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The Design and Control of Distillation Column with Side Reactors for
Chlorobenzene Production*
BO Cuimei (薄翠梅)1,2,**, TANG Jihai (汤吉海)2, BAI Yangjin (柏杨进)1, QIAO Xu (乔旭)2,
DING Lianghui (丁良辉)2 and ZHANG Shi (张湜)1
1
College of Automation and Electrical Engineering, Nanjing University of Technology, Nanjing 210009, China
2
State Key Laboratory of Materials-oriented Chemical Engineering, Nanjing University of Technology, Nanjing 210009,
China
Abstract The distillation column with side reactors (SRC) can overcome the temperature/pressure mismatch in
the traditional reactive distillation, the column operates at temperature/pressure favorable for vapor-liquid separa-
tion, while the reactors operate at temperatures/pressures favorable for reaction kinetics. According to the smooth
operation and automatic control problem of the distillation column with side reactors (SRC), the design, simulation
calculation and dynamic control of the SCR process for chlorobenzene production are discussed in the paper. Firstly,
the mechanism models, the integrated structure optimal design and process simulation systems are established, re-
spectively. And then multivariable control schemes are designed, the controllability of SRC process based on the op-
timal steady-state integrated structure is explored. The dynamic response performances of closed-loop system against
several disturbances are discussed to verify the effectiveness of control schemes for the SRC process. The simulat-
ing results show that the control structure using conventional control strategies can effectively overcome feeding
disturbances in a specific range.
Keywords distillation column with side reactors (SRC), mechanism models, multivariable control schemes, simula-
tion system, chlorobenzene production
zene production is designed, and the dynamic control where yj,1, yj,2, yj,3, zj,1, zj,2 and zj,3 are the inlet and
system is researched. The configuration of SRC for outlet mole compositions of benzene, chlorobenzene
chlorobenzene production is shown in Fig. 1. In Fig. 1, and dichlorobenzene from the reactor which is con-
the lighter component benzene moves toward the col- nected with the j-th tray; FRj is the inlet liquid flow
umn top and the heavier component chlorobenzene and rate to the reactor; FCl2 is chlorine feed flow rate; V is
the volume of the reactor; and a and b are the mole MESH equations include the material balance
fractions of chlorine used to form chlorobenzene and equations, phase equilibrium equations, the mole fraction
dichlorobenzene, respectively. Dividing Eq. (7) by Eq. of the normalized equation and heat balance equation
(6) and introducing the rate-constants ratio ω = k1 / k2 , [14]. MESH equations of tray j are shown as follows:
Eq. (8) can be obtained.
M j ,i = I j FR z j ,i + (1 − I j ) L j −1 x j −1,i −
z j ,2 − y j ,2 k1 ⋅ z j ,1 − k2 ⋅ z j ,2 ω ⋅ z j ,1 − z j ,2 2a
= = = (8) L j x j ,i + V j +1 y j +1,i − V j y j ,i (14)
z j ,3 − y j ,3 k2 ⋅ z j ,3 z j ,3 b
When the reaction temperature is 55 °C, ω = 8 . rj ,i PjS,i
E j = y j ,i − x j ,i (15)
zj,1, zj,2 and zj,3 can be evaluated by shifting Eqs. (5-7) P
as follows: c c
z j ,1 = y j ,1 − FCl2 FRj ⋅ a + y j ,2 (9) S xj = ∑ xi , j − 1 S yj = ∑ yi , j − 1 (16)
i =1 i =1
z j ,2 = FCl2 FRj ⋅ a + y j ,2 (10)
H j = I j FRj H Rj + I j FHClj H HClj + (1 − I j ) L j −1 H Lj −1 −
z j ,3 = ( FCl2 FRj ) ⋅ (b / 2) + y j ,3 (11) L j H Lj + V j +1 H Vj +1 − V j H Vj +
Substituting zj,1, zj,2, zj,3 described by Eqs. (9) and VGj +1 H VGj +1 − VGj H VGj
(10) to Eq. (8), Eqs. (12) and (13) can be obtained.
