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A model of uncatalyzed oxidation of cyclohexane in the liquid phase, including both kinetics and mass transfer,
is presented. The reaction rate constants as well as the activation energies were determined on the basis of the
experimental results obtained in a laboratory reactor with carefully passivated inner surface. A mathematical model
of an industrial reactor for the cyclohexane oxidation is also presented. The results of the uncatalyzed cyclohex-
ane oxidation simulations are compared with the data from the industrial reactor. The results of the present work
have been used for modernization of the Polish CYCLOPOL process, and enabled the development of CYCLOPOL-bis
[Gruszka, M., Krzysztoforski, A., Moniuk, W., Oczkowicz, S., Pohorecki, R., Wierzchowski, P.T. and Żyliński, M., 2005,
CYCLOPOL-bis – the second youth of the Polish process for oxidation of cyclohexane, Przemysł Chemiczny (Chem
Ind), 84: 493–502 (in Polish)].
© 2008 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
∗
Corresponding author. Tel.: +48 22 825 8564; fax: +48 22 825 8564.
E-mail address: pohorecki@sadyba.elartnet.pl (R. Pohorecki).
Received 31 July 2008; Accepted 19 August 2008
0263-8762/$ – see front matter © 2008 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
doi:10.1016/j.cherd.2008.08.007
350 chemical engineering research and design 8 7 ( 2 0 0 9 ) 349–356
Fig. 1 – Experimental setup: 1, PARR reactor; 2, stirrer; 3, heater; 4, flow meters; 5, gas analyzer; 6, reflux condenser; 7, air
cylinder; 8, nitrogen cylinder; 9, cooler; 10, gas sparger.
following products were determined: cyclohexyl hydroper- relations (Reid et al., 1988; Moniuk and Pohorecki, 1998). The
oxide, cyclohexanone, cyclohexanol, reactive by-products D value of Henry’s constant was taken from Suresh et al. (1988)
(acids: valeric, caproic, adipic, formic, 6 – hydroxycaproic; data.
hydrocarbons: butane, pentane; dicyclohexyl ether; dicyclo-
hexyl peroxide; diols). 4. Results
The concentrations of the non-reactive by-products in the
gas phase D (CO, CO2 ) were determined by gas analyzer (5). Solving differential equations (A2)–(A7), (A26) together with
The mass transfer characteristics of the PARR reactor (ε, a Eqs. (A22), (A23), (A24) and (A25) and making use of the
and kL ) have been previously determined using other reactive experimental data (products concentrations), the reaction rate
systems (Moniuk et al., 1997a,b) and are given in Table 2 for constants were determined. The values of the reaction rate
comparison with the industrial reactor. Oxygen diffusivity in constants (t = 160 ◦ C) as well as the activation energies are pre-
cyclohexane was calculated from King, Hsueh and Mao cor- sented in Table 3.
A comparison of the results calculated using the model
with the experimental data is shown in Figs. 2–5.
Table 2 – Comparison of the process parameters in the The correlation coefficient for diagrams illustrated in
laboratory and the industrial reactors Figs. 2–4 is equal 0.972, whereas for diagrams illustrated in
Fig. 5 is equal 0.994. The correlation coefficients for each dia-
Parameter Laboratory Industrial
reactor reactor gram are given to show the accuracy of the model.
The concentrations of by-products D and D are defined as
Interfacial area, a, m2 /m3 150 700 kmol C6 /m3 , i.e.: number of the molecule moles containing six
Physical mass transfer 2.9 × 10−4 1.4 × 10−3
atoms of carbon per unit solution volume.
