The design and operation of a PDU-scale tube wall methanation system are discussed. The tube wall reactor was constructed from a stainless steel pipe with a surrounding jacket. The inside surface of the tube was flame sprayed with Raney nickel catalyst for 14 ft of length. The catalyst coating was activated by leaching with a caustic solution. A liquid coolant in the outer shell of the reactor removed the heat of methanation and maintained the system at near isothermal conditions. Exposure velocity and recycle ratio were varied during the run. Concentration and temperature profiles were periodically measured along the length of the catalyst bed. Catalyst performance, methane production, deactivation, and other results are presented for the test which was terminated after 1179 h on stream.

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Pilot plant data are presented from a 1291-h test on an adiabatic catalytic methanation reactor employing recycled product gas for cooling. Topics discussed include conversion, product yields, catalyst properties, and deactivation rates. A mathematical model postulating an irreversible Langmuir-HInshelwood mode of deactivation is presented and applied.

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