(17)
{ω ⋅ y j ,1 − ω ⋅ ( FCl FRj ) ⋅ (a + b / 2) −
2
where j = 1, 2," , N means the number of the column
tray; i = 1, 2, 3 means benzene, chlorobenzene and
⎡( FCl2 FRj ) ⋅ a + y j ,2 ⎤
⎣ ⎦ } ⎡⎣( F
FRj ) ⋅ a + y j ,2 ⎤ =
Cl2 ⎦ b
2a
dichlorobenzene, respectively. x j ,i and y j ,i are liquid
phase and vapor phase molar composition of compo-
(12) nent i in the tray j ; L j and V j , represent liquid and
a + b =1 (13) vapor flow rate of the tray j; H Lj and H Vj are liquid
When the reactor feeding conditions are known and vapor enthalpies of the tray j; FRj is the flow rate
( FCl2 , FR, yj,1, yj,2), we calculate the selectivity of the from the reactor into the tray j; z j ,i is the molar com-
chlorine on the chlorobenzene and dichlorobenzene. position from the reactor into the tray j; H Rj is the liq-
The materials mole distribution of the reactor outlet uid enthalpy from the reactor into the tray j. The prod-
can be calculated by Eqs. (9-11). For liquid phase uct hydrogen chloride get into the distillation column
reactions, the above Eqs. (5-13) can be used to calcu- system, and its influence on the vapor-liquid equilib-
late the liquid mole fraction and the distribution rate rium is very little. It only affects the pressure and en-
of material chlorine on product.
ergy balance of the column. FHClj and H HClj represent
hydrogen chloride vapor phase flow rate and enthalpy
3.2 Column MESH model from reactor into tray j; and VGj and H VGj are hydro-
gen chloride liquid flow rate and enthalpy of tray j.
The mechanism model of the distillation column
can be built as a column with several side streams.
3.3 Solution and simulation of mechanism model
The activity coefficients of the liquid phase are calcu-
lated using the Wilson model. A schematic diagram of
equilibrium tray is shown in Fig. 2. For the calculation of strong nonlinearity and
(a) Ij = 0 (b) Ij = 1
Figure 2 Column equilibrium schematic of the tray j (Ij is the signs for reactor site, Ij = 1 mean tray j linked with side reactor)
1116 Chin. J. Chem. Eng., Vol. 20, No. 6, December 2012
coupled relation between thermodynamic equilibrium components. The initial tray temperature ( T j ) is set to
and the kinetic equations of non-ideal system, the so- be the boiling point of benzene at the given pressure.
lution of mechanism model is more complex. Since The simulation of the SRC process is completed using
the simulating convergence of model is rather difficult, MATLAB software.
a good initial value to ensure reliable convergence is
needed. In this paper, it is firstly assumed that the ca- 3.4 Simulation results
pacity of the reactor is large enough to promise chlo-
rine to be consumed completely, and the feeding flow
rates of chlorine ( FCl2 ) are defined as the independent The optimal steady-state design of the SCR
reaction amount. Therefore, the mechanism model may process for Chlorobenzene production are obtain by
be equivalent to distillation column simulation problem the economic optimal design procedures based on se-
with multi-stream inlet and outlet. After distillation quential quadratic programming (SQP) algorithmic in
column calculating convergent, the material properties the literature [15, 16]. The optimization structural pa-
of the reactor can be obtained, which is connected rameters and operating parameters are as follows: the
with the tray j. According to reaction kinetics model, column tray numbers N = 12 ; the reactors numbers
the sizes of reactors are calculated. This solution has N R = 3 ; the tray numbers between reactors N RS = 1 ;
greatly improved the convergence speed of the model the vapor boilup in column bottom Vn = 30 kmol·h−1;
of the SCR process [15] the fresh feeding flow rates of chlorine FCl2 = 9.95
The SRC simulation process is that the above re- kmol·h−1; and the chlorine proportion to three reactors
actors equations and MESH equations are simultane- fb(i) = [0.41 0.31 0.28]. In the simulations, the fresh
ously calculated. The algorithm block diagram of the feeding flow rates of benzene are excess to guarantee
SCR process is shown in Fig. 3. In this paper, Newton- the complete reaction of chlorine, and thus, the opti-
Raphson method with numerical evaluation of the mal feeding flow rates of benzene is calculated by the
Jacobian matrix is used to the steady-state solution of reaction terms. Fig. 4 shows the simulating results. Fig.
the MESH equations. In addition, the initial values of 4 (a) is the composition distribution of liquid material
V j and L j are generated from the constant molar flow in the bottom column, Fig. 4 (b) is the temperature
assumption. The initial column composition profile distribution of the bottom tray; and Fig. 4 (c) is the
x j ,i is guessed according to the distribution rule of the flow rate distribution of the column bottom.