coefficient in the liquid
phase, kL , m/s
The relation between this concentration and molar con-
Hatta number, Ha 0.5 0.1 centration is as follows:
Inlet O2 concentration, % 20.7 20.7 kmolC kmol Nc
c
6
Outlet O2 concentration, % 5.00 1.90 =c · (2)
m3 m3 6
352 chemical engineering research and design 8 7 ( 2 0 0 9 ) 349–356
Table 3 – The values of the reaction rate constants and activation energies
k160 [m3 /kmol s] E [kJ/mol K] k160 [m3 /kmol s] E [kJ/mol K]
−9
k1 1.31 × 10 108.0 k12 4.27 × 10 1
50.0
k2 3.69 × 109 0.619 k13 5.26 × 104 15.4
k3 5.64 × 100 68.6 k14 1.01 × 106 33.9
k4 7.48 × 107 29.0 k15 2.10 × 106 0.343
k5 1.12 × 10−4 s−1 140.0 k16 3.02 × 10−3 40.1
k6 3.00 × 10−3 87.5 k17 5.94 × 10−4 102.0
k7 1.80 × 10−4 30.8 k18 1.09 × 105 5.20
k8 1.25 × 10−6 144.0 k19 5.57 × 108 1.14
k9 8.31 × 107 4.06 k20 3.21 × 107 10.3
k10 6.54 × 101 31.2 k21 2.34 × 105 39.4
k11 1.00 × 10−3 48.1 k22 1.00 × 10−4 s−1 106.0
For the bubble diameter calculation the population balance and Blanch, 1990):
equation, suggested by Fleisher et al. (1996), was used:
3εd2 HL
ni = xi (8)
∂ ∂ ∂ ∂ 2d332
n(z, db , t) + [n(z, db , t)ur (z, db )] + n(z, db , t) db (z, db )
∂t ∂z ∂db ∂t
For the gas holdup calculations the ASMM model (algebraic
= G(z, db , t) (3)
slip mixture model) was used (Sanyal et al., 1999). Equations
of the ASMM model are formulated as follows:
where the first term describes the change of bubble number
concentration with time, the second is the convection term, - equation of continuity for the gas–liquid mixture
the third describes bubble growth, and the right hand side is
the generation function. For the region of equilibrium between ∂ ∂
(m ) + (m umi ) = 0 (9)
coalescence and break up processes, as considered in this ∂t ∂xi
work, we observed experimentally in a pilot plant column that
the bubble size distribution does not change neither in time - equation for mixture momentum (jth phase)
nor along the column axis (Pohorecki et al., 2001c). Moreover,
in the absence of mass transfer and with sufficiently small ∂ ∂
(m umj ) + (m umi umj )
pressure change, one can assume that all the terms on the ∂t ∂xi
left hand side are equal to zero. Dividing the total bubble pop- ∂p ∂ ∂umi ∂umj
ulation into N classes one can write Eq. (3) as: =− + m + + m gj
∂xj ∂xi ∂xj ∂xi
∂
n
Gi = 0 (4) +Fj + εk k uDki uDkj (10)
∂xi
k=1
1
N N N n n n
k
εk k u
Gi = Ci,kl − Cij + 2Bm − Bi (5) m = εk k ; m = m =
εk k ; u Dk = u
; u k − u
m
2 m
k=1 l=1 j=1 k=1 k=1 k=1
(12)
where
The details of the model used and the results obtained using
this model have been described in our earlier paper (Pohorecki
m = 2i (6) et al., 2003).
Interfacial area in the bubbling reactor is equal:
and
6ε
a= (13)
db
Ckl if k + l = i
Ci,kl = (7)
0 if k + l =
/ i The mixing of liquid in the reactor was investigated by
three methods:
The details of the model used to calculate bubble diameters
from the above equations and the results obtained using this - classical stimulus–response technique using radioactive
model have been described in our earlier papers (Pohorecki et tracer with Br-82 isotope to measure the residence time dis-
al., 2001c, 2003). tribution curve;
Bubble concentration can be obtained from the gas hold- - a specially devised technique, consisting in the employment
up and the average bubble diameter using the equation (Prince of a wooden sphere of density identical to that of the reac-
354 chemical engineering research and design 8 7 ( 2 0 0 9 ) 349–356
tion mixture, and containing a radioactive isotope La-140. No less important, however, is the kinetic model itself. This
The trajectories of this sphere in the reactor were observed; model may be further improved by extending the investigated
- a computational fluid dynamics (CFD) method, used to parameter range (especially temperature, as some of the acti-
establish the velocity patterns inside the reactor. vation energies shown in Table 3 are surprisingly low).
All the three methods gave a good picture of the flow pat- 6. Conclusion
tern in the reactor.
