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Ethyl tert-butyl ether (ETBE) is an alternative gasoline oxygenate that combines the blending
properties of methyl tert-butyl ether (MTBE) and the renewability of ethanol. Technologically,
the best means of synthesis utilizes reactive (or catalytic) distillation to maximize hydrocarbon
conversion and energy efficiency while simultaneously producing a high-purity ether product.
Mathematical models of reactive distillation are based on the conventional distillation process
with supplementary equations added to model the reactions present. Ether-alkene-alcohol
systems are highly nonideal in the liquid phase so that careful selection of physical property
routines is required to ensure satisfactory simulation results. Column simulations performed
here using both Pro/II and SpeedUp show excellent agreement with previously published
experimental data for a MTBE system and also agree well with each other for both MTBE and
ETBE systems. A homotopy analysis was performed on the tuned simulation models to
determine the effects of key design and operating variables on column performance and,
subsequently, to develop a design method for reactive distillation columns. Some unusual
behavior was identified in ETBE reactive distillation columns compared with either MTBE
columns or conventional distillation.
here via simulation studies using both Pro/II (Simula- Table 1. Properties of Alternative Oxygenates
tion Sciences, 1994) and SpeedUp (Aspen Technology, property ETBE MTBE ethanol
1993).
molecular weight 102 88 46
oxygen content (wt %) 15.7 18.2 34.8
normal boiling point (C) 73 55 78
Reaction Chemistry blending RVP (kPa) 27 55 122
octane ((RON + MON)/2) 111 110 115
ETBE is produced from the reversible reaction of energy content (MJ/kg) 36.3 35.3 26.7
isobutylene and ethanol over an acid catalyst, such as relative cost moderate low moderate
the acidic ion-exchange resin, Amberlyst 15: renewable source? partly no yes
( )
aETBE required to prevent significant side reactions involving
mcatkrateaEtOH2 aiBut - isobutylene. The LHHW reaction model predicts a large
KETBEaEtOH adsorption equilibrium constant for ethanol, which
rETBE ) (3a)
(1 + KAaEtOH)3 implies that, at ethanol excesses of 4 mol % and above,
the catalyst surface is largely covered with ethanol.
Under these conditions, the dimerization and oligomer-
1323.1
ln KA ) -1.0707 + (3b) ization of isobutylene are essentially eliminated (Kit-
T chaiya and Datta, 1996).
60.4 The ETBE reaction rate also depends on the activity
krate ) 7.418 1012 exp - ( RT ) (3c) of the catalyst which is susceptible to both deactivation
(slow aging) and poisoning (fast aging). Poisoning is
potentially a serious problem as water and, especially
Simplified rate equation (for EtOH > 4 mol %) salts, neutralize active catalyst sites. Deactivation
( )
occurs over a much longer period and is accelerated by
aiBut aETBE
rETBE ) mcatkrate (4a) thermal degradation caused by hot spots due to inad-
aEtOH K
- 2
ETBEaEtOH
equate mixing. In situ regeneration has generally been
unsuccessful and a regular catalyst changeover is
87.2 required for most reactors (Flato and Hoffman, 1992).
krate ) 1.209 1012 exp - ( RT ) (4b) The key physical properties of the reaction compo-
nents differ significantly and are summarized in Table
The ETBE (and MTBE) reaction system also includes 2 (Simulation Sciences, 1994; Furzer, 1994; Brockwell
an unavoidable side reactionsthe dimerization of isobu- et al., 1991; CRC Handbook, 1995). In an industrial
tylene to produce diisobutylene (DIB): situation, isobutylene is likely to only be available as a
component within a mixture of other, nonreactive bu-
(CH3)2CdCH2 + (CH3)2CdCH2 S [(CH3)2CdCH2]2 tylenes. For most practical purposes, the physical
(5) properties of other butylenes present can be assumed
to be similar to those of isobutylene. There is variability
This reaction is also equilibrium limited, but its kinetics in the octane data reported in the literature for each of
and mechanism are not readily available in the open the various ethers, but ETBE is generally claimed to
Ind. Eng. Chem. Res., Vol. 36, No. 5, 1997 1857
Table 3. Significant Azeotropes in the ETBE Reaction maximize conversion. The first reactor operates up to
System 90 C, while the second reactor operates at 50-60 C.
