The Catalytic Oxidation of Benzene
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THE CATALYTIC OXIDATION OF BENZENE '10 Ivi.LEIC ANHYDRIDE, JORGE FERN1DO R$4IREZ SOLIS THESIS PRESENTED FOR THE DEGREE OF DOCTOR OF PHILOSOPHY UNIVERSITY OF EDINBURGH 1974 TO MY PARENTS MA. LUISA y FAUSTINO TO MY BROTHERS VICTOR MAITJEL y JOSE LUIS ACKNOWLEDGMENTS I am deeply indebted to Professor P.H. Calderbank for his continued help, interest and encouragement throughout the course of this work. My thanks are due to Dr. S. Elnashaie for his advice in the programming. I would also like to thank Mr. David Ketchin and his workshop staff for their invaluable help in the building and maintenance of the experimental apparatus, to Dr. G. Nag for proof-reading, and to Mrs Margaret Gall and Miss Susan Robson for typing the manuscript. I am indebted to Lena whose companionship and good spirit are great help through difficulties. Finally, but by no means least, to the Universjd Nacional AutOnoma de Mexico (UNAM) and Banco de Mxico for financial support which made possible the realization of this work. Contents Page Acknowledgements Preface 1 Suimnary 11 Introduction 1 CHAPTER 1. LITERATURE SURVEY, VAPOUR PHASE CATALYTIC OXIDATION OF BENZENE TO MALEIC ANHYDRIDE. 1.1) Genera]. 8 1.2) Reaction Models and Mechanism 12 1.3) Homogeneous - Hetrogeneous Interactions 38 1.14) Object of the Study 145 CHAPTER 2. EXPERIMENTAL APPARATUS AND PROCEDURES (I) 2.1) Catalyst Preparation 148 2.2) General Description of the Experimental Apparatus. 51 2.2.1) Delivery of Reactants. 53 2.2.2) The Reactors. 55 2.2.3) Analytical Equipment 62 2.3) Catalyst Life and Stability 66 2.14) Typical Experimental Schedule 66 2.14) Calibration 68 CHAPTER 3. EXPERIMENTAL RESULTS 3.1) Measurements 71 3.2) Preliminary Experiments 71 3.3) Detection of Heterogeneous - Homogeneous Interactions in the Overall Reaction. Discussion. 72 Chapter 3. Cont... Page 3.14) Detection of Heterogeneous - Homogeneous Interactions in the Maleic Anhydride Combustion. 80 3.5) Effect of Reactor Materials of Construction on the Selectivity of the Overall Reaction 81 3.6) Kinetics of Benzene Disappearance and Selectivities to Maleic Anhydride. 3.6.1) Introduction 88 3.6.2) Experiments in a 100 Catalyst Pellet Catalytic Bed. 90 3.6.3) Experiments in a 250 Catalyst Pellet Catalytic Bed. 90 3.6.14) Effect of Reactor Diameter on Selectivity. io5 3.6.5) The SCB Reactor, Kinetics of Benzene Disappearance. 109 3.7) Kinetics of Maleic Anhydride Combustion. 3.7.1) Introduction. 113 3.7.2) The Tubular Reactor, Kinetics of Maleic Anhydride Combustion. 113 3.7.3) The SCB Reactor, Kinetics of Maleic Lnhydride Combustion A) Oxidation of Maleic Anhydride in the Presence of Catalyst. 118 b) Oxidation of Maleic Anhydride in the Absence of Catalyst. 118 3.8) Discussion of Results A) The Catalyst 121 B) Incorporation of the Experimental Data in the Overall Scheme of Reaction. 122 14• CHAPTER CHARACTEP1SCS OF TIE CATALYST USED IN THE PILOT PINT. 14.1) Introduction. 130 14.2) Kinetics of Benzene Disappearance and Selectivities to Maleic Anhydride. 130 14.3) Maleic Anhydride Combustion. 132 14.14) Conclusions. 