From the investigations of the liquid mixing, it was con- A new, comprehensive model of the noncatalytic cyclohexane
cluded that liquid circulation in the reactor could be described oxidation in the liquid phase, including reaction and mass
by the Tilton and Russell model (1982). transfer kinetics, has been developed. This model, together
The mathematical model of the industrial reactor enabled with a suitable description of hydrodynamics (bubble diam-
the calculation of the following parameters: eter, gas holdup, interfacial area, liquid mixing) has been
used to develop a mathematical model of an industrial reac-
tor in the CYCLOPOL-bis process. Numerical simulations of
- degree of conversion,
the industrial reactor, performed using this model, gave good
- selectivity towards cyclohexanol,
agreement with the operating data.
- selectivity towards cyclohexanone,
- selectivity towards cyclohexyl hydroperoxide,
Acknowledgements
- amount of the by-products (reactive and nonreactive),
- concentration profile of all the above species,
This work was supported by the Nitrogen Works
- concentration profile of dissolved oxygen,
Tarnów–Mościce S.A. (Poland).
- concentration of oxygen in the outlet gases.
Appendix A
The process (CYCLOPOL-bis), employing the uncatalyzed
oxidation step, has been successfully implemented on indus-
The balance equations for the reactions considered (Eq. (1))
trial scale in the Nitrogen Works Tarnów–Mościce S.A. (Poland)
read:
in 2004 (Polish Patent Application, 2003, 2004; Gruszka et al.,
2005) d[RH]
rRH = = −r1 − r3 − r4 − r8 + r14 − r19 − r20 − r21 (A1)
The first step of the process, comprising the uncatalyzed dt
cyclohexane oxidation mainly to the cyclohexyl hydroperox-
ide is carried out in a multisectional flow reactor (Fig. 6). The d[ROOH]
rROOH = = r3 − r5 −r6 −r7 − r8 −r9 −r13 −r14 −r16 (A2)
second step of the process, comprising the selective catalytic dt
decomposition of the cyclohexyl hydroperoxide is carried out
d[ROH]
in a reactor of similar shape. rROH = = r4 − r6 + r9 − r11 + r13 + r15 − r17 (A3)
dt
The results of simulations of the uncatalyzed cyclohexane
oxidation (first step) were compared with the industrial reac- d[RO]
rRO = = −0.3r7 + r10 + r11 − r12 + r15 + r16 (A4)
tor data (reactor volume = 102 m3 ). The results of comparison dt
are shown in Table 4.
The data from two independent runs were used. By a run d[D]
rD = = 0.3r7 + r12 + r17 + r20 − r22 (A5)
dt
one week work under steady conditions is meant. As it is seen,
good agreement between industrial reactor data and results of d[D ]
simulations has been obtained. rD = = r21 + r22 (A6)
dt
As explained in Appendix A, the hydrodynamics and
mass transfer conditions have very important influence on d[O2 ]
rO2 = = −r1 − r2 + r15 + r18 (A6)
the process in the industrial conditions, as they determine dt
the concentration of the dissolved oxygen, appearing in the
d[OH∗ ]
kinetic equations. rOH∗ = = r5 + r7 + r10 − r19 (A8)
dt
d[R∗ ]
Table 4 – Results of calculations and experiments rR∗ = = r1 −r2 +r3 +r4 +r8 −r13 −r14 + r19 + r20 + r21 (A9)
dt