composition composition composition The product from the second reactor is then purified by
at 0 kPa at 950 kPa at 1400 kPa distillation in the third stage of the process. The
Reported from Experimental Data bottoms product from the ether purification column is
EtOH-iBut n/a n/a 0.94% EtOH high-purity MTBE (>99.5%). The distillate product is
EtOH-nBut n/a n/a n/a further processed to recover unreacted methanol in the
EtOH-ETBE 37% EtOH n/a n/a final stage. A liquid-liquid extraction column with
Predicted by UNIFAC water as the solvent is used due to the presence of an
EtOH-iBut no azeotrope no azeotrope 1.25% EtOH azeotrope between methanol and butylenes (at around
EtOH-nBut no azeotrope no azeotrope 1.45% EtOH 10% methanol). The raffinate product from this column
EtOH-ETBE 38% EtOH 59% EtOH 66% EtOH
contains essentially all the nonreactive hydrocarbon
from the original hydrocarbon feed and is suitable for
have an average octane rating one number higher than alkylation as the concentration of isoolefins is very low.
MTBE (Furzer, 1994; Brockwell et al., 1991; Piel and One further column is required to separate water, which
Thomas, 1990; Unzelman, 1989). An octane rating is is recycled to the L-L extractor, from the methanol,
not generally cited for isobutylene due to its high which is recycled to the reactors (ARCO Chemical
volatility, but a blending value of around 100 is antici- Technology, 1995).
pated based on isoolefin trends.
The reactive distillation process for MTBE synthesis
The ETBE system is susceptible to azeotropes due to combines elements of the second and third stages
nonidealities in the liquid phase. Azeotropes between (reaction and purification) into one element of process
ethanol and isobutylene and between ethanol and ETBE equipment, according to the simplified flow diagram
have been recorded experimentally (Gmehling et al., shown in Figure 2 (ARCO Chemical Technology, 1995).
1994). The UNIFAC model predicts the presence of The second reaction stage and peripheral equipment is
these azeotropes and also suggests an azeotrope be- eliminated, and the overall conversion is actually in-
tween ethanol and 1-butylene. The literature data are creased as the effective methanol excess is much higher
incomplete, but the UNIFAC model indicates that the within a distillation system. It is economical to main-
azeotropes between ethanol and butylenes only exist at tain the first reaction stage as the amount of catalyst
high pressure. The compositions of all azeotropes vary
that can be loaded into a reactive distillation column is
with pressure according to the data shown in Table 3.
limited and the operating temperatures therein are
restricted by the intersection with separation conditions.
The recovery equipment downstream of the reactive
ETBE Synthesis Route Using Reactive distillation column operates essentially unchanged, and
Distillation product purities are as high as would be achieved with
a conventional distillation operation.
The conventional process for synthesis of MTBE Conventional ETBE synthesis follows a similar route
consists of four stages: (a) pretreatment; (b) reaction; to MTBE synthesis and uses the same process equip-
(c) purification; (d) recovery of unreacted reactants ment. However, reaction and phase differences create
(ARCO Chemical Technology, 1995). A simplified proc- slightly different operating conditions and change the
ess flow diagram is shown in Figure 1. The hydrocarbon expected conversion and purity. The more restrictive
feed should be rich in isobutylene. In practice, this equilibrium lowers the conversion achieved in the
implies a refinery sourcesvarious fluidized catalytic reaction stage by 1-2%. The absence of any significant
cracking (FCC) units (15-35% isobutylene, depending azeotrope between ethanol and butylenes results in
on the type of catalyst in use), a steam cracking unit unreacted ethanol being recovered with the ETBE
(40-55% isobutylene), or an isobutane dehydrogenation product. The presence of an azeotrope between ethanol
unit (40-55% isobutylene) (Miracca et al., 1996). The and water results in some water being recycled to the
ethanol feed should be essentially pure to minimize the reaction stage via extract from the liquid-liquid extrac-
side reaction of isobutylene hydration. tor. However, there is a much lower load on the
The first stage of the conventional process, pretreat- recovery equipment, as only a small amount of ethanol
ment, consists of a simple water wash and is necessary appears with the distillate product from the main
to remove trace contaminants that could deactivate the purification column. In fact, it is feasible, under some
catalyst. The second stage, reaction, is conducted in two refinery conditions, to eliminate the ethanol recovery
sequential reactors to ensure that high conversions are equipment altogether, creating the simplified flow dia-
achieved. The first reactor normally operates isother- gram shown in Figure 3.
