A novel multichannel minireactor with channel internal diameter in the range of millimeters has been conceptually designed and constructed. Its configuration confers to the new concept reactor some features and advantages compared to conventional fixed-bed reactors g.e. better mass-transfer, avoid hot-spots formation, increased performance (10–20%). Consequently, this new reactor concept is ideal to be applied to exothermic reactions such as the Sabatier reaction that demands continuous removal of the heat produced to avoid hot-spot formation and the sintering of the catalyst. Thanks to its configuration, this reactor could control effectively the heat generated by the reaction and several tests were carried out to validate the reactor features. The results obtained demonstrate that the catalysts activity in the reaction is improved with the application of the novel reactor respect the conventional fixed- and fluidized-bed ones and neither catalyst sintering, nor pressure drop was appreciated during the catalytic tests. At the best reaction conditions, Tecnalia’s multichannel minireactor can handle 820 Nm³/h of CO₂ per square meter of channel section showing the enormous potential of the new reactor concept.

The methanation of carbon dioxide (CO₂) via the Sabatier reaction is an exothermic process that needs the continuous removal of the heat produced for avoiding the sintering of the catalyst. A novel milli-channel reactor with internal diameter of each channel in the millimeter size has been designed, manufactured and tested for the Sabatier reaction. Thanks to its configuration, this reactor could control effectively the heat generated by the reaction, attaining an intensification of the process. A CFD model was used to study the reaction phenomena occurring inside the reactor and the corresponding heat transfers. The kinetic parameters of the reaction have been obtained, and employing different process condition (different temperatures, pressures and gas flow rates) the results obtained have been studied. At the evaluated parameters, the CFD model fits the experimental results in the developed reactor.

The biomass-to-liquid (BtL) process is a promising technology to obtain clean, liquid, second-generation biofuels and chemicals. The BtL process, which comprises several steps, is based upon the gasification of biomass and the catalytic transformation of the syngas that is obtained via the Fischer-Tropsch synthesis (FTS) reaction, producing a hydrocarbon pool known as syncrude. The FTS process is a well-established technology, and there are currently very large FTS plants operating worldwide that produce liquid fuels and hydrocarbons from natural gas (NG) (gas-to-liquids, GtL process) and coal (coal-to-liquids, CtL process). Due to the limited availability of local biomass, the size of the BtL plants should be downscaled compared to that of a GtL or CtL plant. Since the feasibility of the XtL (X refers to any energy source that can be converted to liquid, including coal, NG, biomass, municipal solid waste, etc.) processes is strongly influenced by the economies of scale, the viability of small-scale BtL plants can be compromised. An interesting approach to overcome this issue is to increase the productivity of the FTS process by developing reactors and catalysts with higher productivities to generate the desired product fraction. Recently, by integrating membrane reactors with the FTS process the gas feeding and separation unit have been demonstrated in a single reactor. In this review, the most significant achievements in the field of catalytic membrane reactors for the FTS process will be discussed. Different types of membranes and configurations of membrane reactors, including H₂O separation and H₂-feed distribution, among others, will be analyzed.