RAPIC PROJECT: TOWARD COMPETITIVE HEAT … · and heat and mass transfer intensification: ......
Transcript of RAPIC PROJECT: TOWARD COMPETITIVE HEAT … · and heat and mass transfer intensification: ......
RAPIC PROJECT:
TOWARD COMPETITIVE HEAT
EXCHANGER/REACTOR
19TH SEPTEMBER 2012
ANR Sustainable Chemistry Conference | Zoé ANXIONNAZ-MINVIELLE
CONTEXT
Chemical syntheses = f(T)
Heat transfer limitations in
batch reactors
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Transposition from batch to plug flow continuous reactors and heat and mass transfer intensification: • Continuous production
• Quality enhancement
• Safer process
• Environmental-friendly
CONTEXT
Plate heat exchanger/reactors
Industrial well-known plate heat exchanger technology Compact technology Demonstrated in the 1-10kg/h range… …But expensive apparatuses
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RAPIC Project to develop an
innovative and low-cost component
Scientific and technical challenges:
• Compacity vs. Residence time?
• Scale-up x10 up to x100
• Low-cost manufacturing technique
RAPIC PROJECT - OBJECTIVES
• Funded by the French National Research Agency
• Consortium : CEA LITEN, Rhodia, Fives Cryo, LGC et LTN
• Budget : 1,9 M€ / 4 ans
• Objectives:
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• To develop an innovative and low-cost component
• To comply with the implementation constraints of
exo/endothermal reactions
•To be as close as possible to mature
technologies of the heat exchanger
sector
• To respect the cost constraints
imposed by the market
RAPIC PROJECT - STRUCTURE
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1. End-user specifications
2. Design of a basic HEX/reactor
3. Optimization of the design
4. Lab-scale pilots
Process fluid
Cooling fluid
Process fluid Cooling fluid
Structuration of the
process flow
Plates assembled by
HIP (Hot Isostatic
Pressing) or brazing
RAPIC PROJECT - SPECIFICATIONS
Rhodia chemical reaction target:
Homogeneous liquid-phase exothermal reaction
Adiabatic temperature rise = 200°C
Residence time = 2-3 min
Isothermal reactor: max temperature rise = 10°C
𝑈∙𝐴
𝑉𝑓𝑙𝑢𝑖𝑑= 580 kW ∙ 𝑚−3 ∙ 𝐾−1
Lab-scale: 1-10 kg.h-1
Production scale: 100-4000 kg.h-1
Assessment of a maximal cost to be equivalent to the industrial batch process
cost assessment from reactants to building
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1ST SIMPLE PLATE REACTOR CONCEPT
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Process side
Straight stainless steel tubes (8/10mm)
Twisted inserts
Copper matrix
2x25 process plates (1.25 x 0.8 x 0.02 m3) and 60 tubes/plate
Cooling side
Straight perforated fins (h=0,4mm – e=0,5mm)
51 plates
Reactor
580 kW.m-3.K-1
Vreactor = 1,44 m3
ΔP = 7 bars
1ST SIMPLE PLATE REACTOR CONCEPT
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Manufacture of the 1st concept mock-up:
To validate the pre-sizing correlations
To assess the manufacture costs
2nd step objective : more efficient, compact and cheaper heat
exchanger/reactor:
Modification of channel cross-section shape Structuration of the channel geometry (2D)
LAB-SCALE MOCK-UPS
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Objectives:
Manufacturing qualification processes:
Machining, fins bending
Brazing, hot isostatic pressing
Thermo-hydraulic characterizations
Flow structure: pressure drops, RTD
Heat and mass transfers
Overall dimensions:
~320 x 130 x 20 mm3
Material: 316L, copper, PMMA
Milli-reaction channel
LAB-SCALE MOCK-UPS
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2D-structure of the reaction channel
Process side Utility side
LAB-SCALE MOCK-UPS
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2D-structure of the reaction channel
Thermo-hydraulic performances
• Global mixing
• Thermal performances
PMMA mock-ups: flow characterization in the
2D reaction channel
Flow hydrodynamics
• Residence Time Distribution
• Pressure drops
PhD Thesis
LGC/CEA
0,01
0,1
1
10
10 100 1 000 10 000
Nombre de Reynolds
Coeff
icie
nt
de D
arc
y
Maq. aMaq. bMaq. cMaq. dMaq. etube droit littératuretube droit exp carré
0,01
0,1
1
10
10 100 1 000 10 000
Nombre de Reynolds
Coeff
icie
nt
de D
arc
y
Maq. aMaq. bMaq. cMaq. dMaq. etube droit littératuretube droit exp carré
LAB-SCALE MOCK-UPS
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2D-structure of the reaction channel
12
Reynolds number
Da
rcy c
oe
ffic
ien
t
Reynolds number
UA
/V (
kW
.m-3
.K-1
)
0
1000
2000
3000
4000
5000
0 2 4 6 8 10 12 14 16 18
Débit côté procédé (kg.h-1
)
