[KAUST•International Delivery] Pofil Catalytic Reaction Evaluation Unit Deployed in the Middle East

Introduction

Researchers at King Abdullah University of Science and Technology (KAUST) faced several technical challenges when conducting complex gas–solid catalytic reaction studies, including Fischer–Tropsch synthesis and methane conversion. These challenges included the precise control of multiple gas streams and the staged separation and collection of complex reaction products from the effluent.

To address these requirements, Perfectlight developed the PLR-RVTF-TO Catalytic Reaction Evaluation System. The system has successfully overcome these technical challenges and has now been installed and commissioned at KAUST, providing reliable and powerful support for the university’s advanced catalysis research.

PLR-RVTF-TO Catalytic Reaction Evaluation System

Core Advantages

1. Dual-Reactor Configuration: Cross-Scale Parallel Evaluation from Laboratory-Scale Powder Screening to Catalyst-Pellet Scale-Up

Conventional Challenge: Conventional single-channel systems offer limited experimental throughput. A reactor with only one specification cannot simultaneously meet the requirements of rapid screening of powdered catalysts at the laboratory scale and the evaluation of catalyst pellets under conditions closer to pilot-scale operation.

Perfectlight Solution:

The system incorporates two independent reaction units, each equipped with its own feed lines and control modules.

• Cross-scale catalyst evaluation: The system includes a customized 10 mL reactor for rapid screening of powdered catalysts and a 100 mL reactor for evaluating catalyst particles smaller than 2 mm. A single integrated system therefore supports the complete development process from fundamental research to pilot-scale evaluation.

• Efficient parallel comparison: The two reaction channels can operate independently or simultaneously. Under consistent feedstock conditions, researchers can rapidly compare the effects of different operating parameters on conversion, selectivity and catalyst performance.

2. Eight High-Precision Calibrated Gas Channels for Accurate Syngas Control and Helium Internal-Standard Quantification

Conventional Challenge: Fischer–Tropsch synthesis and methane conversion involve multiple gases, including CH₄, CO, CO₂ and H₂. Conventional feeding systems often cannot provide sufficiently accurate control over multicomponent gas ratios or support reliable online quantitative analysis.

Perfectlight Solution:

The system integrates eight calibrated high-precision gas-feeding channels and two liquid-feeding channels.

• Accurate multicomponent gas control: The system provides precise control of methane (CH₄), syngas (CO/H₂), carbon dioxide (CO₂) and other reaction gases.

• Dedicated helium internal-standard channel: A specially calibrated helium channel is provided for use as an internal standard, ensuring high-accuracy quantitative analysis during subsequent online gas-chromatography measurements.

3. Two-Stage Hot and Cold Separation for Efficient Collection of Gaseous, Liquid and Wax Products

Conventional Challenge: Fischer–Tropsch reaction effluent contains a highly complex mixture of high-boiling heavy waxes, light liquid hydrocarbons and unreacted gases. Conventional single-stage condensation can cause wax deposition and pipeline blockage.

Perfectlight Solution:

The system is equipped with a combined hot-separation and cold-separation module.

• Hot-separation stage: High-boiling and readily solidifying heavy components, particularly high-carbon-number waxes, are preferentially captured and collected. This effectively prevents wax deposition and pipeline blockage.

• Cold-separation stage: Light liquid products are subsequently condensed and collected, while the remaining gaseous effluent is smoothly transferred to downstream analytical equipment or the gas-compression system.

4. Secondary Tail-Gas Compression for Stable High-Pressure Recycling under Realistic Industrial Conditions

Conventional Challenge: Most laboratory catalytic evaluation systems operate in a single-pass configuration, in which unreacted syngas is discharged directly. Such systems cannot accurately reproduce industrial tail-gas recycling or evaluate the long-term deactivation behaviour of catalysts under realistic process conditions.

Perfectlight Solution:

The system integrates an independent intermediate gas-compression system and a feed-gas compression system.

• Reliable high-pressure recycling: At operating pressures of up to 6.5 MPa, separated unreacted tail gas can still be reliably recompressed and reintroduced into the feed-gas system.

