Analysis of the runaway in an industrial heterocatalytic reactor

Varga, Tamás; Szeifert, Ferenc; Réti, József; Abonyi, János

doi:10.1016/s1570-7946(07)80148-9

Cited by 4 publications

(4 citation statements)

References 6 publications

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“…Lyapunov's stability analysis is suitable for the detection of the development of runaway, 26 and the algorithm based on this stability analysis can separate the cases where runaway occurs in the reactor or not. Although it is applicable to detect when the runaway has occurred, which is interesting from veiwpoint of the analysis of historical process data, it cannot be used in online process monitoring and control, where the operator is interested in the region of safe operation and the last time instant when the runaway could have been avoided by the control system.…”

Section: Stability Analysis Based Runaway Detectionmentioning

confidence: 99%

Detection of Safe Operating Regions: A Novel Dynamic Process Simulator Based Predictive Alarm Management Approach

Varga

Szeifert

Abonyi

2009

Ind. Eng. Chem. Res.

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The operation of complex production processes is one of the most important research and development problems in process engineering. A safety instrumented system (SIS) performs specified functions to achieve or maintain a safe state of the process when unacceptable or dangerous process conditions are detected. A logic solver is required to receive the sensor input signal(s), to make appropriate decisions based on the nature of the signal(s), and to change its outputs according to user-defined logic. The change of the logic solver output(s) results in the final element(s) taking action on the process (e.g., closing a valve) to bring it back to a safe state. Alarm management is a powerful tool to support the operators' work to control the process in safe operating regions and to detect process malfunctions. Predictive alarm management (PAM) systems should be able not only to detect a dangerous situation early enough, but also to give advice to process operators which safety action (or safety element(s)) must be applied. The aim of this paper is to develop a novel methodology to support the operators how to make necessary adjustments in operating variables at the proper time. The essential of the proposed methodology is the simulation of the effect of safety elements over a prediction horizon. Since different manipulations have different time demand to avoid the evolution of the unsafe situation (safety time), the process operators should know which safety action(s) should be taken at a given time. For this purpose a method for model based predictive stability analysis has been worked out based on Lyapunov's stability analysis of simulated state trajectories. The proposed algorithm can be applied to explore the stable and unstable operating regimes of a process (set of safe states), information that can be used for PAM. The developed methodology has been applied to two industrial benchmark problems related to the thermal runaway.

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Section: Stability Analysis Based Runaway Detectionmentioning

confidence: 99%

Detection of Safe Operating Regions: A Novel Dynamic Process Simulator Based Predictive Alarm Management Approach

Varga

Szeifert

Abonyi

2009

Ind. Eng. Chem. Res.

Self Cite

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“…12 Many scholars have done theoretical research on preventing temperature runaway of the chemical reaction. [13][14][15] It is believed that temperature runaway incidents are closely related to the chemical reaction mechanism, catalyst structure-activity, and sensitivity of operating parameters. The production of vinyl acetate by the acetylene process generates many by-products, mainly containing vinylacetylene, acetaldehyde, acetone, crotonaldehyde, and some advanced acetylenes.…”

Section: Introductionmentioning

confidence: 99%

A multiscale simulation on the formation mechanism of crotonaldehyde and the influence of operating parameters on the process during the production of vinyl acetate from acetylene

et al. 2023

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“…Partial heat accumulation may occur in the reactor bed and lead to temperature runaway if the heat released by an exothermic reaction in the reactor can't be removed in time. The unit has to be shut down, and it may cost a considerable quantity of workforce and material resources [4], [5]. Therefore, it's particularly essential to prevent the occurrence of temperature runaway.…”

Section: Introductionmentioning

confidence: 99%

Study on the Influence of Parameter Fluctuation on Ethylene Epoxidation Reaction Process

2019

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Ethylene epoxidation reactor is a kind of critical equipment in an oxidation unit. Due to the complex coupling effect of the extreme operating environment of high temperature, high pressure and potential risk factors, the reactor tends to work abnormally under the impact of parameter fluctuation, and temperature runaway incident may occur and cause severe loss. For studying the influence of parameter fluctuation on ethylene epoxidation reaction process and preventing temperature runaway accidents, physical modeling is performed firstly in this paper to acquire the chemical reaction mechanism therein and confirm the operation parameters which should be focused. The unsteady simulation of the operation process under normal situation has been performed. On such basis, a test of single-factor effect is performed to analyze the impact of parameter fluctuation on the temperature balance and operation efficiency of the reactor. Comparison analysis has been carried out between the simulation data acquired according to the established model and real production data, and it was found that the result is consistent. The analysis result indicates: higher ethene concentration, oxygen concentration, feed flux, feed temperature, drum temperature, operating pressure or smaller porosity may improve bed temperature and accelerate reaction rate; therein, ethene concentration, oxygen concentration, drum temperature, and porosity are operation parameters that need special monitoring. Based on the risk analysis of the ethylene epoxidation reactor and the simulation of the impact of parameter fluctuation, this paper studies the cause of the reactor's temperature runaway to provide a technical basis for the forecast of reactor's temperature runaway, early warning, and high-efficient operation of equipment. Model established based on abnormal condition parameters fluctuation, can contribute to early warning reactor temperature runaway, revealing the influence mechanism of parameter fluctuation for the reaction system, monitoring reaction process, eliminating temperature runaway in the bud, and providing theoretical and technical basis for petrochemical equipment fault diagnosis, accident prevention and control and safely long-time running. INDEX TERMS Fixed bed reactor, ethylene oxide, temperature runaway, CFD, parameter sensitivity.

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Analysis of the runaway in an industrial heterocatalytic reactor

Cited by 4 publications

References 6 publications

Detection of Safe Operating Regions: A Novel Dynamic Process Simulator Based Predictive Alarm Management Approach

Detection of Safe Operating Regions: A Novel Dynamic Process Simulator Based Predictive Alarm Management Approach

A multiscale simulation on the formation mechanism of crotonaldehyde and the influence of operating parameters on the process during the production of vinyl acetate from acetylene

Study on the Influence of Parameter Fluctuation on Ethylene Epoxidation Reaction Process

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