An innovative pillow-plate reactor for the synthesis of methanol from biogas: a simulation study

This work investigates the performances of a pillow-plate heat exchanger utilized as reactor for small-scale methanol synthesis. When downscaled, multi-tubular packed bed reactors are complicated to use since they undergo rapid losses in catalyst activity. A possible pathway to improve the unit performances is to diminish the tubes diameter and number. As this this kind of reactors is governed by convective heat transfer, though, the use of long tubes is required to keep the mixture velocity high. This leads to the use of very long reactors, which cannot be easily realized with traditional designs. In order to tackle this issue, we propose the utilization of an innovative design, the pillow-plate reactor, increasing heat and mass transfer and the unit compactness. The study compares the performances of a packed-bed and a pillow-plate reactor through temperature profiles and methanol productivity at varying reactor lengths (1 – 6 m). It is proved that the pillow-plate unit, unlike the multi-tubular one, well manages scale reduction: when 1 m long reactors are employed, the outlet methanol fraction is close to equilibrium (5.8% vs. 4.9% for packed beds) and the hot-spots are well controlled (537 K vs. 557 K for tubular reactors). Moreover, it is also shown that the distance of metal layers in the pillow arrangement remarkably influences heat exchange, which is very effective for close layers, with a hot-spot of 518 K with a 3 mm gap, and much worse for the 12 mm design (552 K).