A Systematic Methodology for the Synthesis of Advanced Reactive Distillation Technologies

Abstract

This study is the first to provide a systematic approach to assessing the potential of advanced reactive distillation technologies to expand the applicability of reactive distillation. The work presented here focuses on the synthesis of advanced reactive distillation technologies, proposing a conceptually based methodology for earlystage screening. The methodology uses basic thermodynamic and kinetic data to navigate a decision-making flowchart in four steps: compositions and splits, basic properties and operating windows, kinetics, and phase equilibria. The results qualify advanced reactive distillation technologies as advantageous, technically feasible, or not applicable. Five industrially relevant case studies illustrate the application of the methodology to develop preliminary process flowsheets. The proposed methodology aims to guide technology selection using basic data while providing flexibility to meet the objectives of the design problem. This methodology contributes to integrating a technology-oriented approach normally followed in process intensification studies into a process systems engineering approach by developing a conceptual flowsheet in the early stages of process design.

Conceptual methods for synthesis of reactive distillation processes: recent developments and perspectives

“…Only recently a few studies have focused on the conceptual process design and synthesis of advanced RD technologies. 170,171 Pazmiño-Mayorga et al 171 proposed the use of operating windows to identify suitable operating limits for advanced RD technologies. The dataset required to construct such operating windows include thermodynamic properties, kinetic parameters, constraints of materials and experimental methods, and heuristics.…”

“…For instance, an identified side reaction for the case of methyl acetate production is not likely to happen at the operating conditions identified. Pazmiño-Mayorga et al 170 presented a synthesis methodology to qualify advanced RD technologies as advantageous, technically feasible, or not applicable, by considering four aspects consecutively: compositions and splits, basic properties and operating windows, kinetics, and phase equilibria. This synthesis methodology relies on the use of heuristics and first principles, aiming to reduce computational effort compared to mathematical programming-based methods.…”

“…This synthesis methodology relies on the use of heuristics and first principles, aiming to reduce computational effort compared to mathematical programming-based methods. Although advanced RD technologies lack specific heuristics, Pazmiño-Mayorga 172 adapted heuristics proposed by Kiss 111 and those obtained from case-specific investigations to support the development of synthesis methodologies for advanced RD, such as the one presented in Pazmiño-Mayorga et al 170 Further studies could be performed to include the interplay of mass and heat transfer and miscibility gaps in advanced RD technologies.…”

“…92,169 In addition, the mass-transfer resistances of all components are assumed to be identical, and heat transfer through the wall is assumed to be negligible. 176 According to Weinfield et al, 169 R-DWC is most promising for reversible reactions with the components sharing suitable boiling-point characteristics, allowing simultaneous separation and reaction, and when more than two outlet streams are expected, as noted by Pazmiño-Mayorga et al 170 Weinfeld et al 169 were the first to review experimental, modeling and dynamic control studies and research in the field of R-DWC, while also identifying knowledge gaps that should be addressed to bring the technology to commercial scales. Liu et al 177 proposed control strategies using intelligent fussy logic and model predictive control, and demonstrated that overshoot and transition time are mitigated when compared to PID control.…”

“…188,190 Simultaneously, optimizing the operation of R-HIDiC, including economic assessments, becomes crucial in assessing the balance between energy savings and capital costs. 200 Additionally, the development of methodologies for simultaneous process synthesis and integration becomes essential to uncover the potential of R-HIDiC during flowsheet development, such as the one described in Pazmiño-Mayorga et al 170 Reactive HiGee Reactive high-gravity distillation combines high-gravity distillation (HiGee) and rotating packed-bed reactors (RPB), 204 providing a potential for solid-catalyzed gas-liquid reactions. This potential mainly results from the intensified gas-liquid mass transfer rates and the good catalyst wetting at high gravity.…”