integrated chemical processes - media control€¦ · synthesis, operation, analysis, and control...

Integrated Chemical Processes

Synthesis, Operation, Analysis, and Control

Edited by Kai Sundmacher,Achim Kienle andAndreas Seidel-Morgenstern

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Edited by

Kai Sundmacher,

Achim Kienle,Andreas Seidel-Morgenstern

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Further Titles of Interest

K. Sundmacher, A. Kienle (Eds.)

Reactive DistillationStatus and Future Directions

2003

ISBN 3-527-30579-3

J. G. Sanchez Marcano, T. T. Tsotsis

Catalytic Membranes and Membrane Reactors2002

ISBN 3-527-30277-8

T. G. Dobre, J. G. Sanchez Marcano

Chemical EngineeringModelling, Simulation and Similitude

2005

ISBN 3-527-30607-2

S. Pereira Nunes, K.-V. Peinemann (Eds.)

Membrane Technologyin the Chemical Industry

2001

ISBN 3-527-28458-0

Ullmann’s

Processes and Process Engineering3 Volumes

2004

ISBN 3-527-31096-7

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Synthesis, Operation, Analysis, and Control

Edited by Kai Sundmacher,Achim Kienle andAndreas Seidel-Morgenstern

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Prof. Dr.-Ing. Kai SundmacherProf. Dr.-Ing. Achim KienleProf. Dr. Andreas Seidel-MorgensternMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

and

Otto-von-Guericke-UniversityMagdeburgUniversitätsplatz 239016 MagdeburgGermany

All books published by Wiley-VCH are carefully produced. Nevertheless, authors, editors, and publisher do not warrant the information contained in these books, including this book, to be free of errors. Readers are advised to keep in mind that statements, data, illustrations, procedural details or other items may inadvertently be inaccurate.

Library of Congress Card No.: applied for.

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Bibliographic information published by Die Deutsche BibliothekDie Deutsche Bibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data is available in the Internet athttp://dnb.ddb.de

© 2005 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim

All rights reserved (including those of translation into other languages). No part of this book may be repro-duced in any form – by photoprinting, microfilm, or any other means – nor transmitted or translated into a machine language without written permission from the publishers. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law.

Printed in the Federal Republic of Germany.

Printed on acid-free paper

Typesetting Shiv e-Publishing Technologies Pvt. Ltd.Bangalore, IndiaPrinting betz-druck GmbH, DarmstadtBookbinding Schäffer GmbH i.G., Grünstadt

ISBN-13: 987-3-527-30831-6ISBN-10: 3-527-30831-8

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V

Contents

Preface XV

Part I Integration of Heat Transfer and Chemical Reactions 1

1 Enhancing Productivity and Thermal Efficiency of High-Temperature Endothermic Processes in Heat-Integrated Fixed-Bed Reactors 3Grigorios Kolios, Achim Gritsch, Bernd Glöckler and Gerhart EigenbergerAbstract 3

1.1 Introduction 3

1.2 Heat-Integrated Processes for Endothermic Reactions 41.2.1 Optimality Conditions 61.2.1.1 Efficiency of Heat Recovery 6

1.2.1.2 Temperature Control 81.3 Multifunctional Reactor Concepts 101.3.1 Regenerative Processes 12

1.3.1.1 Simultaneous Mode 131.3.1.2 Asymmetric Mode 131.3.1.3 Symmetric Mode with Side Stream Injection 20

1.3.1.4 Counter-cocurrent Mode 211.3.1.5 Overheating During Oxidative Coke Removal 241.3.2 Recuperative Processes 27

1.3.2.1 Processes for Large-Scale Applications 291.3.2.2 Processes for Small-scale Applications 311.4 Conclusions 39

Symbols and Abbreviations 39References 41

2 Conceptual Design of Internal Reforming in High-Temperature Fuel Cells 45

Peter Heidebrecht and Kai Sundmacher 2.1 Introduction 452.2 Technical Background 462.3 Modeling 48

2.3.1 Model Derivation 482.3.1.1 Anode Channel 49

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Contents VI

2.3.1.2 Mixing Rules 52

2.3.1.3 Cathode Channel 532.3.1.4 Reaction Kinetics 542.3.1.5 Cell Power 55

2.3.2 Conversion Diagram 562.4 Applications 582.4.1 Comparison of Reforming Concepts 59

2.4.2 Anode Cascade 592.4.3 Anode Exhaust Gas Recycling 632.5 Summary and Conclusions 65

Symbols 66References 67

3 Instabilities in High-Temperature Fuel Cells due to Combined Heat and Charge Transport 69

Michael Mangold, M Krasnyk, Achim Kienle and Kai Sundmacher3.1 Introduction 69

3.2 Modeling 703.2.1 Model Assumptions 703.2.2 Model Equations 70

3.2.3 Simplified Model 723.3 Potentiostatic Operation 743.3.1 Cell with Infinite Length 74

3.3.2 Cell with Finite Length 763.4 Galvanostatic Operation 783.5 Conclusions 81

Symbols 82Appendix: Numerical Methods for the Bifurcation Analysis in Section 3.0 83References 84

