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Modelling of So2 Oxidation Kinetic Data of A CS/V Catalyst Rates Based On at High Pressures and Conversions
Modelling of So2 Oxidation Kinetic Data of A CS/V Catalyst Rates Based On at High Pressures and Conversions
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Printed in Great Britain. 0 1988 Pergamon Journals Ltd.
high conversions (Doering et al., 1987) indicated that concentrations. Two mass flow controllers were used
Boreskov’s six-step reaction mechanism could explain to give the desired preconverted gas flow to the reactor.
our physical property data very well. Since much of the The Kim I microcomputer (Doering and Berkel, 1987)
catalyst in a sulfuric acid plant converter operates in automated the selection of the feed gas flows through
the lower temperature range and high SO,/low SO2 and around the preconverter. Different conversions in
gas (greater than 90% conversion), we decided to the reactor were obtained at each feed gas com-
evaluate catalysts under these conditions. Kinetic data position, pressure and temperature by varying the total
of this type is rare (Livbjerg and Villadsen, 1972; Neth gas flow to the reactor between SO-500 scc/min. Excess
ef al., 1980) and is of great interest to industrial gas was vented through a back-pressure regulator
practice. Thus this paper has two purposes. The first is which was located immediately before the two mass
to present kinetic data for the first time at conversions flow controllers. A back-pressure regulator im-
close to equilibrium and at elevated pressures and mediately after the reactor was heated in a 150°C hot
temperatures below 400°C. The second purpose is to box to control reactor pressure. The remainder of the
compare various kinetic equations and to determine flow and analytical system was the same as that
which equation predicts kinetic data the best under reported earlier (Doering and Berkel, 1987).
these conditions. The catalyst was prepared in the same way as
reported elsewhere (Doering and Berkel, 1987). Final
EXPERIMENTAL METHODS
catalyst properties were: 0.0696 gV/g support, 2.03 g
catalyst/g support, and 0.871 g catalyst/cc. The catalyst
A pressure reactor system was built to obtain kinetic
support consisted of 4.5 mm by 4.5 mm cylindrical
data on various catalysts at pressures up to 10 atm
silica pellets supplied by Houdry (HSC-534). The
(1 atm = 101.3 kPa). The flow system was similar to
support properties were: 1.1 cc/g pore volume,
that discussed elsewhere (Doering and Berkel, 1987).
258 M’/g surface area and the following pore volume
The differences for high pressure operation will be
distribution (measured by a mercury penetration po-
described here.
rosimeter): 25 “/0of the volume at 900 A or greater pore
The reactor was a 5 in. (12.7 cm) standard Berty type
diameter, 50”/, of the volume at 100 A or greater pore
acquired from Autoclave Engineers, Inc. The entire
diameter and 75 7” at 85 A. The bed volume of catalyst
vessel was made from 316 stainless steel. A catalyst
used for the kinetic measurements was exactly 100 cc.
basket with a 150 cc volume was positioned in the
To insure steady-state measurements, the catalyst
center of the reactor cavity so that the impeller could
remained at each conversion for eight hours before
direct gas flow up around the outside and down
changing to the next conversion condition.
through the catalyst basket. The net result was a
completely internal recycle reactor. Changes were
CALCULATION METHODS
made in the magnedrive assembly of the Berty reactor
to prevent bearing failures. An additional Purebond The rate of reaction for each operating condition
3310 bearing (part No. 107A-0642) was installed on the was calculated in the same way as discussed before
upper end of the drive shalt. A stainless steel spring was (Doering and Berkel, 1987). Various kinetic models
added to prevent the bearings from spinning. Stainless have been derived from proposed reaction mechan-
steel spacers were shortened so that the additional isms. The 3-step mechanism proposed by Villadsen
bearing and spring could fit. A 5 scc/min Nz stream was and Livbjerg (1978) will give the following rate equa-
fed at the bottom of the magnedrive assembly to purge tion when oxidation of V4+ is the rate limiting step
the bearings during pressure changes only. (Doering and Berkel, 1987):
Temperature in the reactor was maintained by a
R = kp:;p,o$l - BlK,)l(~so, + APSO~
jacketed resistance heater with three heating zones
1100 W each. The three zones were controlled by a + CPSO*PS03)~ (2)
single on-off type temperature controller provided by
k = k, v,, A = l/(K,K,) and C= l/K,. Ki is
Autoclave Engineers. A 7.50 W ring heater was in- the equilibrium constant for reaction step i, ki/k-i.
stalled on the base of the reactor vessel to prevent heat Kinetic equation (1) can be derived from the reaction
loss through the bottom. mechanism of Ivanenko et al. (1974) where A = l/K,.
