Optimal control of an advection-dominated catalytic fixed-bed reactor with catalyst deactivation

Aksikas, Ilyasse; Mohammadi, L.; Forbes, J. Fraser; Belhamadia, Youssef; Dubljević, Stevan

doi:10.1016/j.jprocont.2013.09.016

Cited by 17 publications

(5 citation statements)

References 11 publications

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“…Optimal control over the operation of catalytic reactors to regulate the reactor temperature and reagent concentrations are key to reducing deactivation, which in turn is crucial for the success of chemical transformation and the profitability of the continuous plant, that is, how long a catalyst bed lasts. 192 Additionally, reactor design can play its part to reduce deactivation, such as the addition of a guard column to remove particulate contaminants from the flow stream. 193 Rarely discussed in the literature concerning fixed bed reactors is the changeout of deactivated/spent catalyst beds; an exception in the case of large scale reactors, where the European catalyst manufacturers association have produced a best practice guide that includes catalyst changeout proce-dures.…”

Section: Effective Reaction Ratementioning

confidence: 99%

Section: Trickle Bed Reactor (Tbr) and Respective Critical Parametersmentioning

confidence: 99%

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Fixed Bed Continuous Hydrogenations in Trickle Flow Mode: A Pharmaceutical Industry Perspective

Masson

Maciejewski

Wheelhouse

et al. 2022

Org. Process Res. Dev.

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Since the 1930s, fixed bed reactors (FBR) have been operated for continuous hydrogenation reactions in the petrochemical/fine chemical industries, with publications each year detailing engineering principles, scientific breakthroughs, equipment design and setup, from these industries. Only in the last two decades, FBR have started to be utilized in the pharmaceutical industry as a result of sustainability commitment and growing demand of complex and specialized drugs. Most of the engineering knowledge is transferable across industries; however, there are differentiators inherent to each industry, with the pharmaceutical industry having its own unique challenges. One of the main differentiators between industries is the reactor scale and, consequently, reactor catalyst requirements. Petrochemicals or fine chemicals operate on a large industrial scale, with up to 72 m high reactors, with an internal diameter on the order of 5 m (China Petroleum & Chemical Corporation), and require large volumes of catalysts because of the high product demand for thousands of tonnes per year, while for the pharmaceutical industry, a smaller scale reactor is required for product demand in the thousands of kilograms per year range. It is the reactor size that defines catalyst specifications, such as particle size and geometry. Many transformations have emerged from academic and medicinal chemistry groups utilizing the ThalesNano H-Cube; however, there are relatively few reported processes that have been scaled within the pharmaceutical industry. This Perspective outlines a review of continuous flow hydrogenation technologies; focusing on the trickle bed reactor (TBR) and the respective process operation and effect of process variables on reaction rate requirements for the pharmaceutical industry; it also reflects on transformation examples using TBR across the pharmaceutical industry.

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Section: Effective Reaction Ratementioning

confidence: 99%

Section: Trickle Bed Reactor (Tbr) and Respective Critical Parametersmentioning

confidence: 99%

Fixed Bed Continuous Hydrogenations in Trickle Flow Mode: A Pharmaceutical Industry Perspective

Masson

Maciejewski

Wheelhouse

et al. 2022

Org. Process Res. Dev.

View full text Add to dashboard Cite

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“…It was noticed that the best strategy to start up the reaction system is to stabilize the catalyst at low temperatures. Aksikas et al 15 studied a control problem for a time-changing partial differential equation (PDE) model introduced for a FBR. The dynamic behavior of the model was evaluated through employing the conception of evolution systems.…”

Section: Introductionmentioning

confidence: 99%

A Dynamic Heterogeneous Dispersion Model Evaluates Performance of Industrial Catalytic Hydrotreating Systems

Azarpour

Zendehboudi

2018

Ind. Eng. Chem. Res.

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Catalyst deactivation is one of the main challenges in industrial reaction operations. In this paper, a dynamic heterogeneous model is developed for the crude terephthalic acid hydropurification process. The model incorporates the effects of axial mixing and deactivation of the commercial catalyst of palladium supported on carbon on efficiency of the hydropurification operation. The transport phenomena governing equations lead to a series of partial differential equations which are simultaneously solved. The model validation is accomplished using the industrial data. The proposed model satisfactorily simulates the real process, and it is more accurate than the plug flow model to forecast the process behaviors. A decline in the catalyst particle size improves the catalyst performance; an increase in the catalyst porosity prolongs the catalyst lifetime, while maintaining an acceptable pressure drop in the catalyst bed. It is concluded that the effective control of p-xylene oxidation reactor (in terms of process conditions) and inlet temperature rise lead to more efficient purification process.

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“…Reduction of SO x and NO x is to be considered in hydrotreating processes. , The other matter is to design more sophisticated reactors. The reactors should be designed to distribute gas and liquid uniformly, minimize thermal instability, and maximize reactor catalyst usage. − Also, an important challenge in this field is the prediction of kinetics parameters. The complicated calculation of these parameters might be due to coupled catalytic and thermal reactions, especially when the deactivation of catalyst takes place. − …”

Section: Introductionmentioning

confidence: 99%

Prediction of Pd/C Catalyst Deactivation Rate and Assessment of Optimal Operating Conditions of Industrial Hydropurification Process

Azarpour

Borhani

Alwi

et al. 2015

Ind. Eng. Chem. Res.

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One of the key concerns of the purification section of a purified terephthalic acid (PTA) production plant is the deactivation of palladium supported on carbon (Pd/C) catalyst. In this work, the deactivation rate model of 0.5 wt % Pd/C catalyst has been developed considering temperature, active surface area, and residual catalytic activity. Moreover, the optimal operating conditions of the industrial hydropurification process have been investigated. The results show that PTA production rate (PPR) can be improved by 5.4% through 18% increase in hydrogen flow rate. Furthermore, PPR can be increased by 7.6% via the temperature rise in the reaction mixture. The optimization results further reveal that PPR can be enhanced by 17.3% by improving the feed concentration under the normal operation by means of limiting the inlet 4-carboxybenzaldehyde concentration. The research findings can be applied in the actual working plant to enhance the efficiency of the hydropurification process.

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Optimal control of an advection-dominated catalytic fixed-bed reactor with catalyst deactivation

Cited by 17 publications

References 11 publications

Fixed Bed Continuous Hydrogenations in Trickle Flow Mode: A Pharmaceutical Industry Perspective

Fixed Bed Continuous Hydrogenations in Trickle Flow Mode: A Pharmaceutical Industry Perspective

A Dynamic Heterogeneous Dispersion Model Evaluates Performance of Industrial Catalytic Hydrotreating Systems

Prediction of Pd/C Catalyst Deactivation Rate and Assessment of Optimal Operating Conditions of Industrial Hydropurification Process

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