mally and is used to perform the majority of the A reactive distillation process for ETBE synthesis
reaction. A tubular reactor is normally used to allow would utilize the same principles as the MTBE process
the substantial heat which is liberated to be removed and should yield the same benefits of increased conver-
adequately before it affects the reaction equilibrium. An sion, increased energy efficiency, and reduced capital
adiabatic reactor can be used, if a slipstream of the cost. The majority of the reaction (say, 80%) would be
product is cooled and recycled to the reactor inlet to performed in an isothermal, tubular reactor operating
control the temperature rise, but a lower conversion is at moderate conditions of temperature (around 90 C)
expected and the risk of hot spots deactivating the and pressure (1500-2000 kPa to ensure all components
catalyst is increased (Sarathy and Suffridge, 1993). The remain in the liquid phase). The feed to the reactive
second stage can mostly be operated adiabatically as distillation column would, therefore, be rich in ETBE
much less heat is liberated and a packed-bed reactor is but still contain some ethanol and isobutylene. The
more economical. The packed bed allows more catalyst products from the bottoms and overheads of the reactive
to be used so that the reactor can be operated at lower distillation column would be ETBE with some ethanol
temperatures to improve the reaction equilibrium and and nonreactive hydrocarbon with a small amount of
1858 Ind. Eng. Chem. Res., Vol. 36, No. 5, 1997
isobutylene and ethanol, respectively. The distillate Heat balance) equations for systems in vapor-liquid
product may or may not require further processing equilibrium and the MERQ (Material balance, Energy
depending on its composition and the refinery configu- balance, Rate equations for mass transfer, and phase
ration. This scheme is shown in Figure 4 without eQuilibrium at the vapor-liquid interface) equations for
ethanol recovery equipment. mass transfer can be used to model distillation proc-
esses. The MERQ equations have been recommended
Reactive Distillation Model by some researchers (Sundmacher and Hoffman, 1995)
and are gaining in popularity due to advances in
Both the MESH (Material balance, vapor-liquid computational power available. However, they are more
Equilibria equations, mole fraction Summations, and complex, require the estimation of more empirical
Ind. Eng. Chem. Res., Vol. 36, No. 5, 1997 1859
parameters, and appear to offer no improvement in Total Condenser
accuracy for most systems. The MESH model was used
here (see eqs 8-37) and produced satisfactory results. material balance V-L)0 (28)
Separation Stage component balance Vyi - Lxi ) 0 (29)
material balance Lin + Vin - Lout - Vout ) 0 (8)
energy balance VHV - LHL - Qc ) 0 (30)
component balance Linxi,in + Vinxi,in -
Loutxi,out - Voutxi,out ) 0 (9)
equilibrium P) iyiPvap
i (31)
L V
Partial Reboiler
energy balance LinHi,in + VinHi,in -
L V material balance Lin - Lout - Vt ) 0 (32)
LoutHi,out - VoutHi,out ) 0 (10)
component balance Linxi,in - Loutxi,out - Vyi ) 0
equilibrium Pyi ) ixiPvap
i (11) (33)
r1,ETBE ) -r1,EtOH ) -r1,iBut (15) The basic set of MESH equations was modified for
reactive distillation by adding equations to model the
r2,DIB ) -2r2,iBut (16) chemical reactions present. The equations shown here
are fully rigorous in that both reaction equilibrium and
reaction rate expressions are included, but chemical
r1,nBut ) r1,DIB ) r2,ETBE ) r2,EtOH ) r2,nBut ) 0 (17)
equilibrium could have been assumed for this system
( )
due to the relative speed of the reaction. This would
aETBE have been done by eliminating eqs 18, 20, and 21
mcatkrateaEtOH2 aiBut -
KETBEaEtOH (effectively assuming an infinite supply of catalyst). The
r1,ETBE ) (18) construction of the equations is such that the heat of
(1 + KAaEtOH)3 reaction is calculated implicitly and does not need to
be separately specified. The overhead pressure and
4060.59 stage-to-stage pressure drop were fixed for these simu-
ln KETBE ) 10.387 +
T
-
lations but could have been modeled more rigorously
2.89055 ln T -0.0191544T + by incorporating variable relationships between holdup
5.28586 10-5T2 - 5.32977 10-8T3 (19) and vapor-liquid flows (see part 2 of this series).