Part II Integration of Separations and Chemical Reactions 85

4 Thermodynamic and Kinetic Effects on the Feasible Products of Reactive Distillation: A-zeo-tropes and A-rheo-tropes 87

Kai Sundmacher, Zhiwen Qi, Yuan-Sheng Huang and Ernst-Ulrich Schlünder4.1 Introduction 874.2 Azeotropes 89

4.2.1 Reactive Condenser and Reboiler 894.2.2 Conditions for Singular Points 904.2.2.1 Potential Singular Point Surface 90

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Contents VII

4.2.2.2 Reaction Kinetic Surface 91

4.2.3 Examples 924.2.3.1 Hypothetical Ternary Systems 924.2.3.2 Real Ternary System: MTBE-Synthesis 97

4.2.3.3 Real Ternary System with Phase Splitting: Methanol Dehydration 1014.2.3.4 Real Quaternary System: Isopropyl Acetate Hydrolysis 1034.2.4 Application of Feasibility Diagram: Column Feasible Split 106

4.2.5 Remarks on Azeotropes 1104.3 Arheotropes 1104.3.1 Definition and Conditions 110

4.3.2 Illustrative Examples 1114.3.2.1 Example 1: Stagnant Sweep Gas 1114.3.2.2 Example 2: Flowing Sweep Gas 114

4.3.2.3 Example 3: Flowing Sweep Gas with Pervaporation 1174.3.2.4 Example 4: Reactive Liquid Mixture 1194.3.3 Remarks on Arheotropes 126

4.4 Kinetic Arheotropes in Reactive Membrane Separation 1274.4.1 Model Formulation 1274.4.1.1 Reaction Kinetics and Mass Balances 127

4.4.1.2 Kinetics of Vapor Permeation 1294.4.2 Residue Curve Maps 1304.4.2.1 Example 1: Ideal Ternary System 130

4.4.2.2 Example 2: THF Formation 1334.4.3 Singular Point Analysis 1374.4.3.1 Approach 137

4.4.3.2 Ideal Ternary System 1384.4.3.3 THF-System 1424.4.4 Remarks on Kinetic Arheotropes 144

4.5 Summary and Conclusions 144Symbols and Abbreviations 145References 147

5 Equilibrium Theory and Nonlinear Waves for Reaction Separation Processes 149

Achim Kienle and Stefan Grüner 5.1 Introduction 1495.2 Theoretical Background 150

5.2.1 Wave Phenomena 1505.2.2 Mathematical Model 1535.2.3 Prediction of Wave Patterns 157

5.3 Analysis of Reaction Separation Processes 161

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Contents VIII

5.3.1 Reactive Distillation 161

5.3.2 Chromatographic Reactors 1635.3.2.1 Reactions of Type 1645.3.2.2 Reactions of type 166

5.3.2.3 Binaphthol Separation Problem 1685.3.3 Extension to Other Processes 1715.4 Applications 172

5.4.1 New Modes of Operation 1725.4.2 New Control Strategies 1735.5 Conclusion 175

Acknowledgments 177Symbols 178References 179

6 Simulated Moving-Bed Reactors 183

Guido Ströhlein, Marco Mazzotti and Massimo Morbidelli6.1 Introduction 1836.2 Continuous Reactive Chromatography 1856.2.1 Annular Reactive Chromatography 185

6.2.2 Simulated Moving-Bed Reactors 1856.3 Design Parameters for Simulated Moving-bed Reactors 1886.4 Modeling Simulated Moving-bed Reactors 195

6.5 Influence of the Stationary Phase Properties on SMBR Efficiency 1976.6 Conclusion 200

References 200

7 The Dos and Don’ts of Adsorptive Reactors 203

David W. Agar7.1 Introduction 2037.1.1 Adsorptive Reactors 203

7.1.2 Multifunctional Reactors 2047.1.3 Preliminary Evaluation 2057.2 Reaction Systems 206

7.2.1 The Claus Process 2077.2.2 Direct Hydrogen Cyanide Synthesis 2087.2.3 Water-gas Shift Reaction 210

7.2.4 The Deacon Process 2117.3 Catalyst and Adsorbent 2127.3.1 The Claus Process 212

7.3.2 Direct Hydrogen Cyanide Synthesis and Water-gas Shift Reaction 2147.3.3 The Deacon Process 217

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Contents IX

7.3.4 Other Adsorptive Catalysts 217

7.4 Reactor and Regeneration 2187.4.1 Fixed-bed Reactors 2187.4.2 Fluidized-bed Reactors 219

7.4.3 Pressure Swing Regeneration 2207.4.4 Temperature Swing Regeneration 2217.4.5 Reactive Regeneration 221

7.5 Design and Operation 2227.5.1 Fixed-bed Macrostructuring 2227.5.2 Pellet Microstructuring 223

7.5.3 Operating Parameter Profiling 2247.5.4 Heat Effects 2277.6 Conclusions and Perspectives 228

Acknowledgments 230References 230

8 Reactive Stripping in Structured Catalytic Reactors: Hydrodynamics and Reaction Performance 233

Tilman J. Schildhauer, Freek Kapteijn, Achim K. Heibel, Archis A. Yawalkar and Jacob A. Moulijn