136 CHAPTER 5. EXPERIMENTAL APPARATUS AND pocuas (II) Page 5.1) The Reactor and Reactor Shell 139 5.2) The Fluidizing Air System. 1146 5.3) Delivery of Reactants. 1146 5:3.1) The Air System. 146 5.3.2) The Benzene System. 147 5.14) Control and Instrumentation. 1148 5.5) Analytical Equipment. 149 5.6) Typical Experimental Schedule. 1149 CHAPTER 6. A MATHEMATICAL MODEL OF THE FIXED BED CATALYTI C REACTOR. 6.1) Introduction. 153 6.2) A Steady State Mathiatics1 Model of the Fixed Bed Reactor. 156 6.2.1) Mass Transfer in Packed Beds. 159 6.2.2) Heat Transfer in Packed Beds. 160 6.2.3) Form of the Model and Simplifications Introduced. 1614 6.2.4) Method of Solution of the Mathematical Model. 171 CHAPTER f. EXPERIMENTS WITH AND MODELLING OF THE PILOT PLANT REACTOR. 7.1) Introduction. 175 7.2) Results of Experimental and Modelling Work. 175 CHAPTER 8. CONCLUSIONS AND SUGGESTIONS FOR FURTHER WORK. 227 Appendix A Chemicals. Catalyst Support. Rotameter Capacities. 236 Appendix B Experimental Results from Chapter 3. 238 Appendix C Experimental Results from Chapter 14. 256 Page Appendix D Calculation of Rate Velocity Constants for the SCB and Tabular reactors. 261 Appendix E Least Squares Calculation of Slopes of straight Lines. 263 Appendix F Experimental Axial Teirxtrature Profiles in the One and Two inch Diameter Non-Isothermal Reactors. 266 Appendix G Computer Listing Program for One-Dimensional Plug Flow Model. 269 Bibliography 234 Nomenclature 295 Figures Figure Page 1.1 Activation Energy of the Isotopic Exchange of Oxygen and Selectivity in the Oxidation of Benzene and Butene to Maleic Acid. 37 2.1 Flow Diagram of the Experimental Apparatus 52 2.2 Aluminium Tubular Reactor Used in the Experiments at Isothermal Conditions. 56 2.3A 5GB Reactor and Stirrer Drive Unit. 58 2.3B SCB Reactor. Detail of the Catalyst Basket. 2. 14A SCBR. Mixing Characteristics of Carberry's (153) Reactor. 61 2.14B Sc13R. Mixing Characteristics of Brisk's (152) Reactor. Ci 2.5 Schematic Diagram of the Hot Sampling Valve. 63 2.6 Typical Chromatogram. 65 2.7 Benzene and Maleic Anhydride (FID) Calibration Curves. 69 3.3.1 Effect of Dilution and Free Space After the Bed., Reactor Arrangements. 75 3.3.2 Effect of Dilution and Free Space After the Bed on MA-A. Production. 75 3.3.3 Effect of Packing and Free Space After the Bed on Benzene Converted. 77 3.14.1 MM Combustion in Empty Reactors (Aluminium, Titanium, Stainless Steel and Glass). 82 3.5.1 Aluminium Reactor, Product Distribution with Temperature.- 83 3.5.2 Titanium Reactor, Product Distribution with Temperature. 84 3.5.3 Stainless Steel Reactor, Product Distribution with Temperature. 85 3.5.14 Effect of Reactor Materials of Construction on Selectivity to MAA. 86 3.5.5 Benzene Disappearance, Arrhenius Plots using Different Reactors but same Catalyst. 87 3.6.1 Short Bed Reactor (100 Catalyst Pellet Bed), XB vs (w/F). 91 3.6.2 Short Bed Reactor (100 Catalyst Pellet Bed), Product Distribution at 1475°C. 92 3.6.3 Short Bed Reactor (100 Catalyst Pellet Bed), Product Distribution at 500°C. 93 Short Bed Reactor (100 Catalyst Pellet Bed), 3.6.14 0 Selectivity vs Benzene Converted at 500 C. 93 3.6.5 Benzene Conversion vs Space Velocity (W/F), (250 Catalyst Pellet Bed). 