(a) The composition distribution (b) The temperature distribution (c) The flow rate distribution
■ C6H6; ● C6H4Cl2; ▲ C6H5Cl ■ liquid; ● vapour
Figure 5 Multivariable control schemes of the SRC process for chlorobenzene production
When the feeding flow rates of chlorine is 9.95 demonstrates that the simulated results are closed to
kmol·h−1, the feeding flow rates of benzene calculated the experimental results. Thus, the simulated results can
by the reaction terms is FB = 9.58 kmol·h−1. In the be used in the guidance of chlorobenzene production.
simulated results, the purity of chloride production is
0.9683, the purity of benzene is 0.099%, and the se- 4 DESIGN AND ANALYSE OF CONTROL SYS-
lectivity is 0.968/(1−0.0309) = 99.88%. TEM
Comparing the experimental data, i.e., the chloro-
benzene in column bottom is about 96% with various
kinds of catalysts, the conversion rate of benzene is 99%, The dynamic control of the SRC process is the
and the selectivity of chlorobenzene is about 97%, it significant element during the engineering application
1118 Chin. J. Chem. Eng., Vol. 20, No. 6, December 2012
design of integrated technology [17]. Comparing with the effectiveness of this control structure, the distur-
the conventional distillation, the dynamic characteristics bances of feed flow rates, the feed composition and
of the SRC process are more complicated. As a result the steam calorific value disturbances are applied to
of the interaction between the reaction and the separa- the system, respectively.
tion, the SRC process has strong nonlinear, coupling
and multi steady-stable characteristics [18]. The above 4.2.1 Change of temperature set-value
characteristics make the dynamic operation and con- The temperature set-value Tsp of the column bot-
trol for the SRC process become bottleneck problems. tom temperature is adjusted respectively ±5 °C. Fig. 6
shows the dynamic response of the control structure to
set-value change.
4.1 Design of multivariable control schemes As seen in Fig. 6, the temperature controlled vari-
ables track to the new set-value for both positive and
Based on the above economic optimal design and negative changes in a short time. The chlorobenzene
simulation analysis of the SRC process for chloro- composition of the product can be settled down smoothly
benzene production, the multivariable control schemes to steady-state values within specification values of
are developed with the conventional control strategies 92%-93.5%.
as shown in Fig. 5.
The control schemes include several control loops, 4.2.2 Change of production rate handle
such as the liquid level control loops (LIC-100, LIC-101), To check the effectiveness of this control structure,
the pressure control loop (PIC-100), the feed flow rate the ±5% step changes of the production rate (the feed
control loops (FIC-101, FIC-102), outlet flow rates flow rate of chlorine FCl2 ) are applied to the system.
control loops of the three reactors (FIC-103, FIC104, The feed flow rate of benzene is growing with increas-
FIC105), the temperature cascade control loop (TIC-100), ing feed flow rate of chlorine under the ratio control
etc., which are given in Table 2. For the composition structure. Fig. 7 shows the dynamic response of the
analyzers have higher cost, require more maintenance, control structure to these disturbances. As seen in Fig.
and can introduce dead-time into the control loop, the 7, the fluctuation range of the temperature is within
temperature cascade control loop is proposed. The about 0.5 °C range. The chlorobenzene composition of
temperature control of column bottom is the main loop the production is also maintained in the fluctuation
(TIC-100), and the control of the steam flow rate is range within about 0.2% range.
sub-loop (FIC-100), which are shown in Fig. 5. 4.2.3 The 5% impurities in fresh-feed stream
The 5% impurities of nitrogen in fresh-feed
4.2 The performance analysis of the close-loop stream FCl2 are applied to the system. Fig. 8 gives the
control system responses of control structure to 5% impurities of ni-
trogen in fresh-feed stream FCl2 . The control structure
keeps the temperature within range of about 1 °C and
The dynamic simulation of the SRC process for product purities within 1.5% of their specified values
chlorobenzene production with the above designed con- for the 5% feed stream impurity.
trol structures are explored with chemical simulation
software HYSYS. Through reasonable setting control
system parameters and operating parameters, the 4.3 Analysis of the system performance indexes
closed loop control system of the SRC process can run
smooth and attain the expected control goals. To check The performance indexes of the SRC process for
(a) (b)
Figure 6 Dynamic response under the temperature set value Tsp changes
Tsp + 5 °C; Tsp − 5 °C
(a) (b)
Figure 7 Dynamic response under step change (±5%) in production rate handle
flow +5% ; flow −5%
(a) (b)
Figure 8 The dynamic response under the 5% impurities in fresh-feed stream
chlorobenzene production, such as the settling time ts, in Table 2. Through the analysis of the performance
the absolutely integral error IAE and the steady-state indexes of the control system in Table 3, the recom-
error e(∞) are calculated further under the above dis- mended multivariate control structure can overcome
turbances conditions. The calculating results are given effectively the above different type disturbances within
1120 Chin. J. Chem. Eng., Vol. 20, No. 6, December 2012