8.1 Introduction 233

8.2 Hydrodynamics 2368.2.1 Flow Patterns 2368.2.1.1 Monoliths 236

8.2.1.2 Sulzer DX® 240

8.2.1.3 Sulzer katapak-S® 2418.2.2 Hold-up, Pressure Drop, and Flooding Limits 242

8.2.3 Residence Time Distribution 2448.2.4 Gas–Liquid Mass Transfer 2478.2.5 Conclusions 248

8.3 Reactive Experiments 2498.3.1 Model Reaction 2508.3.1.1 Kinetics 250

8.3.1.2 Side Reactions 2508.3.2 Experimental 2518.3.2.1 Catalysts 251

8.3.2.2 Experimental Set-ups 2518.3.3 Experimental Results 2538.3.3.1 Effect of Water Removal 253

8.3.3.2 Co-current versus Countercurrent 2548.3.3.3 Selectivity 255

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Contents X

8.3.3.4 Acid Excess 257

8.3.4 Conclusions 2588.4 Comparison of Different Internals 2598.4.1 Film-flow Monoliths 259

8.4.2 Monoliths versus DX® and katapak-S® 2608.4.2.1 Activity 260

8.4.2.2 Selectivity 2618.5 Conclusions and Future Trends 262

Acknowledgments 263

Symbols 263References 264

9 Reactive Absorption 265

Eugeny Y. Kenig and Andrzej Górak9.1 Introduction 2659.2 Reactive Absorption Equipment 2679.3 Modeling Concept 270

9.3.1 General Aspects 2709.3.2 Equilibrium Stage Model 2709.3.3 HTU/NTU-concept and Enhancement Factors 271

9.3.4 Rate-based Stage Model 2729.3.4.1 Balance Equations 2739.3.4.2 Mass Transfer and Reaction Coupling in the Fluid Film 274

9.4 Model Parameters 2769.4.1 Thermodynamic Equilibrium 2769.4.2 Chemical Equilibrium 277

9.4.3 Physical Properties 2789.4.4 Mass Transport and Fluid Dynamics Properties 2809.4.5 Reaction Kinetics 280

9.5 Case Studies 2829.5.1 Absorption of NOx 2839.5.1.1 Chemical System 283

9.5.1.2 Process Set-up 2849.5.1.3 Modeling Peculiarities 2849.5.1.4 Model Parameters 285

9.5.1.5 Results 2869.5.2 Coke Gas Purification 2869.5.2.1 Chemical System 286


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Contents XI

9.5.2.5 Results 291

9.5.2.6 Dynamic Issues 2929.5.3 CO3 Absorption by Aqueous Amine Solutions 2959.5.3.1 Chemical System 295


9.5.3.5 Results 2989.5.4 SO2 Absorption into Aqueous NaHCO3/Na2CO3 Solutions 299

9.5.4.1 Chemical System 2999.5.4.2 Process Set-up 3009.5.4.3 Modeling Peculiarities 301

9.5.4.4 Model Parameters 3019.5.4.5 Results 3029.6 Conclusions and Outlook 304

Acknowledgments 305Symbols 305References 307

10 Reactive Extraction: Principles and Apparatus Concepts 313

Hans-Jörg Bart 10.1 Introduction 31310.1.1 Physical Extraction 313

10.1.2 Reactive Extraction 31410.1.3 Additives 31910.2 Phase Equilibria 321

10.3 Reactive Mass Transfer 32310.4 Hydrodynamics 32810.5 Conclusions 332


11 Development of Reactive Crystallization Processes 339

Christianto Wibowo, Vaibhav V. Kelkar, Ketan D. Samant, Joseph W. Schroer and Ka M. Ng

11.1 Introduction 339

11.2 Workflow in Process Development 33911.3 Process Synthesis 34111.4 Reactive Phase Diagrams 344

11.4.1 Projections and Canonical Coordinates 34411.4.2 High-Dimensional Phase Diagrams 346

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Contents XII

11.5 Kinetic Effects 351

11.5.1 Reactive Crystallization with a Solid Reactant 35111.6 Asymmetric Transformation of Enantiomers 35311.6.1 Base Case (BC) 353