An SO1 saturator tank was used to supply high From the first four steps of Boreskov’s six-step mech-
pressure SO, to the reactor. The tank was a Whitey one anism (Boreskov et al.,1980) another kinetic equation
gallon stainless steel cylinder and it was wrapped with can be derived if we assume that the second step
a silicone insulated heating tape. Nitrogen was bub- (oxidation of a V,05-SO2 species) is rate determining
bled through the SO2 in the tank at 40°C. A Brooks and half-order with respect to 0,. Another assumption
Model 5841 mass flow controller kept the N, feed that the V205 species concentration is very small when
constant. Liquid level in the saturator tank was compared to the other vanadium species was
monitored by a heavy wall sight glass which was shown to be possible by Chumachenko er al. (1982).
isolated by valves at either end. Incorporation of the various assumptions will give the
After passing through the saturator tank, the following rate equation:
SO,/N, stream was mixed with mass flow controlled
N2 and O2 streams to give the desired feed gas R = kp::::p,02(l - BIK,)I(Pso~ + APSOJ (3)
Kinetic modelling of Cs/V catalyst 223
Run T (“C) P(atm) u/oSO2 ‘;/,O, ‘XX Rate x lo5 Run T (“C) P(atm) %SOz %O, %X Ratex lo5
1 403.4 10 10.92 10.02 99.2 1 2.083 70 395.6 2.5 8.99 14.07 98.63 2.504
2 403.6 10 10.93 10.06 98.95 3.435 71 395.4 2.5 9.42 14.05 98.08 4.37
3 403.7 10 10.90 10.01 98.53 5.658 72 392.5 2.5 9.17 14.24 96.74 7.688
4 403.5 10 10.97 10.04 97.68 10.32 73 393 2.5 9.18 14.21 95.60 10.69
5 403.6 10 11.02 10.05 96.81 14.69 74 392.7 2.5 9.4 1 14.25 94.24 14.10
6 395 2.5 10.92 10.02 98.51 1.844 75 392.6 10 8.87 8.0 99.40 0.558
7 395 2.5 10.91 10.05 98.32 2.936 76 392.7 10 8.81 8.02 99.27 0.883
8 394.4 2.5 11.01 10.08 97.19 5.171 77 393.1 10 8.86 7.95 99.21 1.12
9 365.5 10 10.86 10.11 99.67 0.205 78 393 10 8.86 7.91 98.86 2.67
10 365.8 10 10.93 10.06 99.66 0.406 79 393.2 10 8.85 7.90 98.50 4.025
I1 365.3 10 11.15 10.12 99.52 0.834 80 393 10 9.14 7.89 98.12 5.469
12 365.6 10 10.92 10.12 99.05 1.519 81 394.3 2.5 8.52 7.98 98.92 0.50
13 365.4 10 11.14 10.04 97.74 3.593 82 394.9 2.5 8.47 7.91 98.74 0.935
14 369 2.5 10.83 10.05 99.14 0.209 83 395 2.5 8.64 7.88 98.57 1.401
15 369.3 2.5 10.78 10.03 99.26 0.440 84 393 2.5 8.40 7.97 97.99 2.657
16 369.8 2.5 10.83 to.05 98.32 0.798 85 394 2.5 8.48 7.97 97.40 3.972
17 395 10 13.08 t4.07 99.70 0.737 86 394 2.5 8.73 7.99 96.60 5.017
18 395.6 10 12.78 14.09 99.48 1.421 87 379 5 8.48 8.01 99.47 0.133
19 395 10 13.24 14.05 99.34 2.548 88 379.5 5 8.54 7.84 99.36 0.285
20 394.3 10 13.23 14.06 98.74 5.166 89 379.5 5 8.42 7.89 99.23 0.599
21 394.6 2.5 13.35 14.03 99.06 1.299 90 380.2 5 8.41 7.90 98.95 1.269
22 393.7 2.5 13.18 14.03 98.84 2.213 91 380 5 8.53 7.84 98.64 1.912
