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The Design and Control of Distillation Column with Side Reactors for
Chlorobenzene Production*
BO Cuimei ()1,2,**, TANG Jihai ()2, BAI Yangjin ()1, QIAO Xu ()2,
DING Lianghui ()2 and ZHANG Shi ()1
1
2
College of Automation and Electrical Engineering, Nanjing University of Technology, Nanjing 210009, China
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 separation, 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, respectively. And then multivariable control schemes are designed, the controllability of SRC process based on the optimal 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 simulating 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, simulation system, chlorobenzene production
INTRODUCTION
PROCESS DESCRIPTIONS
Chlorobenzene is widely used in dye and pharmaceutical industry to manufacture some organic intermediates such as phenol, aniline, nitro phenol. Chlorobenzene is produced from the reaction of benzene and
chlorine. The production is chlorobenzene and the byproduct is dichlorobenzene (mainly o-dichlorobenzene
and dichlorobenzene). Reaction equations are as follows:
(1)
1114
(2)
r1 =
d[C6 H6 ]
= k1[C6 H 6 ][Cl2 ]
dt
(3)
d[C6 H 4 Cl2 ]
= k2 [C6 H5 Cl][Cl2 ]
(4)
dt
where r1 and r2 are the reaction rate for monochloride
and dichloride; k1 and k2 are the reaction rate constants. The ratio of rate constants = k1 / k2 is about 8
at a reaction temperature of 55 C. The physical properties of benzene (C6H6), chlorobenzene (C6H5Cl) and
dichlorobenzene (C6H4Cl2) are shown in the Table 1.
r2 =
Table 1
benzene
Boiling point
/C
Molar mass
/gmol 1
C6H6
80.1
78.11
chlorobenzene
C6H5Cl
132.2
112.56
dichlorobenzene
C6H4Cl2
180.4
147
Each reactor was assumed to be a perfectly adiabatic mixed stirred tank reactor, and in the continuous
chlorination reaction system continuous reaction material equilibrium equations with the tray j are as follows Eqs. (5)-(13):
Figure 1
where yj,1, yj,2, yj,3, zj,1, zj,2 and zj,3 are the inlet and
outlet mole compositions of benzene, chlorobenzene
and dichlorobenzene from the reactor which is connected with the j-th tray; FRj is the inlet liquid flow
rate to the reactor; FCl2 is chlorine feed flow rate; V is
1115
k1 z j ,1 k2 z j ,2
k2 z j ,3
z j ,1 z j ,2
z j ,3
M j ,i = I j FR z j ,i + (1 I j ) L j 1 x j 1,i
2a
=
(8)
b
L j x j ,i + V j +1 y j +1,i V j y j ,i
(9)
z j ,2 = FCl2 FRj a + y j ,2
(10)
z j ,3 = ( FCl2 FRj ) (b / 2) + y j ,3
(11)
y j ,1 ( FCl FRj ) (a + b / 2)
2
} ( F
2a
FRj ) a + y j ,2 =
b
(12)
a + b =1
(13)
When the reactor feeding conditions are known
( FCl2 , FR, yj,1, yj,2), we calculate the selectivity of the
chlorine on the chlorobenzene and dichlorobenzene.
The materials mole distribution of the reactor outlet
can be calculated by Eqs. (9-11). For liquid phase
reactions, the above Eqs. (5-13) can be used to calculate the liquid mole fraction and the distribution rate
of material chlorine on product.
( FCl2 FRj ) a + y j ,2
3.2
Cl2
(a) Ij = 0
Figure 2
S xj = xi , j 1
i =1
E j = y j ,i
rj ,i PjS,i
P
x j ,i
(14)
(15)
S yj = yi , j 1
(16)
i =1
(b) Ij = 1
Column equilibrium schematic of the tray j (Ij is the signs for reactor site, Ij = 1 mean tray j linked with side reactor)
1116
Figure 3
Simulation results
1117
Figure 5
1118
the effectiveness of this control structure, the disturbances of feed flow rates, the feed composition and
the steam calorific value disturbances are applied to
the system, respectively.
4.2.1 Change of temperature set-value
The temperature set-value Tsp of the column bottom temperature is adjusted respectively 5 C. Fig. 6
shows the dynamic response of the control structure to
set-value change.
As seen in Fig. 6, the temperature controlled variables track to the new set-value for both positive and
negative changes in a short time. The chlorobenzene
composition of the product can be settled down smoothly
to steady-state values within specification values of
92%-93.5%.
4.2.2 Change of production rate handle
To check the effectiveness of this control structure,
the 5% step changes of the production rate (the feed
flow rate of chlorine FCl2 ) are applied to the system.
The feed flow rate of benzene is growing with increasing feed flow rate of chlorine under the ratio control
structure. Fig. 7 shows the dynamic response of the
control structure to these disturbances. As seen in Fig.
7, the fluctuation range of the temperature is within
about 0.5 C range. The chlorobenzene composition of
the production is also maintained in the fluctuation
range within about 0.2% range.
4.2.3 The 5% impurities in fresh-feed stream
The 5% impurities of nitrogen in fresh-feed
stream FCl2 are applied to the system. Fig. 8 gives the
responses of control structure to 5% impurities of nitrogen in fresh-feed stream FCl2 . The control structure
keeps the temperature within range of about 1 C and
product purities within 1.5% of their specified values
for the 5% feed stream impurity.
4.3
Controlled variable
Manipulated variable
Control target
LIC-101
50%
LIC-100
50%
PIC-100
emission of HCl
101.3 kPa
FIC-101
9.95 kmolh 1
FIC-102
9.58 kmolh 1
FIC-103
10 kmolh 1
FIC-104
24 kmolh 1
FIC-105
25 kmolh 1
FIC-106
fb(1)
FIC-107
fb(2)
FIC-108
fb(3)
cascade control
135 C
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(a)
Figure 6 Dynamic response under the temperature set value Tsp changes
Tsp + 5 C;
Tsp 5 C
(b)
(a)
Figure 7 Dynamic response under step change (5%) in production rate handle
flow +5% ;
flow 5%
(b)
(a)
Figure 8
(b)
Disturbance
Tsp change
production rate handle FCl2
5% impurities in feed stream FCl2
Disturbance
amplitude
ts/min
+5
5
Composition response
IAE
e()
ts/min
IAE
e()
30
76.42
0.5
30
0.04
0.001
75
183.66
0.3
75
0.06
0.002
+5%
3.4
0.22
0.5
3.4
0.001
0.002
5%
3.4
0.28
0.3
3.4
0.001
0.002
5%
2.87
43
0.12
2.87
1.22
0.015
1120
REFERENCES
a certain range.
5
CONCLUSIONS
2
3
4
10
NOMENCLATURE
11
FCl2
FRj
fb
HLj
HRj
HVj
i
j
k
Lj
N
NR
NRS
NS
r
Tj
Vj
xj,i
yj,c
yj,i
zj,c
12
13
14
15
16
17
18