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HAZOP study of a fixed bed reactor for MTBE synthesis using a dynamic
approach

Article  in  Chemical Papers- Slovak Academy of Sciences · February 2008


DOI: 10.2478/s11696-007-0078-4

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Chemical Papers 62 (1) 51–57 (2008)
DOI: 10.2478/s11696-007-0078-4

ORIGINAL PAPER

HAZOP study of a fixed bed reactor for MTBE synthesis using


a dynamic approach‡

Juraj Labovský, Zuzana Švandová, Jozef Markoš, Ľudovít Jelemenský*

Institute of Chemical and Environmental Engineering, Faculty of Chemical and Food Technology,
Slovak University of Technology, Radlinského 9, 812 37 Bratislava, Slovak Republic

Received 13 April 2007; Revised 6 August 2007; Accepted 7 August 2007

A methodology for hazard investigation based on the integration of a mathematical model ap-
proach into hazard and operability analysis is presented. This approach is based on mathematical
modelling of a process unit where both steady-state analysis, including analysis of the steady states
multiplicity and stability, and dynamic simulation are used. The dynamic simulation serves for the
investigation of consequences of failures of the main controlled parameters, i.e. inlet temperature,
feed temperature and feed composition. This simulation is also very useful for the determination
of the influence of failure duration on the reactor behaviour. On the other hand, the steady state
simulation can predict the reactor behaviour in a wide range of failure magnitude and determine
the parametric zones, where shifting from one steady state to another one may occur. A fixed bed
reactor for methyl tertiary-butyl ether synthesis was chosen to identify potential hazard and oper-
ational problems of a real process.
c 2008 Institute of Chemistry, Slovak Academy of Sciences

Keywords: fixed-bed reactor, safety analysis, HAZOP, mathematical modelling, nonlinear dynam-
ics

Introduction The second drawback is that HAZOP requires many


hours of work of a team of experienced engineers and
Hazard and operability (HAZOP) analysis is one of it is not easy to record the engineering reasoning,
the best and most rigorous techniques for identifica- basic input information, or the results. Therefore is
tion of hazard and operability problems in a chemical the application of the HAZOP technique to a detailed
plant. The HAZOP procedure formally examines all chemical plant design a complex and time consuming
equipment step by step as well as deviations from its task. Both these drawbacks can be reduced by inte-
normal operation conditions, and considers what fail- gration of a model approach into the HAZOP. In the
ures can appear. A HAZOP report includes all the past 20 years, a lot of research effort has been ded-
deviations, their causes, consequences on the equip- icated to the development of computer-based analy-
ment performance, analysis of these consequences, im- sis methods which can be roughly divided into two
plemented protection (active and/or passive), and the main groups: expert approach and model-based ap-
resulting suggestions. It can be successfully applied proach.
not only to existing plants, but also to new designed A typical expert approach to a HAZOP study,
technologies and equipment. On the other hand, two which usually comprises three or four knowledge bases
essential drawbacks of the HAZOP study exist. The and an inference engine, was proposed by Shimada et
primary drawback is related to the possibility that al. (1996). Other expert approaches with additional fa-
hazards and operability problems may be overlooked. cilities were developed by Göring and Schecker (1993),

*Corresponding author, e-mail: ludovit.jelemensky@stuba.sk.


‡ Presented at the 34th International Conference of the Slovak Society of Chemical Engineering, Tatranské Matliare,
21–25 May 2007.
52 J. Labovský et al./Chemical Papers 62 (1) 51–57 (2008)

