Details

Reactive Distillation Design and Control

1. Aufl.

von: William L. Luyben, Cheng-Ching Yu
152,99 €
Verlag:	Wiley
Format:	PDF
Veröffentl.:	30.03.2009
ISBN/EAN:	9780470377796
Sprache:	englisch
Anzahl Seiten:	608

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Beschreibungen

Titelbeschreibung

After an overview of the fundamentals, limitations, and scope of reactive distillation, this book uses rigorous models for steady-state design and dynamic analysis of different types of reactive distillation columns and quantitatively compares the economics of reactive distillation columns with conventional multi-unit processes. It goes beyond traditional steady-state design that primarily considers the capital investment and energy costs when analyzing the control structure and the dynamic robustness of disturbances, and discusses how to maximize the economic and environmental benefits of reactive distillation technology.

Inhaltsverzeichnis

Preface xvii 1 Introduction 1 1.1 History 2 1.2 Basics of Reactive Distillation 3 1.3 Neat Operation Versus Excess Reactant 7 1.4 Limitations 8 1.4.1 Temperature Mismatch 8 1.4.2 Unfavorable Volatilities 9 1.4.3 Slow Reaction Rates 9 1.4.4 Other Restrictions 9 1.5 Scope 9 1.6 Computational Methods 10 1.6.1 Matlab Programs for Steady-State Design 10 1.6.2 Aspen Simulations 10 1.7 Reference Materials 11 Part I Steady-State Design of Ideal Quaternary System 15 2 Parameter Effects 17 2.1 Effect of Holdup on Reactive Trays 20 2.2 Effect of Number of Reactive Trays 22 2.3 Effect of Pressure 24 2.4 Effect of Chemical Equilibrium Constant 27 2.5 Effect of Relative Volatilities 29 2.5.1 Constant Relative Volatilities 30 2.5.2 Temperature-Dependent Relative Volatilities 30 2.6 Effect of Number of Stripping and Rectifying Trays 32 2.7 Effect of Reactant Feed Location 33 2.7.1 Reactant A Feed Location (NFA) 33 2.7.2 Reactant B Feed Location (NFB) 35 2.8 Conclusion 36 3 Economic Comparison of Reactive Distillation with a Conventional Process 37 3.1 Conventional Multiunit Process 38 3.1.1 Assumptions and Specifications 38 3.1.2 Steady-State Design Procedure 40 3.1.3 Sizing and Economic Equations 42 3.2 Reactive Distillation Design 43 3.2.1 Assumptions and Specifications 44 3.2.2 Steady-State Design Procedure 45 3.3 Results for Different Chemical Equilibrium Constants 47 3.3.1 Conventional Process 47 3.3.2 Reactive Distillation Process 54 3.3.3 Comparisons 61 3.4 Results for Temperature-Dependent Relative Volatilities 61 3.4.1 Relative Volatilities 62 3.4.2 Optimum Steady-State Designs 64 3.4.3 Real Chemical Systems 69 3.5 Conclusion 70 4 Neat Operation Versus Using Excess Reactant 71 4.1 Introduction 72 4.2 Neat Reactive Column 72 4.3 Two-Column System with Excess B 75 4.3.1 20% Excess B Case 76 4.3.2 10% Excess B Case 78 4.4 Two-Column System with 20% Excess of A 81 4.5 Economic Comparison 85 4.6 Conclusion 86 Part II Steady-State Design of Other Ideal Systems 87 5 Ternary Reactive Distillation Systems 89 5.1 Ternary System without Inerts 90 5.1.1 Column Configuration 90 5.1.2 Chemistry and Phase Equilibrium Parameters 90 5.1.3 Design Parameters and Procedure 92 5.1.4 Effect of Pressure 94 5.1.5 Holdup on Reactive Trays 94 5.1.6 Number of Reactive Trays 94 5.1.7 Number of Stripping Trays 94 5.2 Ternary System with Inerts 99 5.2.1 Column Configuration 99 5.2.2 Chemistry and Phase Equilibrium Parameters 99 5.2.3 Design Parameters and Procedure 100 5.2.4 Effect of Pressure 102 5.2.5 Control Tray Composition 103 5.2.6 Reactive Tray Holdup 105 5.2.7 Effect of Reflux 107 5.2.8 Chemical Equilibrium Constant 109 5.2.9 Feed Composition 109 5.2.10 Number of Reactive Trays 113 5.2.11 Number of Rectifying and Stripping Trays 113 5.3 Conclusion 116 6 Ternary Decomposition Reaction 119 6.1 Ternary Decomposition Reaction: Intermediate-Boiling Reactant 120 6.1.1 Column Configuration 120 6.1.2 Chemistry and Phase Equilibrium Parameters 120 6.1.3 Design Parameters and Procedure 121 6.1.4 Holdup on Reactive