In this paper we discuss design guidelines for solid-catalyzed reactive distillation systems. The guidelines are used to generate initial estimates for column pressure, reactive zone location, catalyst mass, reactant feed location, reactant ratio, reflux ratio, column diameter, number of equilibrium stages, and packed height. They form a part of a methodical design procedure that makes extensive use of both nonequilibrium (rate-based) and equilibrium-stage simulation models. Important choices prior to design include selection of reliable thermodynamic and reaction kinetic models. We tested the guidelines for two etherification systems and validated them experimentally for a hydration reaction. The results from a case study, the manufacture of tert-amyl methyl ether, are shown here. Superimposing reaction on separation leads to unique design trade-offs. Thus, column diameter depends both on maximum vapor velocity and on packing catalyst density, reactant ratios are a function of conversion and azeotrope formation, the operating pressure affects the relative volatility, chemical equilibrium, and reaction rate (reactive zone temperature), and the reflux ratio impacts both separation and conversion. The guidelines and procedures presented here simplify the detailed reactive column design considerably.

The geometry of catalyst-containing bale packing is characterized in this paper. The calculated packing parameters (specific surface area and void fraction) are employed in conjunction with a model to predict two-phase pressure drop, maximum capacity, and height equivalent to a theoretical plate (HETP). Experimental data obtained in a 5.3-cm (2.1-in.) column, operated at total reflux, are presented for two systems (cyclohexane/n-heptane and acetone/methyl ethyl ketone) at pressures of 138 and 241 kPa (20 and 35 psia). Model predictions for pressure drop and HETP are validated with experimental data obtained under nonreactive conditions. An appropriate procedure for scaleup of HETP and pressure drop, with associated limitations, is also discussed.

Nonlinear and linear model-based control (MBC) strategies including process model-based control (PMBC), model predictive control (MPC), internal model control (IMC), and advanced conventional control (ACC) have been experimentally compared for flow, temperature, pressure, and composition control. The test systems have nonlinear characteristics and include a pilot scale fluid flow and heat exchanger system, a commercial plasma reactor, and a laboratory scale distillation column. The evaluation criteria includes the effort required for model development and implementation, as well as conventional measures of controlled and manipulated variable activity.

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