Weatherill and Cameron (1989), and Mushtaq and The dynamic analysis serves for analysing the time
Chung (2000). and trajectory of shifting from one steady state to an-
In contrast to the knowledge-based approach, the other one due to a failure deviation. It is also very
model-based approach has gained more importance in useful for the investigation of dynamic behaviour of
recent years. It is based on the description of a chem- the reactor with respect to the time duration of the
ical plant using a mathematical model. This proce- failure. Finally, the results of safety analysis were re-
dure holds the promise of reducing the time and effort produced and utilised in HAZOP studies. The contri-
required in HAZOP significantly, making the study bution of this work is to demonstrate that combination
more smooth and detailed and minimising the influ- of a standard identification method, like HAZOP, with
ence of human factors. Parmar and Lees (1987) at- mathematical modelling has the potential to become
tempted, as the first, to automate the HAZOP study a very practical and robust tool for the reactor safety
using qualitative propagation equations for the initi- analysis.
ation and termination events. A hybrid model pre- However, it is important to point out that the in-
sented in (Dimitriadis et al., 1996) uses a continu- vestigation of multiple steady states for the chosen sys-
ous description of differential equations supplemented tem is affected by the selection of an adequate math-
with discrete controller actions. Graf and Schmidt- ematical model and is strongly dependent on the pa-
Traub (2001) used a combination of expert and model- rameters which describe physical properties, kinetics,
based approaches with the aim to take advantage of mass and heat transfers, etc.
qualitative modelling of chemical plants and methods
for logical controller verification. Other model-based
approaches were published by Eizenberg et al., (2006) Case study
and Srinivasan et al., (1997).
The model-based approach with a set of mathe- The presented safety analysis methodology is
matical equations derived from the quantitative de- demonstrated on the case study of a fixed bed reactor
scription of a chemical plant seems to be the most for the methyl tertiary-butyl ether (MTBE) synthesis
straightforward procedure. Usually, the HAZOP anal- according to the following reaction scheme
ysis does not consider the duration and amplitude of
the deviations generated during the operation. How- CH3 OH + (CH3 )2 C = CH2 ⇔ (CH3 )3 COCH3 (1)
ever, what exactly does the deviation ‘less flow’ mean:
90 % or 20% of the usual operation value? Does the where isobutene (IB) reacts with methanol (MeOH) to
deviation occur as an immediate (step) decrease of the form MTBE in a reversible exothermic reaction. The
flow lasting 10 min or more, or is it only an impulse? reaction is catalysed by a strong acid ion-exchange
Is this decrease continuous at some rate? Answers to resin. The reaction rate equation and its parameters
these questions can be obtained using an appropriate are given by Rehfinger and Hoffmann (1990). Possi-
mathematical model. In such a model, the extent of ble side-reactions were ignored. Reaction rates were
the deviations can be easily incorporated and possi- calculated assuming a pseudo-homogenous model.
ble consequences investigated (Labovský et al., 2006, The reaction is usually carried out in the presence
Švandová et al., 2005a, 2005b). of inert components. These components result from
In the presented paper, the model-based approach upstream processing where isobutene is produced. In
including the HAZOP methodology was applied for our case study, 1-butene (1-B) was used as the inert.
a fixed bed reactor for MTBE synthesis. In the first Physical-chemical properties of all pure components
step, a mathematical model of the fixed bed reactor were taken from the HYSYS 2.1 database.
was formulated. In the next step, a safety analysis The adiabatic fixed bed reactor (Fig. 1) was filled
using the steady state and dynamic approaches was with a catalyst (ion-exchange resin) and the design
performed (Molnár et al., 2005). operation parameters were set in the following way:
The steady state approach was used for the anal- – temperature of the fresh feed (stream 3) to 302 K,
ysis of the system stability and the locus of operating – molar flow rate of fresh methanol into the fixed
conditions. It was focused on identification of the phe- bed reactor (stream 1) to the value of 96 kmol h−1 ,
nomenon of multiple steady states and regions where – molar flow rate of the mixture of IB (18.7 %) and
oscillation may occur. The selected reaction system 1-B (81.3 %) into the fixed bed reactor (stream 2) to
(MTBE production) is known for its ability to switch the value of 460 kmol h−1 ,
between different steady states. A detailed descrip- – the mixture of stream 1 and stream 2 was pre-
tion of the multiple steady states in MTBE produc- heated in the heat exchanger to the temperature of
tion units can be found in several articles (Chen et 302 K,
al., 2002, Güttinger & Morari, 1997, Mohl et al., 1999, – the fixed bed reactor reflux (stream 4) to the
Švandová, et al., 2006). Sustained oscillations in a re- value of 0.5,
active distillation column for the production of MTBE – the fixed bed reactor pressure to the value of 1940
can be found in the paper (Schrans et al., 1996). kPa.
J. Labovský et al./Chemical Papers 62 (1) 51–57 (2008) 53
NI
 NI
 dT
wF CiF Cpi T F = w Ci Cpi T − λEZ (5)
i=1 i=1
dz
and for z = L,
dCi dT
=0 =0 (6)
dz dz
where wF is the superficial fluid velocity on the reactor
inlet, CiF concentration of component i in the feed, T F
feed temperature, and L reactor length.
The initial conditions are as follows

t=0 Ci = Ci0 T = T0 (7)

