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Reactive Distillation
MICHAEL SAKUTH, Sasol Solvents Germany GmbH, Moers, Germany
DIETER REUSCH, Degussa AG, Marl, Germany
RALF JANOWSKY, Degussa AG, Mobile, Alabama, United States
1.
2.
2.1.
2.2.
3.
3.1.
3.2.
Introduction. . . . . . . . . . . . . . . . . . . . . . . .
Mathematical Modeling of Reactive
Distillation Processes . . . . . . . . . . . . . . . . .
Equilibrium-Based Models . . . . . . . . . . . .
Rate-Based Models . . . . . . . . . . . . . . . . . .
Design of Reactive Distillation Processes . .
Procedures for Process Design Studies . . .
Flow sheet for Process Development . . . . .
. 264
.
.
.
.
.
.
265
265
266
267
267
269
4.
4.1.
4.2.
4.3.
xj:
Yi:
yij:
yijI:
yj:
DHr:
ni:
n T:
Industrial Applications . . . . . . . . . . . . . . .
Commercial Packing Structures . . . . . . . .
Industrial Catalytic Distillation Processes .
Novel Application of CD with regard to
Process Intensification . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . .
Interface
liquid phase
vapor phase
Subscripts
B:
D:
F:
P:
R:
i:
. 275
. 275
Superscripts
I:
L:
V:
. 270
. 270
. 272
bottom
distillate
feed
product
reference component
component number
264
j:
t:
Reactive Distillation
stage number
total
Azobisisobutyronitrile
Chemical distillation
Diisopropylbenzene
Ethyl tert-butyl ether
High-boiling
Height equivalent to a theoretical plate
1. Introduction
Reactive distillation (RD) is a process in which a
catalytic chemical reaction and distillation (fractionation of reactants and products) occur simultaneously in one single apparatus. Reactive
distillation belongs to the so-called processintensification technologies. From the reaction
engineering view point, the process setup can be
classified as a two-phase countercurrent fixedbed catalytic reactor.
In the literature this integrated reaction
separation technique is also known as catalytic
distillation (CD) or reaction with distillation
(RWD). According to [1], CD is a process in
which a heterogeneous catalyst is localized in a
distinct zone of a distillation column. RD is the
more general term for this operation, which does
not distinguish between homogeneously or heterogeneously catalyzed reactions in distillation
columns. RWD is a trademark of the Koch
Engineering Company for reactive distillation
technology that uses their KataMax packing
structures. A brilliant overview on the current
status of RD technologies, modeling, industrial
applications, etc., can be found in [2].
The present article exclusively deals with RD
processes that operate with a heterogeneous catalyst system, i.e., CD technology. The most
important advantage of CD technology for equilibrium-controlled reactions is the elimination of
equilibrium limitation of conversion by continuous removal of products from the reaction mixture. It is the application of Le Chateliers principle to displace the chemical equilibrium by
increasing the concentrations on the one side of
the reaction, i.e., the reactants, and decreasing it
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LB:
Low-boiling
MB: Medium-boiling
MESH: Material balance/equilibrium condition/
summation equation/heat balance
MTBE: Methyl tert-butyl ether
RD:
Reactive distillation
RWD: Reaction with distillation
TAME: tert-Amyl methyl ether
TAEE: tert-Amyl ethyl ether
TIPB: Triisopropylbenzene
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There are three important constraints for applying CD technology to catalytic chemical
reactions:
.
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265
In the literature, it can be found that endothermic reactions are not suitable for the CD technology, because the reaction heat condenses part
of the vapor stream. Although endothermic reactions require more reboiler duty and therefore
exhibit no large energy savings, there are no
restrictions with regard to the application of this
technology [3].
Chemical reactions, which may benefit from
CD technology, should fulfill the above-mentioned criteria in general. Reactions of this type
include, for example, etherifications, esterifications, transesterifications, hydrations, hydrolysis, condensations, hydroisomerizations, oligomerizations, alkylations, transalkylations, and
selective hydrogenations.
An excellent overview of the current status of
published applications is given in [2].
2. Mathematical Modeling of
Reactive Distillation Processes
2.1. Equilibrium-Based Models
Multicomponent separation processes, such as
normal distillation processes, have been modeled
by using the equilibrium-stage concept for a
century. Therefore, early works on reactive distillation also used the equilibrium-stage model to
simulate reactions with superimposed distillation.
The principal assumption of the equilibriumstage model is that the vapor and the liquid stream
that leave the stage are in thermodynamic equilibrium. In most real distillation columns, of
course, the residence time is too short to reach
total equilibrium. For this reason, efficiencies
have been introduced into the model (e.g., Murphree efficiency, vaporization efficiency, etc.) to
account for the nonideal behavior. MESH (i.e.,
Material balance, Equilibrium relationship,
Summation of all substances, and enthalpy balance H) equations are used to simulate conventional distillation columns (! Distillation, 1.