RUN I RUN II
By application of the quasi-steady-state hypothesis for the Solving equations (A19) we obtained
free radicals
a0 c3 /a2 c3 + c2 a3 + b0 c3 /a2 c3 + c2 a3 + c2 c4
[R∗ ] = (A21)
d[OH∗ ] d[R∗ ] d[RO∗ ] d[RO∗2 ] b1 c3 + c1 c3 − c1 a3 /a2 c3 + c2 a3
= 0; = 0; = 0; =0 (A12)
dt dt dt dt
−b1 c3 + c1 b3 /a2 c3 + c2 a3 − c2 c4
Eq. (A8) may be rearranged to the form:
On the basis of the literature data (Kharkova et al., 1989) and
∗ k5 [ROOH] + k7 [ROOH][RO] + k10 [ROOH][RO∗2 ] our own simulations (Pohorecki et al., 2001b) we assumed:
[OH ] = (A13)
k19 [RH]
a2 c3 + c2 a3 c2 c4 ; (a2 c3 ∼ 5 × 1010, c2 a3 ∼ 109, c2 c4 ∼ 5 × 108)
Assuming that the concentration of free radical RO∗2
is pro- Therefore Eq. (A21) can be reduced to Eq. (A22):
portional to the concentration of ROOH (Pohorecki et al., 2001b)
c3 · (a0 + b0 )
[R∗ ] = (A22)
[RO∗2 ] = C · [ROOH] (A14) c1 · c4
k1 [RH][O2 ] − k2 [R∗ ][O2 ] + k3 [RH][RO∗2 ] + k4 [RH][RO∗ ] The concentration of cyclohexane can be calculated from
the carbon mass balance:
+k8 [ROOH][RH] − k13 [ROOH][R∗ ] − k14 [ROOH][R∗ ]
+k19 [RH][OH∗ ] − k20 [RO∗ ][RH] − k21 [RH][RO∗ ] = 0 (A16) [RH]0 − [RH] = [ROOH] − [ROOH]0 + [ROH] − [ROH]0
k5 [ROOH] + 2k6 [ROOH][ROH] + k7 [ROOH][RO] + k8 [ROOH][RH] In this balance the concentrations of the free radicals have
∗
−k9 [ROOH][RO ] + k11 [ROH][RO∗2 ] + k13 [ROOH][R∗ ] been neglected.
For the full balance of oxygen in the liquid, the oxygen
+2k18 [RO∗2 ]2 − k20 [RO∗ ][RH] − k21 [RH][RO∗ ] = 0 (A17) transfer from the gas phase to liquid must be taken into
account (Pohorecki et al., 2001a):
d[O2 ] Ha
[O2 ]
= kL a H · yO2 · P − + rO2 (A26)
k2 [R∗ ][O2 ] − k3 [RH][RO∗2 ] + k9 [ROOH][RO∗ ] − k10 [ROOH][RO∗2 ] dt tan h Ha cos h Ha
(A18)
DA · k
Ha = (A27)
kL
Substituting Eq. (A14) to Eqs. (A17) and (A18) we obtained
linear equations: The Hatta number values in the case considered vary in
the range 0.1–0.5. This means that the overall reaction con-
−(b1 + c1 ) · [R∗ ] + a2 · [RO∗ ] + a3 · [RO∗2 ] = −a0 ; suming oxygen is between slow and very slow regimes, where
the dissolved oxygen concentration varies between zero and
c1 · [R∗ ] + c2 · [RO∗ ] − c3 · [RO∗2 ] = 0;
the saturation value (depending on the value of the “hinter-
b1 · [R∗ ] − (a2 + c2 ) · [RO∗ ] + b3 · [RO∗2 ] = −b0 (A19) land ratio”). In our earlier paper (Krzysztoforski et al., 1986)
we have shown that the oxygen balance is well described by
where Eq. (A26).
In this case pseudo-first reaction rate constant, k is defined
a0 = k1 [RH][O2 ] + k8 [RH][ROOH] + k19 [RH][OH∗ ]; by Eq. (A28) (Pohorecki et al., 2001b)
b3 = 2k18 · c[ROOH] + k11 [ROH]; c1 = k2 [O2 ] + k14 [ROOH]; Fleisher, G., Becker, S. and Eigenberger, G., 1996, Detailed
modeling of the chemisorption of CO2 into NaOH in a bubble
c2 = k9 [ROOH]; c1 = k2 [O2 ] + k14 [ROOH]; c2 = k9 [ROOH]; column. Chem. Eng. Sci., 51: 1715–1724.
Gruszka, M., Krzysztoforski, A., Moniuk, W., Oczkowicz, S.,
c3 = a3 + b3 + c4 ; c4 = k10 [ROOH] + 2k15 · c [ROOH]; (A20) Pohorecki, R., Wierzchowski, P.T. and Żyliński, M., 2005,
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