11.6.2 Seeded Crystallization (SC) 35411.6.3 Seeded Crystallization with Racemization (SR) 35611.7 Conclusions 357


12 Analysis and Experimental Investigation of Catalytic Membrane Reactors 359

Andreas Seidel-Morgenstern 12.1 Introduction 359

12.2 Basic Aspects of Chemical Reaction Engineering 35912.2.1 Reaction Rates 36012.2.2 Conversion as a Function of Rate Laws and

Feed Composition 361

12.2.3 Selectivity and Yield 36412.3 Mass Transfer through Membranes 36612.4 Kinetic Compatibility in Membrane Reactors 368

12.5 Example 1: Product Removal with Membranes (“Extractor”) 369

12.5.1 Model Reaction, Procedures and Set-up 37012.5.2 Reaction Rates 370

12.5.3 Fixed-bed Reactor Experiments 37212.5.4 Mass Transfer through the Membrane 37312.5.5 Membrane Reactor Experiments and Modeling 374

12.5.6 Evaluation of the Extractor-type of Membrane Reactor 37612.6 Example 2: Reactant Dosing with Membranes

(“Distributor”) 37812.6.1 Model Reaction, Set-ups and Procedures 380

12.6.1 Reaction Rates 38112.6.2 Fixed-bed and Membrane Reactor Experiments 38212.6.3 Theoretical Analysis 383

12.7 Summary and Conclusions 385Acknowledgments 386

References 387

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Contents XIII

Part III Integration of Mechanical Operations and Chemical Reactions 391

13 Reactive Extrusion for Solvent-Free Processing: Facts and Fantasies 393

Leon P. B. M. JanssenAbstract 393

13.1 Introduction 39313.2 Advantages and Disadvantages 394

13.3 Main Reactions in Extruders 39513.4 Extruder Types 39613.5 Kinetic Considerations 398

13.6 Heat Transfer and Thermal Instabilities 40113.7 Instabilities 40213.8 Conclusions 405

References 406

14 Reactive Comminution 407

Ulrich Hoffmann, Christian Horst and Ulrich Kunz14.1 Introduction 407

14.2 Mechanical Comminution of Solids 40814.2.1 Reactivity of Mechanically Activated Solids 41314.3 Equipment and Processes 415

14.3.1 Milling Designs 41514.3.1.1 Crushers 41514.3.1.2 Cutting Mills 415

14.3.1.3 Roller and Ring-roller Mills 41514.3.1.4 Disk Attrition Mills 41614.3.1.5 Grinding Media Mills 416

14.3.1.6 Impact Mills 41914.3.1.7 Jet Mills 42014.3.1.8 Pressure and Shear Devices 421

14.3.1.9 Special Milling and Activation Devices 42114.3.1.10 Dry and Wet Grinding 42214.3.1.11 Machine Wear 422

14.3.1.12 Energy Efficiency 42214.3.1.13 Solid Guidance 42314.4 Applications 423

14.4.1 Surface Area Creation 42314.4.2 Mechanical Activation 42414.4.2.1 Phase Transitions 424

14.4.2.2 Enhanced Solubility of Minerals 425

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Contents XIV

14.4.2.3 Surface Cleaning 425

14.4.3 Mechanical Alloying 42514.4.4 Simultaneous Reaction and Comminution 42614.4.4.1 Solid–Solid Reactions 426

14.4.4.2 Catalyst Preparation 42714.4.4.3 Solid–Gas Reactions 42814.4.4.4 Solid–Liquid Reactions 429

14.4.4.5 Depolymerization Reactions 43014.5 Conclusions 431

References 431

15 Reactive Filtration 437

Thomas Rieckmann and Susanne Völker 15.1 Introduction 43715.2 Separation of Particulates and Catalytic Reaction of Volatiles 43815.2.1 Flue-gas Treatment 438

15.2.2 Biomass Gasification 44015.3 Separation of Particulates and Reaction of Solids 44115.3.1 Diesel Soot Abatement 441

15.3.1.1 Filter Types and Catalyst Performance 44315.3.1.2 Formal Kinetics and Modeling 44515.3.2 Filtration Combustion of Solid Fuels 447

15.3.3 Reaction Cyclone 44815.4 Conclusions 449

References 450

16 Reaction-Assisted Granulation in Fluidized Beds 453

Matthias Ihlow, Jörg Drechsler, Markus Henneberg, Mirko Peglow, Stefan Heinrich and Lothar Mörl

