Utilizing volatile renewable energy sources (e.g., solar, wind) for chemical production systems requires a deeper understanding of their dynamic operation modes. Taking the example of a methanation reactor in the context of power-togas applications, a dynamic optimization approach is used to identify control trajectories for a time optimal reactor start-up avoiding distinct hot spot formation. For the optimization, we develop a dynamic, two-dimensional model of a fixed-bed tube reactor for carbon dioxide methanation which is based on the reaction scheme of the underlying exothermic Sabatier reaction mechanism. While controlling dynamic hot spot formation inside the catalyst bed, we prove the applicability of our methodology and investigate the feasibility of dynamic carbon dioxide methanation.

Intelligent coolant temperature adjustment allows hot-spot stabilization in exothermic fixed-bed reactors at the industrial-scale and provides additional operating points with increased performance and moderate catalyst temperatures.

CO2 methanation is often performed on Ni/Al2O3 catalysts, which can suffer from mass transport limitations and, therefore, decreased efficiency. Here we show the application of a hierarchically porous Ni/Al2O3 catalyst for methanation of CO2. The material has a well-defined and connected meso- and macropore structure with a total porosity of 78%. The pore structure was thoroughly studied with conventional methods, i.e., N2 sorption, Hg porosimetry, and He pycnometry, and advanced imaging techniques, i.e., electron tomography and ptychographic X-ray computed tomography. Tomography can quantify the pore system in a manner that is not possible using conventional porosimetry. Macrokinetic simulations were performed based on the measures obtained by porosity analysis. These show the potential benefit of enhanced mass-transfer properties of the hierarchical pore system compared to a pure mesoporous catalyst at industrially relevant conditions. Besides the investigation of the pore system, the catalyst was studied by Rietveld refinement, diffuse reflectance ultraviolet-visible (DRUV/vis) spectroscopy, and H2-temperature programmed reduction (TPR), showing a high reduction temperature required for activation due to structural incorporation of Ni into the transition alumina. The reduced hierarchically porous Ni/Al2O3 catalyst is highly active in CO2 methanation, showing comparable conversion and selectivity for CH4 to an industrial reference catalyst.

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This publication is part of a joint Special Collection with ChemElectroChem on "Catalysts and Reactors under Dynamic Conditions for Energy Storage and Conversion (DynaKat)".Please check ourhomepage for more articles in the collection.

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With the increasing need to utilize carbon dioxide, fixed-bed reactors for catalytic hydrogenation will become a decisive element for modern chemicals and energy carrier production. In this context, the resilience and flexibility to changing operating conditions become major objectives for the design and operation of real industrial-scale reactors. Therefore steady-state multiplicity and stability are essential measures, but so far, their quantification is primarily accessible for ideal reactor concepts with zero or infinite back-mixing. Based on a continuous stirred tank reactor cascade modeling approach, this work derives novel criteria for stability, multiplicity, and uniqueness applicable to real reactors with finite back-mixing. Furthermore, the connection to other reactor features such as runaway and parametric sensitivity is demonstrated and exemplified for CO2 methanation under realistic conditions. The new criteria indicate that thermo-kinetic multiplicities induced by back-mixing remain relevant even for high Bodenstein numbers. In consequence, generally accepted back-mixing criteria (e.g., Mears’ criterion) appear insufficient for real non-isothermal reactors. The criteria derived in this work are applicable to any exothermic reaction and reactors at any scale. Ignoring uniqueness and multiplicity would disregard a broad operating range and thus a substantial potential for reactor resilience and flexibility.