Comparison among monolithic and randomly packed reactors for the methanol-to-propylene process

A comparison among the monolithic and randomly packed reactors for the methanol conversion to propylene (MTP) process has been presented in this work by modeling and simulation based on adiabatic heterogeneous reactor models including the interactions of mass and heat transfer and chemical reactions between the gas and catalyst phases and inside the catalyst phase. Simulation results showed that the monolithic catalyst intensifies significantly the methanol conversion efficiency and the propylene selectivity, compared with the randomly packed catalyst pellets. The monolithic reactor can achieve a propylene selectivity high up to 88% with a methanol conversion of 95% at a space time of 7gcatalysthmolMeOH-1, but the random one does 82% with 80% at 27. For a complete methanol conversion, the monolithic catalyst amount is five times less than the random pellet catalyst in an adiabatic reactor. Furthermore, the higher cell density and thinner wall of the monolith produce the higher methanol conversion and propylene selectivity.

• Lower intra-catalyst diffusion resistance benefits the MTP performance.
• Monolithic catalyst intensifies both methanol conversion and propylene selectivity.
• Monolithic catalyst amount is five times less than random one for a complete conversion.
• Higher cell density produces higher efficiency.