UA
/V (
kW.m
-3.K
-1)
'Maquette 'b'Maquette 'c'Maquette 'd'Maquette 'e
LAB-SCALE MOCK-UPS
Manufacturing techniques
d=8 mm
Twisted inserts
Vfluid=301 mL
Ldev=2.88 m
2x4 mm2
Vfluid=34 mL
Ldev=4.67 m
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LAB-SCALE MOCK-UPS
Manufacturing techniques
2x4 mm2
Vfluid=23 mL
Ldev=2.21 m
hfin=5.1 mm
Lfin=1.54 mm
Vfluid=102 mL
Ldev=0.9 m
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LAB-SCALE MOCK-UPS
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Experimental characterizations
UA
/V (
kW
.K-1
.m-3
)
Flowrate (kg.h-1)
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Flowrate (kg.h-1)
Pum
p p
ow
er
(W)
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LAB-SCALE MOCK-UPS
Experimental characterizations
Pe = 40 to 150
Iodide-Iodate method with
adaptive procedure*
FROM THE MOCK-UPS TO THE PILOTS
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• Integration of cooling plates
• 2 manufacturing techniques
• 10 kg/h range
• Tests with exothermic reactions
• Process plate (x3):
– Wavy channel
– Stainless steel
– HIP technique
• Cooling plate (x4):
– Parallell wavy channels
– Stainless steel
– HIP technique
• Dimensions : 320 x 140 x 33 mm3
• Fluid volume = 30 mL
• Process plate (x1):
– Herringbones
– Stainless steel
– Brazing technique
• Cooling plate (x2):
– Herringbones
– Stainless steel
– Brazing technique
• Dimensions : 319 x 129 x 30 mm3
• Fluid volume = 102 mL
• Process plate (x3):
– Straight circular tube with twisted
inserts
– Copper matrix
– HIP technique
• Cooling plate (x4):
– Stainless steel herringbones
– Brazing techniques
• Dimensions: 800 x 400 x 70 mm3
• Fluid volume = 1.17 L
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PILOT-SCALE HEAT EXCHANGER/REACTOR
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2 Na2S2O3 + 4H2O2 Na2S3O6 + Na2SO4 + 4H2O
ΔHr = -586.2 kJ.mol-1 of Na2S2O3
Oxidation reaction:
Process fluid Cooling fluid Conversion
Qp (L.h-1) Re tr (s) Tu,in (°C) Tu,out (°C) Reactor (%)
14.0 2500 6.9 39.7 39.9 60
7.0 1300 13.8 39.7 41.1 88
7.0 1500 13.8 59.4 60.1 95
0
10
20
30
40
50
3000 3200 3400 3600 3800 4000
Time (s)
T (
°C)
Tp,in
Tp,out
Tu,in
Tu,out
Reactants
introduction
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Data of the oxidation reaction experiments (Tu=49°C), heat generated :
Q/V=14.103 kW.m-3
Comparison with batch reactors
Heat that could be removed in a batch reactor
(1L<V<1m3 - ∆T=45°C – Umax=500 W.m2.K-1)
Volume (m3) 1.10-3 1.10-2 0,1 1
Diameter (m) 0,08 0,2 0,4 0,9
Height (m) 0,2 0,3 0,8 1,4
A (m2) 0,055 0,22 1,13 4,6
Qmax/V
(kW.m3) 1200 500 250 100
PILOT-SCALE HEAT EXCHANGER/REACTOR
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Simulation tool • Design assistance
• Operating conditions optimization
• Reaction implementation in safe conditions
PILOT-SCALE HEAT EXCHANGER/REACTOR
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Ac. + KOH intermediate Final product 30°C 40°C
Secondary products
• Batch process
• Operating times >3h to
keep T<40°C
• 2ndary products = 0,2%
Flowrate
(kg/h) 5 9
Res. time (s) 73 480
% 2ndary Prod. 1,3 (Tinlet=60°C
Toutlet=32°C) 0
PILOT-SCALE HEAT EXCHANGER/REACTOR
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PILOT-SCALE HEAT EXCHANGER/REACTOR
Costs assessments
Offset strip fins (refroidissement)
usinage et matière plaques réactionnelles
Main d'œuvre
Herringbones
Process plates machining and
raw materials
Labour costs
Matière première partie réactive
Matière première
refroidissement
Main d'œuvre-Montage
CIC et usinage final
Process plates
raw materials
Utility plates raw
materials
Labour costs
HIP and final
machinig
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CONCLUSION
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Design, manufacture and tests of 3 plate heat exchanger/reactors
Low manufacturing costs
Additional gains thanks to the transopsition from batch to continuous process
Severe operating conditions vs. Residence time
Tests in industrial conditions (Rhodia reaction)
Outlooks
Manufacturing techniques transfer
Scale-up x100
Multiphase applications (G/L, L/L)
LITEN
Département des Technologies Solaires
Laboratoire des Systèmes Thermiques
Commissariat à l’énergie atomique et aux énergies alternatives
Centre de Saclay | 91191 Gif-sur-Yvette Cedex
T. +33 (0)4 38 78 35 67
Etablissement public à caractère industriel et commercial | RCS Paris B 775 685 019
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Z. Anxionnaz-Minvielle | 19 SEPTEMBER 2012
Thank you !