16.1 Introduction 45316.1.1 Gas Cleaning 45316.1.2 Application of the Gas-solid Fluidized Bed 455

16.1.3 Modeling and Experimental Set-up 45616.2 Modeling 46016.2.1 Model Assumptions 461

16.2.2 Phase and Reaction Equilibrium 46216.2.3 Mass and Energy Flows 46316.2.3.1 Gas Balance 463

16.2.3.2 Suspension Balance 46716.2.3.3 Gas–Liquid Phase Boundary 47116.2.3.4 Particle Balance 474

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Contents XV

16.2.3.5 Apparatus Wall Balance 477

16.2.3.6 Solution of the Equations 47716.3 Experiments 47916.3.1 Fluidized-bed Plant 479

16.3.2 Experiments of Absorption without Granulation of Solid (Reactive Absorption) 481

16.3.2.1 Experimental Realization 48116.3.2.2 Influence of the Liquid Injection Rate 481

16.3.2.3 Influence of Ca/S Ratio 48816.3.2.4 Influence of the Gas Inlet Temperature 49316.3.2.5 Influence of Gas Mass Flow 495

16.3.2.6 Influence of the Particle Diameter 49716.3.3 Experiments for Reactive Absorption with Overlapped

Granulation of Solid 50216.3.3.4 Experimental Realization 502

16.3.3.2 Batch Experiments 50316.3.3.3 Continuous Experiments 51016.3.4 Comparison between Measurement and Simulation 519

16.3.5 Simplified Stationary Balancing 51916.4 Conclusions 523

Symbols and Abbreviations 526

References 529

Index 543

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XVII

Preface

In the chemical industries, the pretreatment of educts, their chemical conversioninto valuable products, and the purification of resulting product mixtures in down-stream processes are carried out traditionally in sequentially structured trains of unitoperations. In many cases, the performance of this classical chemical process struc-ture can be significantly improved by an integrative coupling of different processunits.

The integration of unit operations to form multifunctional processes very oftengives rise to synergetic effects which can be technically exploited. By suitable processdesign, an efficient and environmentally benign process operation can be achieved.Possible advantages of process integration include:

• higher productivity;• higher selectivity;• reduced energy consumption;• improved operational safety; and• improved ecological harmlessness by avoidance of auxiliary agents and

chemical wastes.Due to the interaction of several process steps in one apparatus, the steady-state

and the dynamic operating behavior of an integrated process unit is often muchmore complex than the behavior of single, non-integrated units. Therefore, suitablemethods for the design and control must be developed and applied, ensuring opti-mal and safe operation of the considered integrated process.

The major objectives of current research activities in this highly interestingdomain of chemical engineering are to develop new concepts for process integration,to investigate their efficiency, and to make them available for technical application.The importance of this field is reflected by the increasing number of articles in jour-nals and book contributions that have been published during the past three decades(Fig. 1).

Among these published articles and books, some excellent reviews have appearedwhich focused on specific aspects of the process integration. Agar and Ruppel [1]were among the first to investigate the whole area of integration of heat-exchangingfunctions in chemical reactors, whilst Agar [2] later also surveyed other innovativeintegration concepts in chemical reactor engineering. According to the presenteditors’ knowledge, the first review which covered a broader range of integrationconcepts including heat exchange, separation and also mechanical unit operations,was published in 1997 by Hoffmann and Sundmacher [3]. The cited works refer tointegrated chemical processes as “multifunctional reactors”, which is often used as a

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Preface XVIII

synonym. Multifunctional reactors can be seen as a very important sub-class of thearea of “process intensification” which was summarized by Stankiewicz andMoulin [4].

A comprehensive volume covering all aspects of integrated chemical processesincluding heat exchange, separations and mechanical unit operations is still miss-ing, however, and as a consequence the present book was prepared to fill this gap.The book’s chapters have been authored by leading international experts, and pro-vide overviews on the present state of knowledge and on challenging future issues.

The book is divided into three parts. Part I surveys concepts for heat-integratedchemical reactors, with special focus on coupling reactions and heat transfer in fixedbeds and in fuel cells. Part II is dedicated to the conceptual design, control and analysisof chemical processes with integrated separation steps, whilst Part III focuses on howmechanical unit operations can be integrated into chemical reactors.

Part I:Integration of Heat Transfer and Chemical Reactions

Chapters 1 to 3 discuss two recent and important applications of heat-integratedchemical reactions. Chapter 1, by Kolios et al., is concerned with high-temperatureendothermic processes in heat integrated fixed-bed reactors. Emphasis is placed onreforming processes, which are widely used for the production of basic chemicalsand fuels from fossil feed stocks. These processes require large amounts of heat attemperatures up to 1000 °C. In conventional solutions, only about half of the heatsupplied at high temperatures is transferred into the endothermic reaction. Emerg-ing applications such as decentralized hydrogen production for residential andmobile power generation require considerable improvement in specific productivityand thermal efficiency. Therefore, this topic is currently the subject of vivid researchactivities in industry and academia alike. Chapter 1 also includes an introduction to

Fig. 1. Journal publications on integrated chemical processes according to the Science Citation Index.