The mathematical model for the description of the


fixed bed reactor behaviour consisted of a set of six
partial differential equations (PDE) (five mass bal-
Fig. 1. Schematic flow diagram of the MTBE synthesis reactor. ances of the individual species plus an enthalpy bal-
ance). These were solved by the in-house software
DYNHAZ based on the C++ code, which uses:
– the length of the reactor was 10 m and the di- – the method of finite differences – for discretiza-
ameter 0.9 m. tion of the set of PDE in axial coordinate. In all pre-
sented results 100 discretization points were used. The
Mathematical models and computational meth- influence of the number of discretization points was
ods first tested by changing from 20 to 5000 points,
– backward difference formulas up to the 5th or-
Due to mild temperature profiles and negligi- der with a step controller for the time integration of
ble differences (of both, temperature and concentra- (PDE) implicit schemes (Boyce & DiPrima, 2000),
tion) between fluid bulk and solid catalyst, a pseudo- – LAPACK library for solving sparse linear equa-
homogeneous model was chosen for the description of tions.
the reactor behaviour. This model, which describes We used our implementation of the DERRPAR al-
only the axial profile of the radially averaged temper- gorithm (Kubíček, 1976) for finding the dependence
atures and concentrations, reads of the model equations in steady state solution on
a parameter. For the stability and bifurcation points
NR

∂Ci ∂Ci ∂ 2 Ci identification, methods described by Holodniok et al.
ε +w − DEZ = − νji ξ˙Vj (Ci , T ) (2) (1986) were used.
∂t ∂z ∂z 2 j=1

Results and discussion


NI
∂T ∂T ∂2T During a HAZOP study, possible deviations are
Cp ρ +w Ci Cpi − λEZ 2 =
∂t i=1
∂z ∂z generated by rigorous questioning, prompted by a se-
NR
ries of standard “guidewords” applied to the intended
 4UW design (Kletz, 1999). After the guideword is matched
= −∆R Hj ξ˙Vj (Ci , T ) − (T − TC ) (3)
j=1
dR with a parameter, a deviation is generated. The next
step in the HAZOP study is to look for potential con-
where Ci is the concentration of component i in the sequences. At this moment, the application of mathe-
fluid phase, T is the fluid temperature, ε porosity, Cp matical modelling (steady state analysis and dynamic
medium heat capacity of the bed, ρ medium density analysis) is useful in order to find adequate conse-
of the bed, w superficial fluid velocity, Cpi mole heat quences. Steady state solutions over a large interval
capacity of the component i, DEZ axial dispersion co- of operating parameters are obtained by a continua-
efficient, λEZ axial heat conductivity, UW overall heat tion algorithm. This algorithm is able to identify the
transfer coefficient, dR reactor diameter, TC cooling quality of a steady state solution (stability analysis)
medium temperature, z axial position in the reactor, t and multiple steady states (Kubíček, 1976). The infor-
time, νji are stoichiometric coefficients of the i-th com- mation about trajectories and conditions able to shift
the system from one steady state to another can be
ponent in j-th reaction, ξ˙Vj rate of chemical reaction,
obtained by dynamic analysis.
∆R Hj reaction enthalpy. The boundary conditions are
For the proposed safety analysis methodology it
for z = 0
dCi is necessary to investigate all deviations of all oper-
wF CiF = wCi − DEZ (4) ating parameters; i.e. temperature, composition, and
dz
54 J. Labovský et al./Chemical Papers 62 (1) 51–57 (2008)

1.0 0.920 310


0.9 308
0.8 306
0.915
0.7 a 304

T /K
0.6
302

F
0.910
XIB

0.5

XIB
300
0.4
298
0.3 0.905
0.2 296

0.1 294
0.900
0.0 0 2 4 6 8 10 12 14
280 285 290 295 300 305 310 315 320
F
time / h
T /K

Fig. 2. Solution diagram for the reactor feed inlet temperature


as the continuation parameter. ◦
limit points, Hopf • 0.95
310
bifurcation point, desired operating point, solid lines 308
0.90
– stable steady states, dashed line – unstable steady 306
0.85
state. b
0.80 304

T /K
0.75 302

XIB

F
0.70 300
flow rate of all feed streams into the system and also 0.65 298
of the recirculated stream, as well as all deviations of 0.60
296
their combinations and their consequences. This com- 0.55
294
plex task was, however, out of the range of this paper. 0.50
0 2 4 6 8 10 12 14
Therefore, only the temperature of fresh feed into the time / h
fixed bed reactor (stream 3) is analysed and discussed
here in detail. The rest of the deviations is briefly sum-
marised at the end of this chapter in the form of con- 1.0 310
tinuation diagrams. 308
The main monitored output parameter is the 0.8
306
isobutene conversion (XIB ) in the fixed bed reactor c 304
outlet. The fixed bed reactor conversion of isobutene