However, constant stage-to-stage pressure drop is a
1323.1 common assumption and does not introduce any sig-
ln KA ) -1.0707 + (20) nificant error for steady-state simulations.
T
The choice of physical property routines is important
60.4
krate ) 7.418 1012 exp - ( RT ) (21) due to the highly nonideal nature of the ether-alcohol-
alkene system. The UNIFAC model has been used
successfully to predict liquid phase activities by several
5819.26 researchers including developers of reaction equilibrium
ln KDIB ) 95.2633 + - 17.2 ln T - 0.0356T
T constant expressions and rate equations for the ETBE
(22) (Jensen and Datta, 1995, 1996) and MTBE (Zhang and
Datta, 1995) reactions. It has also been found (see Table
component balance Linxi,in + Vinxi,in - Loutxi,out - 3) to accurately represent the azeotropes compared with
Voutxi,out ) r1,j + r2,j ) 0 (23) experimental data (Gmehling et al., 1994). Alterna-
tively, the UNIQUAC model (Bravo et al., 1993) or the
energy balance L
LinHi,in V
+ VinHi,in - Wilson equation (Abufares and Douglas, 1995) can be
used to predict liquid phase activities in ether systems.
L V
LoutHi,out - VoutHi,out ) 0 (24) Vapor phase nonideality is less significant as etherifi-
cation columns operate at only modest pressures and
equilibrium Pyi ) ixiPvap (25) any one of a range of prediction methods should be
i
adequate. The Soave-Redlich-Kwong (SRK) method
is widely used for the prediction of enthalpy and other
TV ) TL (26) properties although alternative methods (e.g., Peng-
Robinson) would also be acceptable for the pressure and
yi ) 1 (27) temperature conditions.
1860 Ind. Eng. Chem. Res., Vol. 36, No. 5, 1997
The results presented below for various ETBE reac- synthesis route shown in Figure 4, the feed is to stage
tive distillation columns were obtained from two differ- 6 and consists of a 80% prereacted mixture of iso-
ent commercial simulators: Pro/II (Simulation Sciences, butylene and 1-butylene (40/60 split) plus ethanol at a
1994) and SpeedUp (Aspen Technology, 1993). The Pro/ stoichiometric excess of 5.0%. Three reactive stages
II simulation results were obtained using the built-in were specified for the ETBE column so that a higher
reactive distillation unit operation and required only the loading of catalyst was possible to accommodate the
specification of components, reaction equilibria, feed lower reaction rate of ETBE compared with MTBE. This
conditions, operating pressure, column configuration, column is shown in Figure 5. The feed rate and reboiler
and two operating parameters (from reboiler and con- duty were based on a pilot scale (154 mm diameter)
denser duties, reflux rate/ratio, and various product ETBE reactive distillation column which has recently
specifications) to generate simulation results. The been constructed at Curtin University, Western Aus-
UNIFAC model was used for liquid phase activities. The tralia. Operating conditions were adjusted slightly from
SRK method was used for fugacity coefficients, en- those proposed for MTBE synthesis to compensate for
thalpy, and other properties. The reaction expressions differences between the two systems and improve the
given by eqs 2 and 6 were used to model the reactions overall viability of the process. A slightly higher pres-
present. sure (950 kPa compared with 690 kPa in Smiths
The SpeedUp model was developed from scratch using column) was used to increase the reaction zone temper-
eqs 8-37. The UNIFAC model was again used to ature and, thereby, improve the reaction rate and reduce
predict liquid phase activities. However, an ideal vapor the catalyst requirement. A lower reflux ratio (5.0
phase was assumed to simplify the model. Published compared with 10.0) was also specified to reduce the
Antoine coefficients (Krahenbuhl and Gmehling, 1994; energy requirements. The reboiler duty was optimized
Gmehling and Onken, 1977; Dean, 1992; Reid et al., with respect to isobutylene conversion. The complete
1987) were used to predict vapor pressures and, there- simulation input is shown in Table 4.