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Part II: Integration of Separation Processes and Chemical Reactions XIX

the fundamentals of heat-integrated processes, an overview on recent trends in pro-cess and apparatus design, and an analysis of the state of the art, with specialemphasis on the steam reforming of methane.

The focus in Chapters 2 and 3 is on high-temperature fuel cells with internal reform-ing. In particular, special attention is given to the Molten Carbonate Fuel Cell(MCFC) which is increasingly used for decentralized power generation. In Chapter2, Heidebrecht and Sundmacher use a simple model of an MCFC to discuss the prosand cons of alternative reforming concepts in high-temperature fuel cells.

The temperature management in a fuel cell stack is a key issue in the operation ofhigh-temperature fuel cells. In Chapter 3, prepared by Mangold and colleagues, it isshown that the temperature-dependence of the electrolyte’s electrical conductivity isa potential source of instabilities, hot spots, and spatial temperature patterns.

Part II:Integration of Separation Processes and Chemical Reactions

Due to fact that chemical reactions typically do not deliver the desired product aloneand that separation processes are always required, a wide range of efforts have longbeen undertaken to combine these two processes into a single apparatus. Although acomprehensive overview was published recently [5], nine chapters of the presentbook describe and discuss the possibilities of integrating separation processes andchemical reactions.

In Chapter 4, Sundmacher et al. – in the first contribution – analyze in detail thethermodynamic and kinetic effects relevant to an understanding of reactive distilla-tion processes. Although a comprehensive volume on this type of process integrationwas published in 2003 [6], Chapter 4 focuses on the a priori determination of prod-ucts that can be obtained using such processes.

In exploiting the equilibrium theory, Kienle and Grüner present in Chapter 5 ageneral analysis of the development and propagation of nonlinear waves in reactionseparation processes. Besides considering reactive distillation as one example, theseauthors also analyze reactive chromatography.

In Chapter 6, Morbidelli et al. describe chromatographic separations combined withchemical reactions, the focus of their contribution being to present possibilities ofperforming such processes in a continuous manner.

An analysis of reactors where adsorbents are used as a regenerative source or sink forone or several of the reactants is discussed systematically by Agar, in Chapter 7.

In cases where reactive distillation cannot be applied because some of the reac-tants are temperature-sensitive, reactive stripping might be an efficient alternative,and the current state of the application of this technology is reviewed by Kapteijnand colleagues in Chapter 8.

Another powerful concept is to combine absorption processes with chemical reac-tions, and a large number of possible concepts for this approach is presented inChapter 9 by Kenig and Górak.

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Part III: Integration of Mechanical Unit Operations and Chemical Reactions XX

In addition, extraction processes can be performed with reacting species, andseveral advantages of this technique may be realized compared to conventionalconsecutive processes, as discussed by Bart in Chapter 10.

Based on a thorough analysis of reactive crystallization, Ng and colleagues,in Chapter 11, demonstrate that such integrated processes can also be performedefficiently with solid phases involved.

In the final chapter of Part II, Seidel-Morgenstern presents two examples of howmembrane reactors might become an alternative to conventional technology.

Part III:Integration of Mechanical Unit Operations and Chemical Reactions

The last four chapters of the book are dedicated to the successful combination ofchemical reactions and mechanical process operations. In Chapter 13, Janssen eluci-dates that reactive extrusion has emerged from a scientific curiosity to an industrialprocess. Nonlinear effects in this process can give rise to instabilities that are ofthermal, hydrodynamic, or chemical origin.

In Chapter 14, Hoffmann and colleagues provide a survey on the status and direc-tions of reactive comminution. In this type of process integration, mechanical stressexerted in mills is used to enhance the chemical reactions of solids with fluids.Simultaneously, chemical reactions can generate cracks in solid particles andthereby enhance their comminution.

Filtration and chemical reactions can be usefully integrated in order to separatediesel soot particles efficiently from motor exhaust gases, and this is illustrated byRieckmann and Völker in Chapter 15, together with a series of other examples ofreactive filtration processes which are realized in the chemical industries.

In the final chapter, Mörl and coworkers analyze the complex interaction ofparticle granulation and/or agglomeration with chemical reactions in fluidized beds.For the description of the particle property distribution, a population balanceapproach is recommended which is mathematically challenging but which providesvaluable insight into the steady-state and dynamic process operating behavior.

The Book’s History, and the Editors’ Acknowledgments

The present book is the outcome of the International Max Planck Symposium onIntegrated Chemical Processes held in Magdeburg, Germany, on 22–24 March,2004. At this symposium, renowned scientists met to discuss the current state andfuture trends in the field of integrated chemical processes. The conference wasorganized by this book’s editors and their colleagues at the Max Planck Institutefor Dynamics of Complex Technical Systems, with financial support from theKompetenznetz Verfahrenstechnik Pro3 e.V. in Germany, which is gratefullyacknowledged.