T /K
0.6
302

F
is defined in our case-study as the difference of the
XIB

0.4 300
molar feed flow rate of isobutene into the fixed bed re-
298
actor (stream 5) and the reactor outlet molar flow rate
0.2
of isobutene (stream 6) divided by the molar feed flow 296

rate of isobutene into the fixed bed reactor (stream 5). 0.0
294
0 2 4 6 8 10 12 14
time / h
Steady state analysis
Fig. 3. The effect of the step change of the reactor feed inlet
A steady state solution diagram of the isobutene temperature to the values 299 K (a), 297.5 K (b), and
conversion in the reactor as a function of the feed in- 295 K (c) (solid lines – IB conversion at the reactor out-
let temperature (stream 1) is depicted in Fig. 2. This let XIB , dashed lines – reactor feed inlet temperature
(T F )).
solution diagram (Fig. 2) has a typical ‘S’ profile and
the maximum number of steady states for some values
of the feed temperature is equal to three. The desired
operating point (Fig. 2, upper steady state with the regime characterised by sustained oscillations. When
temperature of 302 K) is located inside the region of a further decrease of the feed inlet temperature to the
multiplicity. Thus, branch switching may occur dur- value of 297 K occurred, a new steady state, on the
ing the failure in the reactor inlet temperature. Due lower stable steady state branch characterised by a
to a close location of the reactor operation point to the very low conversion, was reached. From these results
region of multiple steady states and regions of oscilla- follows, that the feed inlet temperature has a signifi-
tion regimes, the reactor is parametrically sensitive in cant influence on the isobutene conversion in the fixed
the context of safe operation. bed reactor.
The decrease in the feed inlet temperature caused
a slight growth of the isobutene conversion which fol- Dynamic Analysis
lows the upper stable steady state branch up to the
value depicted by the Hopf bifurcation point. After When a step change of the inlet temperature of the
crossing this point, the reactor entered the dynamic feed into the fixed bed reactor from the designed op-
J. Labovský et al./Chemical Papers 62 (1) 51–57 (2008) 55

0.93 325

0.92 320
0.91
a
315
0.90

T /K
310

XIB
0.89

F
305
0.88
300
0.87

0.86 295

0.85 290
0 2 4 6 8
time / h

Fig. 4. The temperature profile of the fluid phase in the reactor


during oscillations as a function of the reactor length
1.0 325
and time.
0.9 320
0.8 b 315
0.7
eration value of 302 K to 299 K was considered, a new 310

T /K
XIB
0.6

F
stable steady state was achieved (Fig. 3a). This steady 305
0.5
state corresponds with the steady state depicted in 300
0.4
the solution diagram (Fig. 2). The solution diagram of
295
isobutene conversion in a fixed bed reactor (Fig. 3a) 0.3

indicates that at this moment the reactor works in 0.2


0 2 4 6 8
290

the steady state, which is localised on the upper sta- time / h


ble steady state branch. After returning the feed tem-
perature to the designed operation value at the time
of 10 h (Fig. 3a), the system returned to the original
steady state without any additional loss of the MTBE 1.0 325
production. 0.9
320
When the feed inlet temperature was changed from 0.8
302 K to 297.5 K, the reactor crossed the Hopf bifur- c 315
0.7
cation point. Fig. 3b shows the dynamic behaviour of

T /K
310
XIB

0.6

F
the reactor in this case. The originally stable branch 0.5 305
entered a dynamic regime characterised by sustained 0.4
300
oscillations. The maximum difference between the 0.3
higher and the lower isobutene conversion was 0.25. 0.2
295

The temperature profile during several periods of sus- 0.1 290


0 2 4 6 8
tained oscillations is shown in Fig. 4. Figs. 3b and 4 time / h
show that the period of the oscillations was approxi-
mately 17 min. After returning the feed temperature Fig. 5. Evolution diagram of a failure of the reactor inlet tem-
to the designed operation value (Fig. 3b), the reactor perature (step change of the reactor feed inlet tempera-
ture to the value 295 K) for 15 min (a), 45 min (b) and
became stabilised in the original steady state. The op- 60 min (c) (solid lines – IB conversion at the reactor
eration of the reactor in a region of sustained oscilla- outlet XIB , dashed lines – reactor feed inlet tempera-
tions would have an unwanted effect on the equipment ture (T F )).
connected to the reactor outlet.
Finally, when the feed inlet temperature dropped
below the value of 295 K, the reactor switched to the In many cases, the duration of the failure may dra-
lower steady state. The lower steady state is char- matically affect the response although this aspect is
acterised by a very low value of the isobutene con- not usually investigated during a “typical” HAZOP
version. When the feed inlet temperature reached the procedure. Thus, for the next simulation, the same
designed operation value again (Fig. 3c), the reactor deviation – higher reactor feed inlet temperature was
continued operating in the lower steady state and a taken into account. The failure was simulated as a
significant loss of the MTBE production occurred. To step change from the operating temperature of 302 K
switch the reactor to the upper steady state, the feed to the value of 295 K with varying failure durations
inlet temperature had to be increased up to 303.5 K (Figs. 5a–5c). In the first case, the failure duration
when the limit point on the lower steady state was was set to the value of 15 min (Fig. 5a). After return-
crossed (Fig. 3). ing the feed inlet temperature to the designed opera-
56 J. Labovský et al./Chemical Papers 62 (1) 51–57 (2008)