fore, vapor-liquid equilibrium. Rigorous reaction ki- The key simulation results for the ETBE column, from
netics were used to model the ETBE reaction (eqs 11- both Pro/II and SpeedUp, are shown in Table 5. The
14), while reaction equilibrium was assumed for the DIB estimates of conversion and purity from the two simula-
side reaction (eq 15). The global system of equations tors are both within 1%, and the key indicator of
for the full model contained a total of 578 variables and bottoms temperature is only 1 C divergent. The
504 linear and nonlinear equations. An ETBE reaction temperature profiles and composition profiles from each
equilibrium model, requiring six fewer equations, was simulation are compared in Figures 6 and 7, respec-
also built to test the assumption of chemical equilibrium tively, and also match well. The most significant
used for the Pro/II simulations. The isobutylene con- discrepancies are between estimates of ethanol concen-
version was found to be only 0.2-0.3% lower for the tration around the middle of the stripping section and
second case using a moderate catalyst loading. In the temperature profile near the top of the column. The
comparing the two process simulators, the SpeedUp variation in predicted ethanol concentration in the
model offers a greater flexibility and the potential to stripping section can be attributed to the assumption
expand the model to investigate dynamic responses, but of an ideal vapor phase in the SpeedUp model as this
it required significantly more time to build and develop assumption was tested using Pro/II. Vapor phase
these models and greater prior knowledge of the system nonideality is low where the ethanol concentration is
compared with Pro/II. less than 10 mol % so that the composition and tem-
perature profiles are generally acceptable over the rest
Simulation Results of the column. The differences in temperature profiles
are likely to be the result of the slightly different vapor
The laboratory column originally used to patent the pressure correlations that were used (Pro/II used built-
catalytic distillation process for MTBE synthesis (Smith, in data, while published Antoine coefficients were used
1980) was used as the basis for the ETBE simulations in the SpeedUp model). The lower isobutylene conver-
presented here. Smiths column contained approxi- sion predicted by the SpeedUp model is at least partially
mately 10 ideal stages, one of which was packed with attributable to the incorporation of the full reaction
catalyst (Abufares and Douglas, 1995). To fit with the kinetics in that model as a satisfactory solution to the
Ind. Eng. Chem. Res., Vol. 36, No. 5, 1997 1861
full kinetic case could not be produced using Pro/II due Table 6 indicates that the presence of some ethanol in
to difficulties in obtaining convergence. The overall the column bottoms product has a negligible impact on
agreement between the two simulators is excellent and the overall properties but the small percentage of
is considered to be an indication of model validity. butylenes (1.8 wt %) significantly reduces the initial
The key blending properties of the reactive column boiling point and flash point and increases the RVP of
bottoms product can be compared with pure ETBE and the mixture. This is a potential disadvantage and may
pure MTBE. These properties were estimated using the necessitate modification of the column operation and/
Pro/II database and are shown in Table 6 (Simulation or design to increase the ETBE product purity. Such
Sciences, 1994). The actual values quoted for pure modifications would include additional separation stages
ETBE and MTBE do not necessarily correspond to and may have the unfortunate side effect of reducing
experimental data but are produced on the same basis the isobutylene conversion.