The present editors wish to thank their colleagues Kristin Czyborra, Anett Raasch,and Carolin Apelt for their excellent support in organizing the symposium, and in

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The Book’s History, and the Editors’ Acknowledgments XXI

collecting the manuscripts which form the basis of this book. Last – but not least –we are thankful to Dr. Hubert Pelc and Rainer Münz from Wiley-VCH for their

helpful assistance during the book’s preparation.

Magdeburg, Germany Kai Sundmacher, Achim Kienle,February 2005 Andreas Seidel-Morgenstern

References

1. D. W. Agar, W. Ruppel, Multifunktionelle Reaktoren für die heterogene Katalyse, Chem. Ing. Tech. 1988, 60, 731–741.

2. D. W. Agar, Multifunctional Reactors: Old Preconceptions and New Dimensions, Chem. Eng. Sci. 1999, 54, 1299–1305.

3. U. Hoffmann, K. Sundmacher, Multifunktionale Reaktoren, Chem.-Ing.-Tech. 1997, 69, 613–622.

4. A. I. Stankiewicz, J. A. Moulin, Process Intensification, Chem. Eng. Progress, 2000, Jan., 22–34.

5. S. Kulprathipanja, (Ed.) Reactive Separation Processes, Taylor & Francis, New York, 2002.

6. K. Sundmacher, A. Kienle, (Eds.), Reactive Distillation, Status and Future Directions, Wiley-VCH, Weinheim, 2003.

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XXIII

List of Contributors

Editors

Prof. Dr.-Ing. Achim KienleMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

and

Otto-von-Guericke-University MagdeburgChair for Automation/ModelingUniversitätsplatz 239016 MagdeburgGermany

Prof. Dr.-Ing. Andreas Seidel-MorgensternMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

and

Otto-von-Guericke-University MagdeburgChair of Chemical Process EngineeringUniversitätsplatz 239016 MagdeburgGermany

Prof. Dr.-Ing. Kai SundmacherMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

and

Otto-von-Guericke-University MagdeburgProcess Systems EngineeringUniversitätsplatz 239106 MagdeburgGermany

Authors

Prof. Dr. David W. AgarUniversity of DortmundInstitute of Chemical Reaction EngineeringDepartment of Biochemical and Chemical EngineeringEmil-Figge-Str. 7044227 DortmundGermany

Prof. Dr. Hans-Jörg BartTechnische Universität KaiserslauternLehrstuhl für Thermische VerfahrenstechnikGottlieb-Daimler-Str.67663 KaiserslauternGermany

Jörg DrechslerAVA – Anhaltinische Verfahrens- und Anlagentechnik Ingenieurgesellschaft Henneberg & PartnerSteinfeldstr. 539176 BarlebenGermany

Prof. Dr.-Ing. Gerhart EigenbergerUniversity of StuttgartInstitute for Chemical Process EngineeringBöblinger Str. 7270199 StuttgartGermany

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List of Contributors XXIV

Bernd GlöcklerUniversity of StuttgartInstitute for Chemical Process EngineeringBöblinger Str. 7270199 StuttgartGermany

Prof. Dr. Andrzej GórakUniversity of DortmundDepartment of Biochemical and Chemical EngineeringEmil-Figge-Str. 7044227 DortmundGermany

Achim GritschUniversity of StuttgartInstitute for Chemical Process EngineeringBöblinger Str. 7270199 Stuttgart Germany

Stefan GrünerUniversity of StuttgartInstitute for System Dynamics and Control EngineeringPfaffenwaldring 970569 StuttgartGermany

Achim K. HeibelDelft University of TechnologyReactor and Catalysis EngineeringJulianalaan 1362628 BL DelftThe Netherlands

Dr.-Ing. Peter HeidebrechtOtto-von-Guericke-University MagdeburgProcess Systems EngineeringUniversitätsplatz 239106 MagdeburgGermany

Jun.-Prof. Dr.-Ing. Stefan HeinrichOtto-von-Guericke-University MagdeburgInstitute of Process Equipment and Environmental TechnologyUniversitätsplatz 239106 MagdeburgGermany

Dr.-Ing. Markus HennebergAVA – Anhaltinische Verfahrens- und AnlagentechnikIngenieurgesellschaft Henneberg & PartnerSteinfeldstr. 539176 BarlebenGermany

Prof. Dr. Ulrich HoffmannTechnische Universität ClausthalInstitut für Chemische VerfahrenstechnikLeibnizstr. 1738678 Clausthal-ZellerfeldGermany

Dr. Christian HorstTechnische Universität ClausthalInstitut für Chemische VerfahrenstechnikLeibnizstr. 1738678 Clausthal-ZellerfeldGermany

Yuan-Sheng HuangMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

Dr.-Ing. Matthias IhlowAVA – Anhaltinische Verfahrens- und AnlagentechnikIngenieurgesellschaft Henneberg & PartnerSteinfeldstr. 539176 BarlebenGermany

