An Analysis of Fixed-Bed Catalytic Reactors Performances for One-Stage Butadiene Synthesis from Ethanol

The present study assesses, using a theoretical approach, the performances of two widely used fixed-bed reactors for the ethanol-to-butadiene (ETB) one-stage (Lebedev) process: multibed adiabatic reactors (MBAR) with inter-bed heating and a multitubular reactor (MTR). The mathematical model consists of mass and heat conservation equations at catalyst particle and particle bed scales, coupled with a published kinetic model specific for a modified MgO–SiO2 catalyst. The process simulations at the level of catalyst particle have shown that the inter-phase concentration and temperature gradients are negligible, the only physical step with a limiting influence on process kinetics being the internal diffusion. A simplified version of the reactor model was also formulated, including empirical expressions developed in the study for the calculation of internal effectiveness factors. The reactor simulations highlighted that the MBAR with inter-bed heating by injection of hot reactants provides worse butadiene (BD) yields as a consequence of reduced reaction times (due to reactant by-pass of catalyst beds). The MBAR with inter-bed heating using heat exchangers provides better performances but inferior to those of MTR if the number of catalyst beds is less than six. A preliminary optimization study for the MBAR and MTR is also presented. The results showed that the maximization of BD yield has the drawback of a low BD production rate, whereas the maximization of BD production rate corresponds to a relatively low BD yield and high ethanol and inert recycles. A trade-off between the two extreme cases can be attained by maximizing the income generated by reactor operation.