Trays 123 6.1.5 Number of Reactive Trays 124 6.1.6 Number of Rectifying and Stripping Trays 126 6.1.7 Location of Feed Tray 126 6.2 Ternary Decomposition Reaction: Heavy Reactant with Two-Column Configurations 127 6.2.1 Column Configurations 127 6.2.2 Chemistry and Phase Equilibrium Parameters 128 6.2.3 Design Parameters and Procedure 128 6.2.4 Reactive Holdup 129 6.2.5 Number of Reactive Trays 131 6.2.6 Number of Rectifying Trays 132 6.3 Ternary Decomposition Reaction: Heavy Reactant with One-Column Configurations 134 6.3.1 Feasibility Analysis 134 6.3.2 Column Configuration 139 6.3.3 Design Parameters and Procedure 139 6.3.4 Reactive Tray Holdup 139 6.3.5 Number of Reactive Trays 139 6.3.6 Number of Rectifying Trays 140 6.3.7 Location of Feed Tray 143 6.3.8 Comparison Between These Two Flowsheets 143 6.4 Conclusion 143 Part III Steady-State Design of Real Chemical Systems 145 7 Steady-State Design for Acetic Acid Esterification 147 7.1 Reaction Kinetics and Phase Equilibria 147 7.1.1 Reaction Kinetics 147 7.1.2 Phase Equilibria 149 7.2 Process Flowsheets 153 7.2.1 Type I Flowsheet: MeAc 153 7.2.2 Type II Flowsheet: EtAc and IPAc 156 7.2.3 Type III Flowsheet: BuAc and AmAc 157 7.3 Steady-State Design 158 7.3.1 Design Procedure 158 7.3.2 Optimized Design 160 7.4 Process Characteristics 168 7.4.1 Type I: MeAc 168 7.4.2 Type II: EtAc and IPAc 168 7.4.3 Type III: BuAc and AmAc 170 7.5 Discussion 175 7.6 Conclusion 177 8 Design of Tame Reactive Distillation Systems 179 8.1 Chemical Kinetics and Phase Equilibrium 180 8.1.1 Chemical Kinetics 180 8.1.2 Phase Equilibrium Using Aspen Plus 181 8.1.3 Conceptual Design 186 8.2 Component Balances 194 8.3 Prereactor and Reactive Column 195 8.3.1 Base Case Design of Reactive Column 195 8.3.2 Effect of Design Parameters on Reactive Column 199 8.4 Pressure-Swing Methanol Separation Section 208 8.5 Extractive Distillation Methanol Separation Section 209 8.6 Economic Comparison 210 8.7 Conclusion 212 9 Design of MTBE and ETBE Reactive Distillation Columns 213 9.1 MTBE Process 213 9.1.1 Phase Equilibrium 214 9.1.2 Reaction Kinetics 214 9.1.3 Aspen Plus Simulation Issues 214 9.1.4 Setting up the Aspen Plus Simulation 215 9.1.5 Effect of Design Parameters 221 9.1.6 Chemical Equilibrium Model 229 9.2 ETBE Process 231 9.2.1 Kinetic Model 231 9.2.2 Process Studied 232 9.2.3 User Subroutine for ETBE 232 9.2.4 Chemical Equilibrium Model 234 9.2.5 Effects of Design Parameters 236 9.3 Conclusion 237 Part IV Control of Ideal Systems 239 10 Control of Quaternary Reactive Distillation Columns 241 10.1 Introduction 242 10.2 Steady-State Design 243 10.3 Control Structures 245 10.4 Selection of Control Tray Location 246 10.5 Closed-Loop Performance 247 10.5.1 CS7-R Structure 247 10.5.2 CS7-RR Structure 248 10.6 Using More Reactive Trays 249 10.6.1 Steady-State Design 249 10.6.2 SVD Analysis 250 10.6.3 Dynamic Performance of CS7-RR 253 10.7 Increasing Holdup on Reactive Trays 254 10.8 Rangeability 256 10.9 Conclusion 259 11 Control of Excess Reactant Systems 261 11.1 Control Degrees of Freedom 261 11.2 Single Reactive Column Control Structures 263 11.2.1 Two-Temperature Control Structure 265 11.2.2 Internal Composition Control Structure 272 11.3 Control of Two-Column System 278 11.3.1 Two-Temperature Control 279 11.3.2 Temperature/Composition Cascade Control 285 11.4 Conclusion 292 12 Control of Ternary Reactive Distillation Columns 293 12.1 Ternary System without Inerts 293 12.1.1 Column Configuration 293 12.1.2 Control Structure CS1 296 12.1.3 Control Structure CS2 300 12.1.4 Control Structure CS3 303 12.2 Ternary System with Inerts 310 12.2.1 Column Configuration 310 12.2.2 Control Structure CS1 310 12.2.3 Control Structure CS2 314 12.2.4 Control Structure CS3 320 12.2.5 Conclusion for Ternary A + B <=> C System 322 12.3 Ternary A <=> B + C System: Intermediate-Boiling Reactant 324 12.3.1 Column Configuration 324 12.3.2 Control Structure CS1 326 12.3.3 Control Structure CS2 329 12.3.4 Control