Hydrocarbon Conversion

Lee Tonkovich and Yong Wang

Project Description

This project developed and demonstrated integrated chemical process systems -- reactors -- built upon Battelle's microchannel technology. A key objective was met to demonstrate the capability to fabricate and operate catalytic micromachined reactors. The production of synthesis gas from methane through either partial oxidation or steam reforming was demonstrated with sufficient kinetics for subsequent deployment in a microchannel reactor. In both cases, thermal integration in a microchemical reactor is paramount to obtain high efficiency that ultimately shrinks the size of the process.

Our objective is to demonstrate a chemical process system with an integral reactor, product separation, and reactant recycle. The goal is to demonstrate a system which can be easily and cost-competitively scaled to large throughputs. In the first year of the project, proof-of-principle demonstrations were conducted which showed enhanced microreactor performance for the partial oxidation of methane (65% yield) and methanol (70% yield) to synthesis gas. The chemistry employed by these systems have significant exothermicity, and as such, selectivity and per pass yields can be improved with integrated microchannel heat exchangers to control process conditions. Further, these target reactions are based on the concept of milli-second residence times, where a hot reaction zone promotes fast reactions and a rapid product quench in the microreactor freezes the desired energetic product.

Technical Accomplishments

Our technical work in FY 1998 focused on demonstrating fast kinetics, which are sufficient for subsequent miniaturization in a microchannel reactor. The microtechnology platform reduces heat and mass transport limitations. For reactor applications, the underlying reaction kinetics must also be fast.

Additional work was done to develop a fabrication method for multiple layer microchannel reactors using the laminate process. A four-layer reactor was constructed from stainless steel shims and thermally bonded. Reactor testing was initiated, but was put on hold to wait for the development of an engineered combustion catalyst that is suitable to reach the desired operating temperature.

Publications and Presentations

Tonkovich, A. Y., Zilka, J. L., Powell, M. R., and C. J. Call, 1998a, The Catalytic Partial Oxidation of Methane in a Microchannel Chemical Reactor, Published in the Proceedings of the Second International Conference of Microreaction Technology, March 1998, New Orleans, Louisiana.

A.L. Y. Tonkovich, Zilka, J. L., Powell, M. R., and C. J. Call, The Catalytic Partial Oxidation of Methane in a Microchannel Chemical Reactor, Presented at the Second International Conference of Microreaction Technology, March 1998, New Orleans, Louisiana.