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http://www.uem.br/acta
ISSN printed: 1806-2563
ISSN on-line: 1807-8664
Doi: 10.4025/actascitechnol.v34i1.9535
Curso de Engenharia Química, Universidade Estadual do Oeste do Paraná, R. da Faculdade, 645, 85903-000, Toledo, Paraná, Brazil.
*Author for correspondence. E-mail: eq.vilmar@hotmail.com
ABSTRACT. An algorithm for the solution of the mathematical model featuring reactive distillation
process in steady-state columns is analyzed. It has been presumed that each stage’s outlet streams in the
model were in phase equilibrium conditions and that chemical kinetics was described by a reaction rate
model. Within the context of the developed algorithm a procedure to solve a set of equations in a sequential
form and a methodology to produce the initial estimates was defined. Broyden’s method was employed to
solve the equations that model the chemical reactions. Algorithm was evaluated by study cases of 2-pentene
metathesis and MTBE synthesis. The simulation results were close to results available in the literature and
the proposed algorithm proved to be efficient since in both cases the convergence towards a solution was
found.
Keywords: reactive distillation, modeling, simulation, initial guess.
Guess T j
Guess ξk j
Guess B and D , Eqs. (1) and (2)
Q1 (QC ) Guess V j , Eqs. (4)-(6)
F1 Stage 1
(Condenser) Guess L j , Eqs. (7)-(9)
U2
Calculate T j , Eq. (22)
W3 V3
L2
Calculate yi j , Eq. (23)
Wj Vj Uj-1
Lj-1
Calculate h j and H j , Eqs. (24) and (25)
Fj Stage j Qj
Calculate QC e QR , Eqs. (26) and (27)
Wj+1 Vj+1 Uj
Lj Calculate V j , Eqs. (28) and (32)
error ≤ tol no
FNp Stage Np
(Reboiler) QNp(-QR)
yes
Print results
LNp(B)
(a) (b)
Figure 1. (a) – Schematic representation of a reactive distillation column; (b) – Algorithm for the simulation of reactive distillation
columns operate in a stead state.
For the initial guess of distillate and bottoms, it is and for the liquid phase balances, with
presumed that for each mol of liquid that evaporates rearrangement of expressions, the following
another mol of vapor condenses, and vice-versa. equations are given:
Liquid and vapor streams are only affected by feed N p −1 Np
in which:
N p −1 Np
( rB + 1) ⋅ F1 + rB ⋅ ( R j − U j ) + ( rB + 1 − q j ) ⋅ Fj − ( rB + 1) ⋅W j
D (0) = j =2 j =2 (2)
rB + rD + 1
l j = L j −1 , j = 2,3,..., N p (13)
in which:
d1 = − V1 ⋅ K i 1 + L1 + D (14)
Nr Nc
R j = ν l i ⋅ ξl j (3)
l =1 i =1 d j = − (U j + L j ) + (W j + V j ) ⋅ K i j , j = 2,3,..., N p − 1 (15)
where:
F is the feed stream, U is the liquid side stream, (
d N p = − B + WN p + VN p ⋅ K i N p
) (16)
W is the vapor side stream, rB is the reboil ratio, rD is
the reflux ratio, q is the feed quality stream, v is the u j = V j +1 ⋅ K i j +1 , j = 1, 2,..., N p − 1 (17)
stoichiometric coefficient, NC is the number of
components, NP is the number of stages and Nr is Nr
b j = − F j ⋅ zi j − ν l i ⋅ ξl j , j = 1, 2,..., N p (18)
the number of reactions. l =1
xi j
L(0) (0)
j j
j = V j +1 − V1 − D + Fm + ( Rm − U m − Wm ), j = 2,3,..., N p − 1 (8) (x )
i j Normalizado = Nc
, i = 1, 2,..., N c ; j = 1, 2,..., N p
(20)
m =1 m=2
x
k =1
k j
L(0)
Np = B
(0)
(9)
Calculation of temperatures is undertaken by the
Once calculated the set of guess values, it may be re-arrangement of the phase equilibrium equation
started the algorithm iterative calculations. using the secant method to solve the equations:
Nc
Equations of component mass balances in each F (T j ) = 1 − Ki j ⋅ xi j = 0, j = 1, 2,..., N p (21)
stage and the condition of phase equilibrium give i =1
d1 ⋅ xi 1 + u1 ⋅ xi 2 = b1 (10)
Mole fractions of the vapor phase are calculated
l j ⋅ xi j −1 + d j ⋅ xi j + u j ⋅ xi j +1 = b j , j = 2, 3,..., N p − 1 (11) directly by the phase equilibrium equation:
Enthalpy of the liquid and vapor phases are Equations of the molar balances may be re-
