Sorption-enhanced syngas-to-olefins in a dual-zone fluidized-bed reactor: Integrated kinetic–adsorption modeling and process intensification
Year: 2025
Type: article
Abstract: The sorption-enhanced syngas-to-olefins (SEOS) process provides an intensified pathway for olefin production by integrating syngas hydrogenation, methanol-to-olefins (MTO) conversion, and in-situ water removal within a single reactor. In this work, a MATLAB-based model was developed for a dual-zone fluidized-bed system formed through natural hydrodynamic segregation of Zn–Zr, SAPO-34, and 3 A molecular sieve particles. The lower zone promotes CO/CO₂ hydrogenation to methanol and dimethyl ether, while the upper zone converts intermediates to light olefins with continuous water removal. The model incorporates intrinsic kinetics, Langmuir-type adsorption, and bed expansion correlations, and was validated against experimental data, showing close agreement in carbon conversion and olefin selectivity. Parametric studies indicate that CO₂ addition (5–10%) lowers overall carbon conversion from 15.5% to 12.8% but exerts little influence on olefin distribution, where propylene (~45%) remains dominant. The inclusion of 3 A sieves enhances carbon conversion up to 20% by suppressing reverse water–gas shift and alleviating water inhibition on SAPO-34. Temperature analysis identifies an optimum near 400 °C, maximizing light-olefin yields while limiting secondary hydrogenation. These results demonstrate that dual-zone SEOS reactors effectively broaden the operating window, improve efficiency, and offer a viable route for sustainable olefin production.
Authors: Hualun Zhu, Jun Cao, Massimiliano Materazzi
Institutions: University College London, Hohai University
Language: English
Subfield: Catalysis
Field: Chemical Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $3,500
OpenAlex ID: W7117537040