as the column bottoms properties for comparative
purposes only. The total fuel concentration for the Model Validation and Comparison
ETBE column bottoms product is defined as the ethanol To validate the simulation results without experi-
concentration plus ETBE concentration. The data in mental data, Smiths MTBE column was simulated for
1862 Ind. Eng. Chem. Res., Vol. 36, No. 5, 1997
Figure 6. Temperature profile in an ETBE column. Table 7. Key Simulation Results and Experimental Data
for Smiths MTBE Column
experi-
property Pro/II SpeedUp mental
condenser temp (C) 61.0 64.6 n/a
reaction zone temp (C) 69.0 70.1 71
reboiler temp (C) 128.0 125.7 127
isobutylene conversion (mol %) 91.6 91.6 91
bottoms MTBE purity (mol %) 92.2 92.6 91.9
DIB bottoms concentration (mol %) 1.2 0.9 6.1
condenser duty (kW) 2.14 1.99 n/a
reboiler duty (kW) 2.32 2.16 n/a
Table 9. Effect of Column Overhead Pressure on the Maximum Isobutylene Conversion and Corresponding Ether
Purity in Two ETBE Columns
10 stage-column 30 stage-column
overhead reaction zone maximum ether purity reaction zone maximum ether purity
pressure (kPa) temp (C) conversion (mol %) (wt %) temp (C) conversion (mol %) (wt %)
400 44-53 99.0 97.0 44-50 99.1 97.1
500 51-59 99.2 97.1 51-56 98.9 97.1
600 57-65 99.1 97.1 57-62 98.7 97.3
700 63-70 99.0 97.0 62-67 98.6 97.6
800 68-74 98.8 96.6 67-72 98.6 98.1
900 72-79 98.5 96.4 72-77 98.2 98.3
1000 77-82 98.2 95.9 77-81 98.0 99.1
1100 81-86 97.8 95.3 81-85 97.7 99.9
Figure 8. Effects of the stoichiometric excess of ethanol on Figure 10. Effects of rectification separation on isobutylene
isobutylene conversion. Ether purity and distillate composition conversion and distillate composition from an ETBE column.
from an ETBE column.
Table 11. Effect of Separation Stages on the Maximum Conversion and Corresponding Ether Purity in ETBE Columns
with Rich Isobutylene Feeds
Table 12. Suggested Reactive Distillation Design Strategy for Ether Oxygenates
1. Define values for the key process objectives of hydrocarbon conversion and ether product purity and determine
the composition of the hydrocarbon feed stream.
2. Identify the key components in the rectification and stripping sections and the effects on the composition profiles of
increasing rectification and stripping separation for the specific feed composition to be used.
3. Select a value for the stoichiometric excess of alcohol reactant considering the conversion and purity requirements identified above
(high for maximum conversion; low for maximum purity).
4. Estimate operating pressure based on reaction equilibrium constant at the boiling point of a mixture that is predominantly
hydrocarbon with some ether and alcohol.
5. Perform rigorous simulations with a range of numbers of rectification and stripping stages and a range of reflux ratios.
6. The minimum reflux ratio cannot easily be determined for reactive distillation because of interactions with chemical equilibrium.
Select a combination of rectification stages, stripping stages, and reflux ratio based on process objectives, local utility costs,
and product values. Note that, for some feed compositions and stoichiometric excesses, the rectification and stripping separation
must be optimized to prevent excessive loss of unreacted reactants in both products and that for these cases there
exists a limit to the conversion and ether purity achievable.
7. Where feed rates are relatively low, ensure the reflux ratio selected is sufficient to adequately load a column of 1.2 m
or greater diameter.
8. Determine the number of reactive stages required using simulations with the selected reflux ratio and number of stages.
Add reactive stages until decomposition occurs on the lowest reactive stages and/or there is no incremental benefit
to isobutylene conversion.
9. Select a value of stage efficiency based on conventional distillation and determine the number of actual stages required
for the rectification and stripping sections.