Structure CS3 334 12.4 Ternary A <=> B + C System: Heavy Reactant with Two-Column Configuration 334 12.4.1 Column Configuration 334 12.4.2 Control Structure CS1 334 12.4.3 Control Structure CS2 335 12.5 Ternary A <=> B + C System: Heavy Reactant With One-Column Configuration 342 12.5.1 Column Configuration 342 12.5.2 Control Structure CS1 342 12.5.3 Control Structure CS2 344 12.5.4 Control Structure CS3 345 12.5.5 Conclusion for Ternary A <=> B + C System 352 Part V Control of Real Systems 353 13 Control of Reactive Distillations for Acetic Acid Esterification 355 13.1 Process Characteristics 355 13.1.1 Process Studies 355 13.1.2 Quantitative Analysis 356 13.2 Control Structure Design 362 13.2.1 Selection of Temperature Control Trays 363 13.2.2 Control Structure and Controller Design 366 13.2.3 Performance 368 13.2.4 Alternative Temperature Control Structures 376 13.3 Extension to Composition Control 380 13.4 Conclusion 388 14 Plantwide Control of Tame Reactive Distillation System 389 14.1 Process Studied 389 14.1.1 Prereactor 390 14.1.2 Reactive Column C1 391 14.1.3 Extractive Column C2 391 14.1.4 Methanol Recovery Column C3 397 14.2 Control Structure 397 14.2.1 Prereactor 397 14.2.2 Reactive Distillation Column C1 399 14.2.3 Extractive Distillation Column C2 399 14.2.4 Methanol Recovery Column C3 401 14.3 Results 403 14.4 Conclusion 406 15 Control of MTBE and ETBE Reactive Distillation Columns 407 15.1 MTBE Control 407 15.1.1 Steady State 407 15.1.2 Control Structure with C4 Feedflow Controlled 408 15.1.3 Control Structure with Methanol Feedflow Controlled 416 15.2 ETBE Control 418 15.2.1 Control Structure with Flow Control of C4 Feed 419 15.2.2 Control Structure with Flow Control of Ethanol Feed 424 Part VI Hydrid and Nonconventional Systems 429 16 Design and Control of Column/Side Reactor Systems 431 16.1 Introduction 431 16.2 Design for Quaternary Ideal System 433 16.2.1 Assumptions and Specifications 434 16.2.2 Reactor and Column Equations 435 16.2.3 Design Optimization Procedure 436 16.2.4 Results and Discussion 437 16.2.5 Reactive Column with Optimum Feed Tray Locations 445 16.3 Control of Quaternary Ideal System 446 16.3.1 Dynamic Tubular Reactor Model 446 16.3.2 Control Structures 447 16.4 Design of Column/Side Reactor Process for Ethyl Acetate System 458 16.4.1 Process Description 458 16.4.2 Conceptual Design 459 16.5 Control of Column/Side Reactor Process for Ethyl Acetate System 474 16.5.1 Determining Manipulated Variables 475 16.5.2 Selection of Temperature Control Trays 479 16.5.3 Controller Design 481 16.5.4 Performance 481 16.5.5 Extension to Composition Control 485 16.5.6 Comparison with Reactive Distillation Temperature Control 485 16.6 Conclusion 485 17 Effects of Boiling Point Rankings on the Design of Reactive Distillation 487 17.1 Process and Classification 487 17.1.1 Process 487 17.1.2 Classification 490 17.2 Relaxation and Convergence 492 17.3 Process Configurations 495 17.3.1 Type I: One Group 496 17.3.2 Type II: Two Groups 501 17.3.3 Type III: Alternating 507 17.4 Results and Discussion 511 17.4.1 Summary 511 17.4.2 Excess Reactant Design 514 17.5 Conclusion 518 18 Effects of Feed Tray Locations on Design and Control of Reactive Distillation 519 18.1 Process Characteristics 519 18.1.1 Modeling 521 18.1.2 Steady-State Design 522 18.1.3 Base Case 522 18.1.4 Feed Locations Versus Reactants Distribution 523 18.1.5 Optimal Feed Locations 527 18.2 Effects of Relative Volatilities 529 18.2.1 Changing Relative Volatilities of Reactants 529 18.2.2 Changing Relative Volatilities of Products 530 18.2.3 Summary 532 18.3 Effects of Reaction Kinetics 533 18.3.1 Reducing Activation Energies 533 18.3.2 Effects of Preexponential Factor 536 18.4 Operation and Control 538 18.4.1 Optimal Feed Location for Production Rate Variation 538 18.4.2 Control Structure 539 18.4.3 Closed-Loop Performance 541 18.5 Conclusion 544 Appendix Catalog of Types of Real Reactive Distillation Systems 545 References 563 Index 573

