Numerical Simulation of the Isoparaffins Dehydrogenation Process in Fluidized Bed Reactor: From Laboratory to Industry

A numerical model was developed to simulate a fluidized bed reactor for isobutane dehydrogenation. First, we constructed a hydrodynamic model of catalyst particle fluidization and a kinetic model for three chemical reactions in a simple lab-scale reactor (H = 70 cm, D = 2.8 cm). Experimental studies and numerical simulation of the laboratory reactor were carried out at four temperatures: 550, 575, 600, and 625 °C. The product yield results from the computational fluid dynamics simulation show a close match to the experimental data. The optimal process temperature in the laboratory reactor is 575 °C, at which the isobutylene yield is ~46.03 wt%. With decreasing temperature, the isobutylene yield decreases, and it rises as temperature increases. However, with rising temperature, the total yield of by-products increases on average to 20 wt%. We compared the CFD simulation results for two laboratory reactor models: a 3D model and a 2D axisymmetric model. For gas phase fractions, absolute deviations ranged from 0.01 to 1.12%, while relative deviations were between 0.006% and 0.114%. However, there are differences in the solid-phase particle dynamics. Second, we applied the constructed CFD model to simulate an industrial-scale reactor (H = 23.81 m, D = 4.6 m). In addition to its size, the industrial reactor differs from the laboratory reactor in its heating principle. In this configuration, the gas, preheated to 550 °C, and the catalyst particles, at 650 °C, are fed into the entire volume. The objective of this study is to test the performance of the model, which was verified on a laboratory reactor, for simulating an industrial reactor. Temperature fields and zones of reaction product formation are analyzed. The average isobutylene yield is ~31.88 wt%, which is consistent with the operation of real reactors but lower than the results for the laboratory reactor at all temperatures. The industrial reactor is more challenging to heat uniformly. It contains many internal elements that affect the movement of the gas–solid system. Overall, the model developed for the laboratory reactor has proven to be suitable for CFD modeling of an industrial reactor.