• Flexible recycle-ratio control: The tail-gas recycle ratio can be accurately adjusted, enabling the system to reproduce industrial operating conditions while significantly improving feed-gas utilization.

5. Decoupled Pressure Control for Multistep Series Reactions such as Methane Reforming and Fischer–Tropsch Synthesis

Conventional Challenge: In multistage series reactions, such as methane reforming under atmospheric or low pressure followed by Fischer–Tropsch synthesis under high pressure, the pressures of different reaction stages are often strongly coupled in conventional systems. This prevents independent pressure control at each stage.

Perfectlight Solution:

The system uses a modular pressure-control architecture that allows each reaction stage to increase or reduce pressure independently. As a result, each step in a multistage reaction can operate efficiently within its own optimum pressure window.

6. PLC Control and Multiple Safety Interlocks for High-Temperature and High-Pressure Experiments

Conventional Challenge: Experiments involving high temperatures, high pressures and flammable, explosive or toxic gases such as H₂, CO and CH₄ place extremely high demands on laboratory safety.

Perfectlight Solution:

• Independently isolated electrical cabinet: The design separates high-current and low-current electrical systems and provides effective isolation between gas and electrical circuits, improving system stability, interference resistance and operational safety.

• Multiple safety interlock mechanisms: The system integrates combustible-gas and toxic-gas detectors, automatic overtemperature and overpressure alarms, safety interlocks and emergency shutdown (ESD) functions.

• Digitally traceable operation: An industrial-grade PLC and supervisory control software automatically record complete historical process data, minimizing errors caused by manual readings and enabling full traceability of experimental conditions.

PLR-RVTF-TO Catalytic Reaction Evaluation System

Key Technical Specifications

Conclusion

Featuring a cross-scale dual-reactor configuration, eight high-precision gas-feeding channels, secondary tail-gas compression, two-stage hot and cold separation, independent pressure control and multiple safety interlocks, the PLR-RVTF-TO Catalytic Reaction Evaluation System provides a powerful laboratory-scale solution for complex gas–solid catalytic reactions.

The system enables researchers to reproduce operating conditions that closely resemble real industrial processes, making it particularly suitable for Fischer–Tropsch synthesis, methane reforming, methane conversion and other complex catalytic reaction evaluation applications.

Are you planning to establish a laboratory for Fischer–Tropsch synthesis, methane reforming or complex gas–solid catalytic reaction evaluation? Contact Perfectlight for a customized technical solution at 400-1161-365.

Founded in 2006, Beijing Perfectlight Technology Co., Ltd. specializes in intelligent, high-precision and high-performance scientific equipment and integrated solutions, combining research and development, manufacturing, sales and technical services. Perfectlight is recognized as a National High-Tech Enterprise, a Zhongguancun High-Tech Enterprise and one of the first Beijing Specialized, Sophisticated, Distinctive and Innovative Enterprises. The company has obtained ISO 9001, ISO 14001 and ISO 45001 management system certifications, and its after-sales service complies with the five-star requirements of GB/T 27922-2011.

Perfectlight’s product portfolio covers more than ten categories, including light sources, photocatalytic, photoelectrochemical, photothermal and thermal catalytic systems, characterization and testing systems, research and pilot-scale equipment, and photochemical synthesis systems. These products serve industries and research fields including new energy, pharmaceutical synthesis, fine chemicals and advanced materials, supporting the entire development process from fundamental research and laboratory-scale testing to pilot-scale development and industrial scale-up.

Perfectlight products are used in more than 3,000 laboratories and have been exported to nearly 50 countries, supporting the publication of more than 10,000 SCI-indexed research papers. The company has led or participated in the development of multiple national and industry standards, undertaken projects under China’s National Key Research and Development Program, and holds numerous core intellectual property rights and Beijing New Technology and New Product certifications. Perfectlight has also supported multiple industrial customers in establishing photochemical production lines with annual capacities ranging from several tonnes to hundreds of tonnes.