Autorenportrait

William L. Luyben, PHD, is Professor of Chemical Engineering at Lehigh University. In addition to forty years of teaching, Dr. Luyben spent nine years as an engineer with Exxon and DuPont. He has written nine books and more than 200 papers. He was the 2004 recipient of the Computing Practice Award from the CAST Division of the AIChE and was elected in 2005 to the Process Automation Hall of Fame. CHENG-CHING YU, PHD, has spent sixteen years as a Professor at National Taiwan University of Science and Technology and four years at National Taiwan University. He has published over 100 technical papers in the areas of plant-wide process control, reactive distillation, control of microelectronic processes, and modeling of fuel cell systems.

Back cover copy

Reactive distillation has economical and environmental advantages Reactive distillation is a breakthrough process innovation with numerous applicationsin the petroleum and chemical industries. In systems with the appropriate chemistryand vapor–liquid phase equilibrium, it combines the reaction and separation operations,which reduces energy and capital costs and environmental impact. After an overview of the fundamentals, limitations, and scope of reactive distillation, Reactive Distillation Design and Control: <ul> <li> Uses rigorous models for steady-state design and dynamic analysis of different types of reactive distillation columns </li> <li> Quantitatively compares the economics of reactive distillation columns with conventional multi-unit processes </li> <li> Goes beyond traditional steady-state design that considers primarily the capital investment andenergy costs when analyzing the control structure and the dynamic robustness of disturbances </li> <li> Discusses how to maximize the economic and environmental benefits of reactive distillation technology </li> </ul> Written by authors who have a background in design and control with an emphasis on practical engineering solutions to real industrial problems, this guide forgoes intricate, complicated mathematics and complex methods of analysis and gets down to business. It's an accessible reference for chemical, process, and petroleum engineers and undergraduate and graduate students in chemical engineering.