Emanuele Giglio , Paolo Bruno , Enrico Catizzone , Girolamo Giordano , Massimo Migliori
{"title":"Optimal design of catalytic reactors for direct biogas methanation through thermodynamic analysis and 2-D reactor modeling","authors":"Emanuele Giglio , Paolo Bruno , Enrico Catizzone , Girolamo Giordano , Massimo Migliori","doi":"10.1016/j.fuproc.2025.108287","DOIUrl":null,"url":null,"abstract":"<div><div>Catalytic methanation upgrades biogas by reacting it with hydrogen. Thermodynamic analysis of a two-step adiabatic process explored temperature control (below 550 °C for catalyst stability). Reactant staging proved insufficient for hot spot management. Product recycling in the first reactor effectively controlled temperature and produced synthetic natural gas (SNG) approaching grid quality. A two-dimensional model of cooled multi-tubular reactors revealed significant radial thermal gradients. A once-through configuration exceeded the temperature limit despite cooling. Reactant staging failed to simultaneously control temperature and achieve targeted conversion. Conversely, product recycling successfully addressed both constraints. Two configurations were proposed: stoichiometric hydrogen (STOIC) and hydrogen-deficient (H-DEF). Optimized reactor designs, employing a 0.30–0.35 recirculation ratio, were developed for both. The STOIC configuration required 18 parallel tubes for the first reactor and 33 for the second. The H-DEF unit utilized 22 tubes in both reactors. These findings highlight product recycling as a viable strategy for efficient and controlled biogas upgrading via catalytic methanation in multi-tubular reactors.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"276 ","pages":"Article 108287"},"PeriodicalIF":7.7000,"publicationDate":"2025-07-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Fuel Processing Technology","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0378382025001110","RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"CHEMISTRY, APPLIED","Score":null,"Total":0}
引用次数: 0
Abstract
Catalytic methanation upgrades biogas by reacting it with hydrogen. Thermodynamic analysis of a two-step adiabatic process explored temperature control (below 550 °C for catalyst stability). Reactant staging proved insufficient for hot spot management. Product recycling in the first reactor effectively controlled temperature and produced synthetic natural gas (SNG) approaching grid quality. A two-dimensional model of cooled multi-tubular reactors revealed significant radial thermal gradients. A once-through configuration exceeded the temperature limit despite cooling. Reactant staging failed to simultaneously control temperature and achieve targeted conversion. Conversely, product recycling successfully addressed both constraints. Two configurations were proposed: stoichiometric hydrogen (STOIC) and hydrogen-deficient (H-DEF). Optimized reactor designs, employing a 0.30–0.35 recirculation ratio, were developed for both. The STOIC configuration required 18 parallel tubes for the first reactor and 33 for the second. The H-DEF unit utilized 22 tubes in both reactors. These findings highlight product recycling as a viable strategy for efficient and controlled biogas upgrading via catalytic methanation in multi-tubular reactors.
期刊介绍:
Fuel Processing Technology (FPT) deals with the scientific and technological aspects of converting fossil and renewable resources to clean fuels, value-added chemicals, fuel-related advanced carbon materials and by-products. In addition to the traditional non-nuclear fossil fuels, biomass and wastes, papers on the integration of renewables such as solar and wind energy and energy storage into the fuel processing processes, as well as papers on the production and conversion of non-carbon-containing fuels such as hydrogen and ammonia, are also welcome. While chemical conversion is emphasized, papers on advanced physical conversion processes are also considered for publication in FPT. Papers on the fundamental aspects of fuel structure and properties will also be considered.