10. Estimate reboiler and condenser duties from simulations based on the above assumptions.
11. Determine column diameter from simulation data for vapor and liquid loadings and column height from stage efficiency
estimates, including appropriate allowances for uncertainties in flooding factor and stage efficiency.
12. If required, adjust the reflux ratio to vary column width and height to produce an acceptable design. Note the impact of
reducing reflux ratio on conversion over and above its effect on separation and the need to optimize separation for some cases.
13. Based on the column configuration defined above, optimize stoichiometric excess, pressure,
and reboiler duty to maximize hydrocarbon conversion and ether product purity using further simulations.
which led to the decomposition of product on the lower conditions of temperature and pressure required for
reactive stages. This is to be expected as the extra adequate reaction. Manipulating the number of strip-
separation occurring with more stages concentrates the ping stages provides a mechanism for controlling the
ether in the lower reactive stages and shifts the chemi- volatility, flash point, and composition of the ether
cal equilibrium back to the reactants. An excessive product.
number of reactive stages can also encourage unwanted Although the separation objectives are clear, in a
side reactions and increase the concentration of impuri- multicomponent system changes in the separation ef-
ties in the ether product. By comparison, the MTBE ficiency tend to adjust composition profiles rather than
case showed no optimum although the benefits of adding produce more clearly defined product splits when in-
a reactive stage became progressively smaller when termediate boiling components (e.g., ethanol) are in-
high numbers of reactive stages were already present,
volved. Consequently, an increase in rectification or
due to the increased likelihood of decomposition on the
stripping separation is not necessarily beneficial for
lower reactive stages.
reaction zone conditions. Too much rectification sepa-
Supplying catalyst on several reactive stages allows ration can result in isobutylene loss via the distillate.
the total catalyst loading in the column to be increased Too much stripping separation can result in ethanol
and may, therefore, extend the time between catalyst being drawn away from the reaction zone and concen-
changeovers/regenerations. However, during the life of
trated just above the reboiler. For some column con-
the catalyst the main reaction site may shift within the
figurations, both rectification and stripping separation
column and change the effective number of rectification
must be optimized. Figures 10 and 11 show examples
and stripping stages and, subsequently, change the
conversion and purity attained. of this phenomenon for a column based on the config-
uration given in Figure 5.
Effects of Separation Stages. Ideally, the rectifi-
cation section of a reactive distillation column for ether The ratio between the number of rectification and
synthesis should (a) remove light inerts from the reac- stripping stages and the feed composition are also
tion zone, (b) prevent loss of ether or alcohol in the important factors that should be considered. If the
distillate, and (c) recycle unreacted reactants (olefin and rectification separation is too great without light inerts
alcohol) to the reaction zone. For an ETBE column, this present to stabilize the reaction conditions, then reboiler
would ideally require a separation between isobutylene operation must be adjusted to compensate the reaction
and the heaviest nonreactive hydrocarbon lighter than conditions and, subsequently, the purity of the ether
isobutylene. In practice, this is almost impossible to product is sacrificed. Tables 10 and 11 show this effect
achieve while maintaining acceptable reaction zone for two different feed compositions: a low isobutylene
conditions. However, the loss of ether in the distillate feed with 15% isobutylene in the hydrocarbon to the
can be minimized without rejecting isobutylene from the primary reactor and a high isobutylene feed derived
column. More rectification stages are required to also from a 50/50 mixture of isobutylene and n-butylenes.
prevent loss of ethanol with the distillate. The number of reactive stages and the reflux ratio were
Ideally, the stripping section should (a) remove ether kept constant for all simulations, and the reboiler duty
from the reaction zone to maintain favorable reaction was optimized with respect to conversion in each case.
conditions, (b) purify the ether product, (c) prevent loss The best combination of rectification and stripping
of reactive olefin with the ether product, and (d) stages is 2 and 16, respectively. Adding rectification
minimize ethanol loss with the ether product. In an stages is beneficial with few stripping stages present
ETBE column, this implies a separation between etha- but detrimental with many. With a high concentration
nol and ETBE, which is largely achievable at the of isobutylene in the hydrocarbon feed, the magnitudes
Ind. Eng. Chem. Res., Vol. 36, No. 5, 1997 1867
of all effects are diminished and the need to optimize
(rather than maximize) separation becomes more likely.