1.0
1.0
0.9
0.9 b
0.8
0.8 a 0.7
0.7

XIB
0.6
0.6
XIB

0.5
0.5
0.4 0.4

0.3 0.3

0.2 0.2
0.1 0.1
0.0 0.0
60 80 100 120 140 160 180 200 100 200 300 400 500 600 700 800
-1 -1
FMEOH /(kmol h ) Fbutenes /(kmol h )

1.0 1.0

0.9 0.9

0.8 c 0.8 d
0.7
XIB 0.7
0.6
XIB

0.6
0.5 0.5

0.4 0.4

0.3 0.3

0.2 0.2

0.1 0.1

0.0 0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 0.06 0.09 0.12 0.15 0.18 0.21 0.24 0.27 0.30

Rx xIB

Fig. 6. Solution diagram for the continuation parameter - fresh methanol feed flow (FMEOH ) (a), butenes feed flow (Fbutenes ) (b),
reactor reflux Rx (c), mole fraction of IB in butanes feed (xIB ) (d). ◦
limit points; •
Hopf bifurcation point; desired
operating point, solid lines – stable steady states, dashed line – unstable steady state.

tion value, the reactor became stabilised in the original Hopf bifurcation point at 122 kmol h−1 (feed flow
steady state, without any significant MTBE produc- by 35 % higher than the designed value) or the limit
tion loss. Fig. 5b shows the effect of a 45 min duration point at 144 kmol h−1 (by 50 % higher than the de-
of the failure. In this case, the return to the original signed value). A different situation occurs in the case
steady state took more than 5 h and the losses of the of butenes. The designed molar flow rate of butenes is
MTBE production were considerable. Finally, Fig. 5c 460 kmol h−1 (marked with an empty square, Fig. 6b)
clearly shows that in the case of a failure longer than and is located in the area of multiple steady states.
1 h, the reactor became stabilised in the lower steady If the feed flow rate of butenes increases, the reactor
state characteristic by a very low isobutene conversion. will follow an upper stable steady state branch and the
Moreover, the reactor stayed in the lower steady state conversion of isobutenes will slowly decrease. However,
in spite of the feed inlet temperature being returned the possibility of shifting to the lower steady state is
to the original operating value. To return the produc- quite impossible due to the transport limitations. This
tion of MTBE to the designed value, a new start up situation could theoretically occur if the butenes feed
of the reactor was required. flow rate increased to the value of 900 kmol h−1 , which
is practically impossible.
Analysis of remaining parameters Another investigated parameter was the reactor re-
flux. In the described reactor, the reflux served for
Methanol and butenes feed flow rates are the ba- adjusting optimal temperature and concentration con-
sic regulation parameters which affect the reactor be- ditions in the reacting zone. The designed value was
haviour significantly. Fig. 6a shows the continuation 0.5. Fig. 6c shows that a decrease of the reactor reflux
diagram for the feed flow rate of methanol. This fig- causes a slight reduction of the reactor conversion. On
ure reveals that a failure in the methanol feed flow the other hand, if the reflux crosses the value of 0.725,
rate may result in switching to lower steady state or the reactor shifts to the lower steady state and the
to formation of oscillations if its value exceeds the conversion decreases significantly. The last analysed
J. Labovský et al./Chemical Papers 62 (1) 51–57 (2008) 57

parameter was the composition of the butenes feed. Mohl, K.-D., Kienle, A., Gilles, E.-D., Rapmund, P., Sund-
The considered content of isobutene was 18.7 %. The macher, K., & Hoffmann, U. (1999). Steady-state multiplic-
operating point lies very close to the bifurcation point. ities in reactive distillation columns for the production of
fuel ethers MTBE and TAME: theoretical analysis and ex-
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