23 396 2.5 12.90 13.94 98.67 2.444 92 379.6 5 8.74 7.86 98.24 2.531
24 395 2.5 13.34 13.94 97.89 5.123 93 365 10 8.52 7.96 99.57 0.103
25 395.4 2.5 13.21 13.92 96.93 7.716 94 363.5 10 8.43 7.87 99.51 0.550
26 396.7 2.5 13.58 13.83 96.12 9.556 95 363.7 10 8.49 7.86 99.00 1.215
27 377.5 5 13.01 14.23 99.70 0.120 96 363.5 10 8.50 7.83 98.59 1.813
28 378.1 5 12.76 14.29 99.67 0.414 97 363.5 10 8.58 7.79 97.92 2.245
29 378.9 5 13.04 14.28 99.61 0.775 98 364.7 2.5 8.14 8.22 99.56 0.156
30 378.6 5 12.86 14.31 99.32 1.846 99 364.7 2.5 8.30 8.05 99.35 0.312
379.3 5 12.71 14.30 99.04 2.637 100 365.4 2.5 8.21 8.14 99.02 0.603
:: 378.5 5 12.93 14.10 98.50 3.649
33 361.7 10 12.99 14.31 99.86 0.033
34 362.4 10 12.98 14.3 1 99.87 0.054 Table 4. Kinetic data at lower conversions
35 362.9 10 12.90 14.36 99.86 0.135
36 362.7 10 12.99 14.31 99.71 0.740 Run T (“C) P(atm) ‘x SO, % 0, “/, X Rate x lo5
37 363.3 10 12.93 14.30 99.59 1.164
38 363.4 10 13.25 14.26 99.41 1.696 a 381 2.5 11.0 10.0 97.79 2.45
39 364.1 2.5 13.16 14.13 99.75 0.072 b 381 2.5 11.0 10.0 94.30 1.24
40 364.6 2.5 13.36 13.99 99.75 0.113 c 366 2.5 8.2 8.0 98.19 1.24
41 365 2.5 13.51 13.52 99.68 0.205 d 366 2.5 8.2 8.0 96.63 1.64
42 365.3 2.5 12.72 13.25 99.39 0.740 e 366 2.5 8.2 8.0 94.29 1.55
43 364.6 2.5 12.48 13.39 98.99 1.24
44 365.5 2.5 12.04 13.62 98.59 1.545
45 391.6 10 9.08 14.14 99.51 1.404 the reaction rate. In fact, at 97.5 “/0conversion the rate
46 390.8 10 9.08 14.13 99.42 2.251 is approximately proportional to P I/‘.
47 390.6 10 9.06 14.15 99.18 3.922
Another important observation is that as conver-
48 390.8 10 9.13 14.19 98.55 7.414
49 391.6 10 9.14 14.08 97.98 10.44 sions were decreased below 97 0/0 for a given tempera-
50 392.2 10 9.43 14.01 97.12 14.30 ture, pressure and gas concentration, the rate of
51 376.6 5 8.78 14.16 99.84 0.048 reaction would actually drop instead of increase.
376.7 8.94 14.23 99.72 0.223 Several examples of this occurrence are shown in
:: 377.1 : 8.85 14.22 99.64 0.537
5 1.252 Table 4. Since a change in the vanadium catalyst
54 376.6 8.96 14.19 99.42
55 377 5 8.87 14.24 99.19 1.94 properties apparently occurred at conversions below
56 378.9 5 9.31 14.10 98.93 2.594 97”/0, we did not attempt to fit data at any lower
57 364.3 10 9.37 14.24 99.63 0.064 conversions.
58 364.4 9.58 14.21 99.61 0.220
The regression analyses of the various kinetic
59 364.6 :: 9.54 14.23 99.55 0.561
60 364.3 10 9.64 14.21 99.35 1.305 models are shown in Table 5. The results can be
61 363.9 IO 9.68 14.26 99.12 1.924 summarized as follows:
62 363.9 10 9.91 14.16 98.89 2.614
63 364.5 2.5 9.02 14.13 99.57 0.109 (1) The best fit was given by eq. (3). Equation (2)
64 364.8 2.5 9.02 14.08 99.47 0.275 reduced to (3) because parameter C was statisti-
65 365.7 2.5 8.95 13.70 99.31 0.583 cally insignificant.