calculated by the elemental reference state (standard arranged so that the liquid phase streams may be
enthalpy of formation of pure components in ideal calculated from the following equations:
gas state):
L1 = rD ⋅ D (37)
( )
Nc
H = yi ⋅ ( ΔH of 298 K ) + ( C igp ) ⋅ dT + H R
T
i 298 K i
(24)
i =1
j j
L j = V j +1 − V1 − D + Fm + ( Rm − U m − Wm ), j = 2,3,..., N p − 1 (38)
( ) − ΔH (T ) + (C ) ⋅ dT ) + h
Nc m =1 m=2
h = xi ⋅ H i (Ti
T
bp
i
vap
i
bp
Tibp
l
p i
E
(25)
i =1
LN p = B (39)
The following equations, used for the calculation
of heat duties in the condenser and reboiler were When the reaction is kinetically-limited, the
obtained from the first stage and global energy extents of reaction are calculated by the reaction rate
balances equations respectively: equation. When the reaction is very fast, tha is, when
the reaction is equilibrium-limited, the extents of
QC = F1 ⋅ hFeed 1 + V2 ⋅ H 2 − V1 ⋅ H1 − ( L1 + D ) ⋅ h1 (26) reaction may be calculated by the equilibrium
Np N p −1 Np
equation.
QR = F j ⋅ hFeed j − V1 ⋅ H1 − LN p ⋅ hN p −
j =1
(Q
j =1
j + U j ⋅ hj ) − W j ⋅ H j
j=2
(27) This is the most complex step in the algorithm
and the step which limits the convergence of the
The combination of molar balances, definition of simulation. The use of a method for the solution of
reboil ratio and energy balances, with modifications, a set of non-linear equations is required since most
provide the following set of linear equations: methods demand the calculation of the derivatives
of the functions. The derivatives are numerically
α j ⋅ V j + β j ⋅ V j +1 = γ j , j = 2, 3,..., N p − 1 (28) evaluated due to the difficulty in obtaining algebraic
derivatives for this set of equations. Broydon’s
in which: method was employed for the solution of this
algorithm step.
α j = h j −1 − H j (29) The end of the iterative process occurs when
the relative variation of some main variables of
β j = H j +1 − h j (30) the model are very low. The smallness of the
variation depends on tolerance (tol) chosen.
γ j = Q j + Fj ⋅ ( h j − hFeed j ) + W j ⋅ ( H j − h j ) + R j ⋅ h j
(31)
2 2 2
j −1 j −1
Np
Tj(k ) − Tj(k −1) Np Vj(k ) −Vj(k −1) Nr Np −1 ξi(,kj ) −ξi(,kj−1)
+ ( Fm ) − (U m + Wm − Rm ) − V1 − D ⋅ ( h j − h j −1 ) + + ≤ tol (40)
i=1 j =2 ξi, j
(k ) (k ) (k )
m =1 m=2 Tj
j =1 j =2 Vj
equilibrium-limited and occurs on stages 2 to 13. A code in FORTRAN was developed to solve
The following chemical equation describes the 2- the case. The program converged with 236
pentene metathesis: iterations, with 1 x 10-10 tolerance, using Intel Core2
QUAD Q6600 2,40GHz processor.
2C5 H10 C4 H 8 + C6 H12 (41) Figures 2a and b show comparisons between
initial guess and simulation results respectively for
Table 1 shows the column’s operational temperature and extent of reaction. Initial guess
conditions. Reboil ratio was adapted so that molar profiles were extremely close to results.
flow rates would be equal for the distillate and Figures 3a and b show comparisons between
bottoms.
initial guess and simulation results respectively for
Whereas the Peng-Robinson equation of state
was employed to represent the behavior of the molar flow rates of the liquid and vapor phases.
vapor phase, the groups contribution method Initial guess of rates of both phases were extremely
UNIFAC was used to represent excess Gibbs’s close to the values calculated by simulation .
free energy, with parameters from Poling et al. Table 2 shows relevant variables in the reactive
(2004). Physical, critical and thermodynamic distillation process obtained in this work, which
properties were taken from Yaws (2003). results is in agreement with reference.
Table 1. Operational conditions of reactive distillation column in Table 2. Comparison between results obtained in this work and
Case 1. those by Chen et al. (2000) for Case 1.
