above 800 °C with high purity (higher than 99%). Experimental results of membrane permeation tests are presented and used for the reactor design with a detailed reactor model. The assessment of the H2 plant has been carried out for different operating conditions and reactor geometry and an energy analysis has been carried out with the flowsheeting software Aspen Plus, including also the turbomachines required for a proper thermal integration. A micro-gas turbine is integrated in the system in order to supply part of the electricity required in the system. The analysis of the system shows that the reforming efficiency is in the range of 62%-70% in the case where the temperature at the auto-thermal reforming membrane reactor (ATR-MR) is equal to 900 °C. When the electric consumption and the thermal export are included the efficiency of the plant approaches 74%-78%. The design of the reactor has been carried out using a reactor model linked to the Aspen flowsheet and the results show that with a larger reactor volume the performance of the system can be improved, especially because of the reduced electric consumption. From this analysis it has been found that for a production of about 790 Nm3/h pure H2, a reactor with a diameter of 1 m and length of 1.8 m with about 1500 membranes of 2 cm diameter is required.

A novel pulse isotopic exchange technique for rapid determination of the oxygen surface exchange rate of oxide ion conductors.

We demonstrate the use of a novel pulse (18)O-(16)O isotopic exchange technique for the rapid determination of the oxygen surface exchange rate of oxide ion conductors while simultaneously providing insight into the mechanism of the oxygen exchange reaction, which contributes to the efficient development of devices incorporating these solids, such as solid oxide fuel cells and oxygen transport membranes.