Simulation of Fluidized Bed Reactor Using Computational Fluid Dynamics in the Process of Methanol Conversion to Light Olefins; Kinetic Modeling Study

Over the past decade, catalytic methanol-to-olefin conversion has been among the most highly developed processes for light olefin production. In this study, computational fluid dynamics (CFD) and COMSOL software were used to investigate the process of methanol conversion to light olefins. The Eulerian-Eulerian model was used to solve continuous and scattered phase flows. A simplified kinetic model was used for methanol conversion to olefin, including a catalyst effect, coke deposition, and the finite element method used to solve the equations. MATLAB software was used to obtain the kinetic parameters of the methanol to olefin process using a kinetic model and a genetic algorithm. A comparison was made between the experimental results and the proposed model for the main products, which showed a good agreement. For ethylene, propylene, and butene, the mean relative error was 2.40%, 1.35%, and 3.11%, respectively. Following the model validation, various parameters such as solid-phase distribution in the bed, velocity vectors, particle size, bed pressure drop, and average mass fraction of the components are investigated on reactor performance. Examining the solid phase distribution in the bed at various input velocities and times revealed that the solid concentration in the whole bed is almost dilute in the Ergun drag model. The flow structure appears generally homogeneous. By studying the particle size effect on velocity vectors, it is found out that as particle diameter increased, the turbulence of flow vectors increased and the number of vortices forming in the bed increased. Furthermore, the average mass fraction of hydrocarbons achieved during reactor output increased. Moreover, the methanol conversion reached more than 90%.