Prof. Dr. Leon P.B.M. JanssenUniversity of GroningenDepartment of Chemical EngineeringNijenborgh 49747 AG GroningenThe Netherlands

Prof. Dr. Freek KapteijnDelft University of TechnologyReactor and Catalysis EngineeringJulianalaan 1362628 BL DelftThe Netherlands

Vaibhav V. KelkarClearWaterBay Technologies Inc.20311 Valley Blvd., Suite CWalnut, CA 91789USA

Dr. Eugeny Y. KenigUniversity of DortmundDepartment of Biochemical and Chemical EngineeringEmil-Figge-Str. 7044227 DortmundGermany

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List of Contributors XXV

Prof. Dr.-Ing. Achim KienleMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

and

Otto-von-Guericke-University MagdeburgChair for Automation/Modeling Universitätsplatz 239016 MagdeburgGermany

Dr.-Ing. Grigorios KoliosChrist Pharma & Life Science AGHauptstr. 1924147 AeschSwitzerland

Mykhaylo KrasnykMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

Prof. Dr. Ulrich KunzTechnische Universität ClausthalInstitut für Chemische VerfahrenstechnikLeibnizstr. 1738678 Clausthal-ZellerfeldGermany

Dr.-Ing. Michael MangoldMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

Prof. Dr. Marco MazzottiSwiss Federal Institute of Technology ZürichInstitut für VerfahrenstechnikSonneggstr. 38092 ZürichSwitzerland

Prof. Dr. Massimo MorbidelliSwiss Federal Institute of Technology ZürichInstitut für Chemie- und BioingenieurwissenschaftenETH-Hönggerberg, HCI-F8093 ZürichSwitzerland

Prof. Dr.-Ing. habil. Dr. h. c. Lothar MörlOtto-von-Guericke-University MagdeburgFaculty of Process and Systems EngineeringInstitute of Process Equipment and Environmental TechnologyUniversitätsplatz 239106 MagdeburgGermany

Prof. Dr. Jacob A. MoulijnDelft University of TechnologyReactor and Catalysis EngineeringJulianalaan 1362628 BL DelftThe Netherlands

Prof. Dr. Ka M. NgHong Kong University of Science and TechnologyDepartment of Chemical EngineeringClear Water BayKowloon, Hong KongChina

Mirko PeglowFraunhofer Institute for Factory Operation and Automation IFF MagdeburgProduct Design and Modelling GroupSandtorstr. 2239106 MagdeburgGermany

Dr. Zhiwen QiMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

Prof. Dr.-Ing. Thomas RieckmannUniversity of Applied Sciences CologneInstitute of Chemical Engineering and Plant DesignBetzdorfer Str. 250679 KölnGermany

Dr. Ketan D. SamantClearWaterBay Technology Inc.20311 Valley Blvd., Suite CWalnut, CA 91789USA

Dr. Tilman J. SchildhauerDelft University of TechnologyReactor and Catalysis EngineeringJulianalaan 1362628 BL DelftThe Netherlands

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List of Contributors XXVI

Prof. Dr.-Ing. Dr. h. c. mult. Ernst-Ulrich Schlünder (emeritus)University of KarlsruheInstitute of Thermal Process EngineeringKaiserstr. 1276128 KarlsruheGermany

Dr. Joseph W. SchroerClearWaterBay Technology Inc.20311 Valley Blvd., Suite CWalnut, CA 91789USA

Prof. Dr.-Ing. Andreas Seidel-MorgensternMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

and

Otto-von-Guericke-University MagdeburgChair of Chemical Process EngineeringUniversitätsplatz 239016 MagdeburgGermany

Guido StröhleinSwiss Federal Institute of Technology ZürichInstitut für Chemie- und BioingenieurwissenschaftenETH-Hönggerberg, HCI-F8093 ZürichSwitzerland

Prof. Dr.-Ing. Kai SundmacherMax Planck Institute for Dynamics of Complex Technical SystemsSandtorstr. 139106 MagdeburgGermany

and

Otto-von-Guericke-University MagdeburgProcess Systems EngineeringUniversitätsplatz 239106 MagdeburgGermany

Dr.-Ing. Susanne Völker42 Engineering – Chemical Engineering Consulting Servicesvon-Behring-Str. 934260 KaufungenGermany

Dr. Christianto WibowoClearWaterBay Technology Inc.20311 Valley Blvd., Suite CWalnut, CA 91789USA

Dr. Archis A. YawalkarDelft University of TechnologyReactor and Catalysis EngineeringJulianalaan 1362628 BL DelftThe Netherlands

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Part IIntegration of Heat Transfer and Chemical Reactions

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integrated chemical processes - media control€¦ · synthesis, operation, analysis, and control...

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