95 3.6.6 M-AA. Production vs Space Velocity (250 Catalyst Pellet Bed). 9' 3.6.7 Overall Reaction (250 Cata1st Pellet Bed), Product Distributicia at 1400 C. 91 3.6.8 Overall Reaction (250 Catalst Pellet Bed), Product Distribution at 1420 C. 98 3.6.9 Overall Reaction (250 Catalst Pellet Bed), Product Distribution at 14140 C. 99 3.6.10 Overall Reaction (250 Catalst Pellet Bed), Product Distribution at 1460 C. 100 3.6.11 Overall Reaction (250 Catalyst Pellet Bed), Product Distribution at 1480 and 500°C. 101 3.6.12 Benzene Disappearance, First Order Plot. 102 3.6.13 Benzene Disappearance, Order Plot from XB vs (W/F) curve at 14140°C. 103 3.6.114 9 Inch Diameter Reactor, Experimental Selectivities as a Function of Benzene Converted. io14 3.6.15 Benzene Disappearance, Arrhenius Plots and 1 inch Dia. Reactors). 107 3.6.16 544 Inch Diameter Reactor, Experimental Selectivities as a Function of Benzene Converted. 108 3.6.17 SCBR, Benzene Disappearance Order Plots. 11]. 3.6.18 Comparison Between Benzene Disappearance Rates in Tubular and SCJ3 Reactors. 112 3.7.1 Aluminium Tubular Reactor, MAA Combustion/Catalyst. 1114 3.7.2 Glass Tubular Reactor, MAA Combustion/Catalyst. 116 3.7.3 Glass Tubular Reactor, Arrhenius Plot for MAA Oxidation/Catalyst. 117 3.7.14 SCLR, Order Plots for MA Oxidation on Catalyst and on Empty Reactor. 119 3.7.5 ScBR, MAA Oxidation on Catalyst and on Empty Reactor. 120 3.8.11.B. Tubular Reactor, Experimental (A) and Predicted (B) Selectivities to IVIAA. 126 3.8.2 Arrhenius Plots for the Steps in the Overall Reaction Scheme. 127 3.8.3 Tubular Reactor, Experimental and Predicted Concentration Profiles for Benzene and Maleic Anhydride at 480 and 5000C. 128 14.1 Arrhenius Plots for Benzene Disappearance and MAA Oxidation (Catalyst 6,s.s. Reactor). 133 14.2 Stainless Steel Tubular Reactor, Reaction Selectivity, vs ]3enzene Converted. 1314 14.3 Co/CO 2 Molar Ratio as a Function of Benzene Converted. 135 5.1 Pilot Plant Flow Diagram. 1141 5.2 The One Inch Diameter Reactor. 1142 5.3 The One Inch Diameter Reactor, Thermocouple Locations. 1142 5.14 The Reactor Shell. 1143 5.5 Heating Elements Arrangement. 11414 5.6 The Two Inch Diameter Reactor. 1145 6.2 Geometrical Interpretation (Predictor). 173 6.3 Geometrical Interpretation (Corrector). 173 7.1 One Inch Diameter Reactor, Difference etween Experimental and Predicted Axial Temperature Profiles (U = 95). 176 11 T.2 Experimental Radial Temperature Profiles in the Two inch Diameter Reactor. 178 7.3 Arrhenius Plots for the Benzene Disappearance Step on Active (green) and Deactivated (black) Catalyst Pellets. 185 7.4 Effect of Kinetic Parameters on Reaction Behaviour. 187 7.5 - 7.14 One Inch Diameter Reactor, Experimental and ?Best Fit? Axial Tem-perature Profiles 194-203 7.15 - 7.23 Two Inch Diameter Reactor, Experimental and 'Best Fit' Axial Temperature Profiles. 2O4-212 7.21 Predicted and 'Best Fit' Overall Heat Transfer Coefficients for the One and. Two Inch Diameter Reactors. 219 7.25 Estimated Peclet Numbers for the One and Two Inch Diameter Reactors as a Function of Mass Velocity. 224 Tables Table Page I Breakdown of Maleic Anhydride usage in the U.S.A.