Effects of Particle Size and Shape on the Performance of a Trickle Fixed-Bed Recycle Reactor for Fischer–Tropsch Synthesis

A previously developed one-dimensional reactor model was employed to understand the effects of pellet size and geometry on the performance of a wall-cooled multitubular fixed-bed Fischer–Tropsch reactor for producing hydrocarbons from synthesis gas. The effects of pellet size/shape on catalyst effectiveness, bed void fraction, and overall heat transfer coefficient were studied through a comprehensive parametric study of a reactor with cobalt catalyst. The relative impact of each of these parameters on the overall required amount of catalyst was also determined. The simulations show that the amount of catalyst required to achieve a specified conversion increases with pellet size and shape in the order: trilobes < hollow cylinders < cylinders < spheres. The pressure drop per unit length can be significantly reduced and the catalyst effectiveness increased by using advanced extrudates, i.e., trilobes or hollow cylinders.