Modeling and Analysis of Coupled Flow Through Packed Beds as a Diagnostic Tool for Packed Bed Reactor Health - 17172
The US Department of Energy, Office of River Protection, is building the Waste Treatment and Immobilization Plant (WTP) in Richland, Washington, to immobilize the hundreds of millions of liters of radioactive waste stored at the Hanford Site in Washington state. The offgas generated during vitrification of these wastes requires treatment to remove and/or destroy chemical and radioactive hazardous components before release to the atmosphere. In particular, volatile and semi-volatile hydrocarbon components are to be catalytically oxidized to carbon dioxide and water, whereas nitrogen oxides (NOx) are to be catalytically reduced to nitrogen and water. These tasks are accomplished in a series of packed bed reactors. Achieving the requisite Destruction/Removal Efficiency (DRE) for each of the tracked components is highly dependent on the flow characteristics of the offgas through the packed beds. The flow kinetics may be monitored and characterized during the initial warm-up of the system. The gases, initially at 76 deg. C (169 deg. F), (a) flow through one side of a countercurrent heat exchanger to recover heat from the exiting gases (which have already passed through the catalytic beds), (b) are then further heated electrically to approximately 400 deg. C (750 deg. F; the preferred operating temperature of the Thermo Catalytic Oxidizer (TCO)), (c) pass through the TCO where the reduced components of the offgas are oxidized over a supported Pt catalyst bed, (d) are partially cooled to approximately 315 deg. C (600 deg. F) by addition of approximately 25% (by weight) diluted ammonia/air mixture, (e) pass through the Selective Catalytic Reducer (SCR) where the NOx components are converted to N{sub 2} and H{sub 2}O over a supported V2O{sub 5}/TiO{sub 2} catalyst bed, and (f) exit through the hot side of the countercurrent heat exchanger. The electrical heater is not powerful enough to raise the temperature of the offgas to the desired 400 deg. C without the contribution of the heat recovered in the heat exchanger. Moreover, the thermal mass of the beds and housings of the TCO and SCR require a significant input of thermal energy to reach the desired operating temperatures; the better part of a day is required to bring the unit from ambient temperatures to operating temperatures. Therefore, the temperature of the stream during the initial warm-up of the system at each point in the system is dependent upon the thermal mass, flow dispersion, and permeability of the components, quantified as characteristic/representative volumes and residence times. By monitoring the temperature of the offgas as it enters and exits each portion of the system during this warm-up period one may model the system as a series of small Continuously Stirred Tank Reactors (CSTR)s (referred to as 'CSTRlets') to explain the flow kinetics through the catalyst beds. These component CSTRlets are adjustable in size and number, that one may model the flow profile of the gases through the catalyst beds. For example, a single large CSTR will present an effluent temperature profile with a simple exponential decay shape. Concatenating more CSTRlets generate more complex sigmoidal responses. Concatenating one CSTRlet significantly larger than the others in the train also alters the shape of the effluent temperature profile, in a fashion not replicable by a train of equal-sized CSTRlets. The ultimate goal is to accurately emulate the entire system as a representative CSTRlet train. Once accomplished, this characterization may be used in subsequent warm-ups (following shutdown for catalyst maintenance, for example) or by an intentional step change in inlet offgas temperature to detect/diagnose anomalies in flow through the beds (e.g., channeling or partial blockage.) This work presents development of this model through analytical, calculational, and empirical means. - The analytic model is accomplished by Laplace transform analysis of each component to recover component process transfer functions. - The calculational portion is performed via brute force finite element calculation. - Fitting empirical data from the warm-up of the TCO skid allows one to select the hypothetical CSTRlet trains which best fit the TCO and SCR beds for the analytical and finite element calculations. The first portion of this paper presents the development of the analytical (Laplace space) model of the coupled system. Estimated values for the initial temperature, mass, specific heat, electrical heat, and relative quantities of the offgas, catalyst beds, stainless steel housings, and ammonia dilution stream are used to generate expected temperature profiles at several selected junctures of the system. The number and size of the component hypothetical CSTRlets are calculated from the analytical model and are used to predict temperature profiles at the exit of the system and at intermediate junctions between system components (where thermocouples are present in the actual unit.) The finite element calculations employ a series of CSTRlet volumes to produce a similar suite of temperature profiles, for comparison with the analytical model results. Finally, empirical data from the Factory Acceptance Test system warm-up are used to select and compare the results from each modeling strategy to select the CSTRlet train(s) which best model the behavior of the actual system. This work presents a novel method of system component characterization, of value to the WTP plant and similar vitrification facilities as well as chemical process industries unrelated to waste management. (authors)