Effects of Reflux Ratio. In a reactive distillation
column, reflux not only enhances separation but recycles
unreacted reactants to the reaction zone and increases
conversion. In an ETBE column, even where the
concentration of isobutylene is high and rectification
separation must be optimized to maximize conversion,
increasing reflux still increases conversion. Therefore,
separation stages and reflux cannot necessarily be used
interchangeably, and high reflux ratios may sometimes
be preferred. Several effects occur as a result of
increasing the reflux ratio: (a) the concentration of
reactants in the distillate is reduced; (b) the reaction
zone temperatures are reduced; (c) the concentration of
ether in the reaction zone is reduced. Each of these
effects contributes to increased conversion. Figure 12
indicates the relationship between reflux ratio and
conversion for the reactive distillation column shown
in Figure 5. Although conversion increases monotoni-
cally with reflux ratio, the ether product purity remains
approximately constant over a wide range of reflux
ratios due to the increasing load on the stripping section
as the amount of ETBE in the column increases.
In an industrial environment, a high reflux ratio is
economically unattractive as it adds to the equipment
size and energy requirements. In conventional distil-
lation, reflux and stages can be traded off against each
other. In reactive distillation, this can also be done but
may incur a conversion penalty. ETBE columns are
susceptible to this penalty, and, depending on the feed
composition, the maximum conversion could be achieved
in a shorter column with high reflux. No significant
conversion penalty exists for MTBE columns, and the
most viable design is a tall column with a low reflux
ratio.
Effects of Reboiler Duty. The reboiler duty is one
of the principal points of control in a distillation column.
In normal distillation, there is a monotonic, albeit
sometimes highly nonlinear, relationship between the
reboiler duty and the principal operating objective
(Kister, 1992). In reactive distillation, the reboiler duty
must be set to ensure sufficient recycle of unreacted,
heavy reactant to the reaction zone without excluding
the light reactant from the reaction zone. If the reboiler Figure 14. Flowchart for reactive distillation design.
duty is too high or too low, conversion, and subsequently
product purity, is reduced. Figure 13 indicates the effect tial of the column and increases the energy required for
of reboiler duty on conversion and ether purity and separation. Split feeding to each of the reactive stages
clearly shows the presence of an optimum duty. is possible but creates a high concentration of ETBE at
Effects of Other Operating and Design Vari- the top of the reactive section (leading to decomposition
ables. The extent of reaction performed prior to the toward the bottoms of the reactive section) and, again,
reactive distillation column should simply be an eco- increases the energy required for separation.
nomic optimization between the relative costs of the two The feed temperature has only a very slight effect on
operations. Initially, it is easy to produce ether in a the operation of either an ETBE or MTBE reactive
simple tubular reactor with some form of temperature distillation column. A cooler feed has a mildly beneficial
control to prevent the exothermicity of the reaction from effect on the reaction zone temperature, but this can
heating the reactor contents and, eventually, stopping be offset by a shift in phase equilibrium. To minimize
the reaction due to equilibrium considerations. How- equipment requirements, the feed should be supplied
ever, at higher conversions, very low reaction temper- at its process temperature, which is likely to be close to
atures are required with a subsequent high demand for the reactor temperature (80-90 C). If intermediate
catalyst due to the low reaction rates. Under these storage is required for any reason, an ambient feed is
conditions, reactive distillation becomes more economi- also acceptable. Neither feed heaters or feed coolers are
cal. required for a satisfactory process design.
The optimum feed point to the reactive distillation
column is just below the reactive section to avoid the Process Design Method
possibility of ETBE decomposition with the relatively
ETBE-rich product from the reactor. Feeding too far Simulations should form a key part of reactive distil-
below the reactive section reduces the stripping poten- lation process design, more so than in conventional
1868 Ind. Eng. Chem. Res., Vol. 36, No. 5, 1997