Exploring Ethylene Generation in a Micro-Flow Reactor with Controlled Temperature Profile

Ethylene is one of the most widely used organic compounds worldwide with ever increasing demand. Almost all the industries currently producing ethylene globally use the method of steam cracking, which, though highly selective and cost effective, is energy intensive along with having a high carbon footprint. This study aims to analyze micro-scale partial oxidation of propane as a novel approach towards ethylene generation which is simpler, less energy consuming, operates at lower temperatures and causes minimum CO2 emission. The experimental study endeavors to maximize the ethylene production by investigating the effect of variables such as temperature, flow rate, equivalence ratio and reactor diameter. The micro-scale partial oxidation of propane is studied inside quartz tube reactors of 1 mm and 3 mm diameter at a temperature range of 800 to 900 oC, at varying flow rates of 10 to 100 sccm and equivalence ratios of 1 to 6. The study reveals ethylene yield has a strong dependence on all the above factors. However, the factors are not completely independent of each other. Adjusting certain factors and levels results in greater ethylene yields as high as 10%, but propane to ethylene conversion efficiency is approximately constant for most conditions. Low CO2 concentrations are also recorded for most of the factor and level combinations, indicating the potential to achieve lower CO2 yields compared to conventional approaches. The investigation indicates promise for application in the field of ethylene generation.