Microchannel Reactor System Design & Demonstration For On-Site H2O2 Production by Controlled H2/O2 Reaction
We successfully demonstrated an innovative hydrogen peroxide (H2O2) production concept which involved the development of flame- and explosion-resistant microchannel reactor system for energy efficient, cost-saving, on-site H2O2 production. We designed, fabricated, evaluated, and optimized a laboratory-scale microchannel reactor system for controlled direct combination of H2 and O2 in all proportions including explosive regime, at a low pressure and a low temperature to produce about 1.5 wt% H2O2 as proposed. In the second phase of the program, as a prelude to full-scale commercialization, we demonstrated our H2O2 production approach by ‘numbering up’ the channels in a multi-channel microreactor-based pilot plant to produce 1 kg/h of H2O2 at 1.5 wt% as demanded by end-users of the developed technology. To our knowledge, we are the first group to accomplish this significant milestone. We identified the reaction pathways that comprise the process, and implemented rigorous mechanistic kinetic studies to obtain the kinetics of the three main dominant reactions. We are not aware of any such comprehensive kinetic studies for the direct combination process, either in a microreactor or any other reactor system. We showed that the mass transfer parameter in our microreactor system is several orders of magnitude higher than what obtains in the macroreactor, attesting to the superior performance of microreactor. A one-dimensional reactor model incorporating the kinetics information enabled us to clarify certain important aspects of the chemistry of the direct combination process as detailed in section 5 of this report. Also, through mathematical modeling and simulation using sophisticated and robust commercial software packages, we were able to elucidate the hydrodynamics of the complex multiphase flows that take place in the microchannel. In conjunction with the kinetics information, we were able to validate the experimental data. If fully implemented across the whole industry as a result of our technology demonstration, our production concept is expected to save >5 trillion Btu/year of steam usage and >3 trillion Btu/year in electric power consumption. Our analysis also indicates >50 % reduction in waste disposal cost and ~10% reduction in feedstock energy. These savings translate to ~30% reduction in overall production and transportation costs for the $1B annual H2O2 market.
- Research Organization:
- Stevens Institute of Technology, Castle Point, Hoboken, NJ 07030
- Sponsoring Organization:
- USDOE Office of Industrial Technology Program (EE-2F)
- DOE Contract Number:
- FC36-02ID14427
- OSTI ID:
- 944992
- Report Number(s):
- DOE/ID/14427-1; TRN: US200911%%20
- Country of Publication:
- United States
- Language:
- English
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