Project Overview

As part of a specialized R&D program, our engineering team at TMEC successfully delivered a full-cycle solution for a laboratory-scale electrothermal fluidized bed reactor (EFB) designed for high-temperature gas–solid reactions. The system has been installed and tested, demonstrating excellent performance in methane reforming and carbon material synthesis experiments.

⚙️ Scope of Work

Our scope covered the complete design-build-deliver cycle, including:

• Process evaluation and conceptual reactor design;
• Thermodynamic modeling and electrical heat balance analysis;
• Development of P&ID and process control architecture;
• Mechanical and electrical system design;
• Manufacturing, testing, installation and commissioning;
• Full operational documentation and user training.

🧠 Expertise and Covered Topics

The project required integration of multiple engineering domains:

• Electrothermal modeling of Joule-heated beds under gas flow;
• Precision gas flow regulation for CH₄, H₂, N₂, Ar, CO₂, CO;
• Multistage safety systems including gas sensors, interlocks, and emergency stops;
• Design of erosion-resistant fluidization zones;
• Heat-resistant materials and insulation strategies;
• Real-time process monitoring and automated temperature control;
• Solid handling system for carbon/catalyst blends in the 100–500 µm range.

🔍 Reactor and System Capabilities

• Operating temperature: 500–1000°C
• Operating pressure: From atmospheric up to 5 bar
• Gas flow rate range: 10 SLPM to 1 m³/h
• Heating power: 3 to 10 kW (DC or AC, up to 200+ A)
• Gases supported: CH₄, H₂, N₂, Ar, CO₂, CO (customizable per application)
• Solid feed rate: Adjustable, with external refill and recovery system
• Cooling system: Closed-loop liquid cooling for reactor wall and terminals
• Filtration: Multi-stage gas outlet purification, including dust, condensate, and volatile capture

🧪 Applications & Results

The EFB reactor is designed for advanced gas–solid experimentation, such as:

• Methane pyrolysis and reforming
• Catalyst testing and aging studies
• Carbon materials production (e.g., carbon black, synthetic graphite)
• Hydrogen generation under inert or reducing atmospheres

The system ensures precise control, robust safety, and reproducible thermal behavior, making it a powerful tool for fundamental and applied research in high-temperature thermochemical conversion.