Variables Specifications Variables Specifications Chen et al. (2000) This work
Pressure All stages 1 atm Rate (kmol min.-1) Distillate 50.0 50.0
Ratio Reflux 4.0 Bottoms 50.0 50.0
Reboil 4.151 Mole fraction (D) 2-pentene 0.0199 0.0220
Feed Saturated liquid Stage 7 2-butene 0.9801 0.9779
Flow rate 100 kmol h-1 3-hexene 7.08x10-5 6.30x10-5
Temperature 310.1 K Mole fraction (B) 2-pentene 0.0199 0.0220
Pressure 1 atm 2-butene 6.50x10-5 6.29x10-5
Mole fraction 2-pentene (1.0) 3-hexene 0.9801 0.9779
3 40 30
C a lc u la te d C a lc u la te d
3 30 In itia l g u e s s
Extent of reaction (kmol h-1)
In itia l g u e ss 25
3 20
Temperature (K)
20
3 10
15
3 00
10
2 90 (b)
(a) 5
2 80
2 70 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14
S ta g e S ta g e
Figure 2. Comparison between the simulation results and initial guess in Case 1: (a) - temperature; (b) – extent of reaction.
300 300
250 250
Vapor rate (kmol h-1)
Liquid rate (kmol h-1)
200 200
150 150
(a) 100
(b)
100
50 50
C a lc u la te d C a lcu la te d
In itia l g u e s s In itia l g u e ss
0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14
S ta g e S ta g e
Figure 3. Comparison between the simulation results and initial guess in Case 1: (a) – Liquid rate; (b) – Vapor rate.
Temperature (K)
H 2 SO4
⎯⎯⎯
i − B + MeOH ←⎯⎯ ⎯→ MTBE (42) 380
500
phase, whereas Wilson model was used for the non- 450
400
ideal behavior of the liquid phase to represent 350
iterations, with 1 x 10-10 tolerance, using Intel Figures 5a and b show comparisons between
Core2 QUAD Q6600 2,40GHz processor. initial guess and simulation results of rate profiles
Table 3. Operational conditions of distillation column in Case 2.
for liquid and vapor phases. Initial estimates of
moles discharge in the two phases are very close to
Variables Specifications
Pressure All stages 11 atm
simulation-calculated rates.
Ratio Reflux 7 Table 4 shows relevant variables in the reactive
Reboil 10,44*
Feed 1 Liquid Stage 10
distillation process obtained in this work.
Rate 711.30 kmol h-1 The results obtained in this work for Case 2
Temperature 320 K
Pressure 11 atm
are reasonably close to those by Singh et al.
Mole fractions MeOH (1.00) (2005). Certain differences may be justified due to
Feed 2 Vapor Stage 11
Rate 1965.18 kmol h-1
some differences in thermodynamic models. The
Temperature 350 K rate of distillate stream values are different,
Pressure 11 atm
Mole fractions i-B (0.36) however, the rate provided by Singh et al. (2005)
n-B (0.64) is not correct, because due to the reaction,
Molar holdup** Reactive stages (j = 4-11) 68529.3 kmol
*
Adjusted for B = 640.8 kmol h-1; **Da = 100, reaction equilibrium column (CHEN
represented by Equation (42), there is a decrease
et al., 2000). in the number of moles.
Acta Scientiarum. Technology Maringá, v. 34, n. 1, p. 61-69, Jan.-Mar., 2012
68 Steffen e Silva
10000
The algorithm used was also efficient since the
results obtained with the code developed were very
8000
close to those in the literature. There were no
Liquid rate (kmol h-1)
4000 Nomenclature
B Bottoms;
2000
Calculated (a)
D Distillate;
Initial guess Da Damköhler number;
0 Fj Feed rate of stage j;
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Stage
h Enthalpy of liquid phase;
H Enthalpy of vapor phase;
12000 Lj Liquid rate of stage j;
Nc Total number of components;
10000
Np Total number of stages;
qj Feed quality of stage j;
Vapor rate (kmol h-1)
8000
Qj Heat load from stage j;
6000
rB Reboil ratio;
rD Reflux ratio;
4000 Tj Temperature of stage j;
(b) Uj Liquid side rate of stage j;
2000
Calculated v Volume;
Initial guess Vj Vapor rate of stage j;
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Wj Lateral vapor outlet of stage j;
Stage xi j Liquid mole fraction of component i on stage j;
yi j Vapor mole fraction of component i on stage j;
Figure 5. Comparison between simulation results and initial
guess in Case 2: (a) –Liquid rate; (a) – Vapor rate.
zi j Mole fraction of component i on stage j.
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SEADER, J. D.; HENLEY, E. J. Separations process License information: This is an open-access article distributed under the terms of the
Creative Commons Attribution License, which permits unrestricted use, distribution,
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