66 365.5 2.5 8.92 13.74 98.89 1.204
(2) Equation (1) gave a poor fit of the data when OZ
67 366.6 2.5 8.81 13.78 98.51 1.769
68 366.9 2.5 2.549 was first order. O2 went to half-order when m was
9.25 13.88 97.97
69 395.3 2.5 9.16 14.15 98.88 1.541 used as a parameter to fit the data.
Kinetic modelling of Cs/V catalyst 225
Regression
Equation coefficients -40 E m n Others %Rz D
(3) The term B/K, raised to the first power gave a Data on K/V catalysts at various pressures
better fit than when the second power was used. (Balzhinimaev et al., 1986) showed that crystallization
This is shown by comparing the second and third of V4 + began occurring at significantly lower tempera-
results for eq. (3). tures when pressures were elevated. Our results with
(4) The power law eq. (4) showed an increase in M and the Cs/‘V catalyst also show little formation of inactive
a decrease in the statistical fit as temperature was V4 + down to 360°C if conversions remain above 97 %_
decreased. The drop in reaction rates at conversions below 97 y0
(5) The power law eq. (4) gave the same value of 0.91 with elevated pressures apparently occurs for the same
for the SO2 and SO, exponents. reason as with atmospheric pressure (Doering et al.,
1987): an inactive V4+ complex forms at temperatures
DISCUSSION below 400°C and decreases the amount of V5+
Earlier work (Doering and Berkel, 1987) showed available for SO, oxidation.
that the activation energy for Cs/V catalysts ap- Because we made very large changes in oxygen
proximately doubled when the reaction temperature pressure during our experiments (Table 2) and our
was below 400°C. Only atmospheric pressures and regression analyses gave excellent fits of the data
conversions above 90 0/0were evaluated. Increased SO, (Table 5), we are convinced that the reaction for our
gas concentrations caused lower vanadium catalyst conditions is half-order in oxygen. We also found that
activity indicating that vanadium was being reduced to the reaction at a given temperature, conversion and gas
an inactive state. Thermal and EPR studies (Doering et composition is half-order in total pressure. This result
al., 1987) on the K/V and Cs/V catalysts found little indicates that eq. (3) with Pg2’Pso in the numerator
V4+ precipitation in the Cs/V molten salts; however, and P,, and/or P,, terms in the dinominator makes
an inactive V4+ compound was forming which ap- sense. Oihers (Mukdlenov et al., 1979; Kokhreidze et
parently caused the break on the Arrhenius plots at al., 1979) had to divide eq. (1) by Pl” to obtain a good
400°C and this compound remained soluble in the fit of their data at elevated pressures. Oxygen was
Cs/V molten salt. assumed to be first-order. Equation (4) fit the data well
The following compares the kinetic results for our at the high conversions apparently because pso was
Cs/V = 3.5 catalyst at high pressures with the atmos- very small compared to pso,. Note that the expohents
pheric pressure results (Doering and Berkel, 1987). on P and P were both close to one; thus, eq. (4)
agreetO&ith eqsy1).
(9 The activation energy from 36CL4OO”C was found
to be 24 kcal/mol- 1 (in Table S) which is the same
CONCLUSIONS
as that found above 400°C at atmospheric
(1) The Cs/V = 3.5 kinetic data is best explained by
pressure.
the model
(ii) Oxygen to the approximately one-half power was
found to be essential for both cases. R = b$,‘f~,,~(l - WK,MP,,~+ AP,,).
(iii) A term for pso in the denominator of the kinetic
(2) An activation energy of 24 kcal mol - ’ at tempera-
equation also &as important.
tures between 36G4OO”C indicates that little inac-
(iv) The rate equation (2) for both cases reduced to (3)
tive V4 l formed on the Cs/V = 3.5 catalyst under
when all the data were fitted. So eq. (3) gave the
high pressures and conversions above 97 “A.
best fit of all the data.
(3) The unexpected result that the reaction rate is half-
The only important difference between the high and order in oxygen for the Cs/V = 3.5 catalyst in-
low pressure conversion data was the activation energy dicates that similar kinetic studies for the K/V
under 400°C. catalyst should be undertaken for comparison.
226 F. J. DQER~NG et al.