Fundamentals, Section 4.3).
To introduce the chemical reaction superimposed to the distillation further equations are
needed to simulate reactive distillation processes
(! Reaction Columns, Chap. 2.). The simplest
way to consider chemical reactions is to use the
equilibrium constant Ki, but many reactions are
not fast enough to reach chemical equilibrium in
266
Reactive Distillation
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yIij 1 0;
as well as
X
xIij 1 0
one theoretical stage. Therefore, it is often necessary to use kinetic expressions, which describes
the reaction rate as a function of temperature and
concentration activities of each component of the
reaction scheme.
NjL cLtj kjL aj xlj xj NtjL xj
must be fulfilled.
To simulate the reactive distillation process,
an expression for the reaction rate rij f (temperature, concentrations/activities) must be
added. For catalytic distillation the chemical
reaction is taken into account in the material
balance of the bulk liquid phase
1sLj Lj xi;j xi;j1 Lj1 fijL NijL rij 0
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Reactive Distillation
267
Xi
Yi
xi nvi xRR
1 nnT RxR
yi nvi yRR
1 nnTRyR
nT
NC
X
ni
10
i1
Xi
NC
X
Yi 1
11
i1
268
Reactive Distillation
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12
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Reactive Distillation
269
insight into the RD process with respect to column parameters (e.g., column diameter, etc.). It
contains calculation procedures with equilibrium-based stage models as well as rate-based
models for a specific process design [14].
270
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Figure 7. Flow sheet for the process development of a CD technology (CSTR continuous stirred tank reactor)
(*: see Chapter 1)
The possible reasons for the observed deviations, discussed in [2], could be:
.
.
.
Sensitivity studies of different CD column parameter can help to understand the order of
magnitude of the deviations on the overall con-
4. Industrial Applications
4.1. Commercial Packing Structures
All commercial CD packing structures have in
common that the catalyst is located in a distinct
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Reactive Distillation
271
272
Reactive Distillation
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porous ion exchange resins are bonded chemically or physically. For example, the active
Raschig rings are prepared by using an opencelled sintered glass, which is impregnated with
a mixture of styrene, a long chain alkane, pdivinylbenzene, and a radical starter (AIBN:
azobisisobutyronitrile). After the polymerization procedure, the resin is sulfonated with
chlorosulfonic acid to build up the active catalytic sites.
These types of reactive rings have been used
in an etherification process in a pilot plant column [7, 22].
Other Technologies. Another interesting,
but as yet not commercialized, technology for
immobilizing catalyst pellets in a distinct zone of
a CD column is to incorporate a fixed-bed in the
downcomer of a conventional tray column [23].
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Reactive Distillation
273
Process (licensor)
Process description
Catalyst
ETHERMAX (UOP)
sulfonated
ion-exchange resin
acidic
ion-exchange resin
trifunctional
ion-exchange resin
acidic ion-exchange resin
Market
share*
ca. 32 %
ca. 58 %
ca. 10 %
274
Reactive Distillation
causes irreversible catalyst deactivation and catalyst damage. The excess alcohol is collected in
the overhead of the CD column and separated
from the hydrocarbon stream by extraction with
water.
In the case of MTBE production, a conversion
of up to 99.9 % is possible by using this technology, if sufficient ether is present at the bottom of
the column. Because of a minimum boiling azeotrope in the binary MTBE methanol system,
the ether carries the alcohol into the reaction zone
of the CD column. This unusual vapor liquid
behavior and the high difference in the heat of
vaporization between C4 hydrocarbons and
methanol are possibly responsible for the known
multiple steady states in CD column operation
[22, 26].
The TAME process usually gives a lower
conversion of 91 95 % only.
Esterification Processes. Esterification is a
good example for the beneficial use of the CD
technology. In conventional methyl acetate production the recovery of methyl acetate from the
reactor outlet stream is complicated, because
methanol forms a low boiling azeotrope with
water and the separation of water from unconverted acetic acid is difficult. Due to these separation problems, the old Eastman Kodak process
used a reactor coupled with eight distillation
columns and an extraction column [28].
In the reactive distillation process, almost
pure methyl acetate can be collected in the
overhead of a single CD column at acetic acid
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References
1 G. G. Podrebarac, F. T. T. Ng, G. L. Rempel, CHEMTECH 1997, 37 45.
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Further Reading
C. A. M. Afonso: Green Separation Processes, Wiley-VCH,
Weinheim 2005.
Z. Lei B. Chen Z. Ding: Special Distillation Processes, 1st
ed., Elsevier, Amsterdam 2005.
Vol. 31
W. L. Luyben, C.-C. Yu: Reactive Distillation Design and
Control, Wiley, Hoboken, NJ 2008.
K. Sundmacher: Reactive Distillation, Wiley-VCH, Weinheim 2003.