Simultaneous synthesis gas and styrene production in the optimized thermally coupled reactor

• The new process concept called methane tri-reforming for synthesis gas production.
• Styrene production reaction takes place in the endothermic side.
• TCR has been optimized to maximize the conversion of EB and methane by DE method.

Styrene (ST) is one of the most important monomers widely used in the production of polystyrene, resins, and elastomers. In this study, a thermally coupled reactor (TCR) has been suggested for styrene production in which styrene production reaction takes place in the endothermic side and a new process concept called methane tri-reforming for synthesis gas production (H2 and CO) is considered in the exothermic side of the reactor. The heat generated in the exothermic side is transferred to the endothermic section. A one dimensional steady state model has been developed for thermally coupled reactor. Furthermore the optimization of TCR has been carried out in order to maximize the conversion of ethylbenzene (EB) and methane by Differential evolution (DE) method. Results of the optimization prove that in addition to saving energy, the production of styrene exceeds in the optimized thermally coupled reactor (OTCR) with respect to the conventional reactor (CR) about 5%. Additionally, high values of CO and H2 yield, 2% and 3% respectively, could be achieved in the exothermic side.