دانلود کتاب Multiphase Reactors: Reaction Engineering Concepts, Selection, and Industrial Applications

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Cover
Half Title
Also of Interest
Multiphase Reactors: Reaction Engineering Concepts, Selection, and Industrial Applications
Copyright
Contents
Preface
Some personal reflections by Jan
Some personal reflections by René
So here it is!
Acknowledgments
About the authors
Part A: Multiphase reactors: chemical reaction engineering
1. Introduction
1.1 Book introduction
1.2 A reaction engineer meets an electronic engineer
1.3 Levenspiel’s genius Problem 1.1
1.4 A short history of chemical reaction engineering
1.4.1 Introduction
1.4.2 Birth of chemical reaction engineering
1.4.3 Founding fathers of CRE
1.4.4 CRE as a language game
1.4.5 Dimensionless numbers in CRE: the persons behind the number
1.5 Reaction engineering as introduction to process design
1.6 Exercises
1.7 Takeaway learning points
References
2. Overview of multiphase reactors
2.1 Introduction
2.2 Two-phase G-S reactors
2.2.1 Fixed bed reactors
2.2.1.1 Exercise for experienced chemical engineers
2.2.2 Gas–solid fluid bed reactors
2.2.2.1 Introduction
2.2.2.2 Fluidization behavior categories
2.2.2.3 Class A fluidization powder behavior
2.2.2.4 Class B fluidization powder behavior
2.2.2.5 Class C fluidization powder behavior
2.2.2.6 Class D fluidization powder behavior
2.2.2.7 Fluid bed reactor types
2.2.2.8 Bubbling fluid reactors
2.2.2.9 Bubbling fluid beds of classes B and D
2.2.2.10 Circulating fluid bed
2.3 Two-phase G-L and L-L reactors
2.3.1 Gas–liquid bubble column reactors
2.3.1.1 Main characteristics
2.3.2 Continuous and batchwise operation
2.3.2.1 Main characteristics
2.3.2.2 Industrial applications
2.3.3 Mechanically stirred gas–liquid reactors
2.3.3.1 Main characteristics
2.3.3.2 Commercial-scale applications
2.3.4 Gas–liquid spray tower reactor and Venturi washer
2.3.4.1 Main characteristics
2.3.4.2 Commercial-scale applications
2.3.5 Gas–liquid packed bed reactor
2.3.5.1 Warning on column design for effluent gas treatment
2.3.6 Two-phase L-L reactors
2.3.6.1 Introduction to liquid–liquid reactors
2.3.6.2 Phases and flows and residence time distribution
2.3.6.3 Fluid agitation and mass transfer
2.3.6.4 Heat transfer
2.3.6.5 Batchwise and continuous operation options
2.3.6.6 Commercial-scale application features
2.4 Three-phase gas–liquid–solid reactors
2.4.1 Slurry reactors (liquid is continuous phase)
2.4.1.1 Three-phase bubble column and fluid bed reactors
2.4.1.2 Three-phase mechanically stirred reactors
2.4.1.3 Three-phase Venturi jet loop reactor
2.4.2 Trickle-bed three-phase reactor with gas as the continuous phase
2.4.2.1 Main characteristics
2.4.2.2 Industrial applications
2.5 Reactors with heat control
2.5.1 Introduction of reactors with heat control
2.5.2 Adiabatic heat control
2.5.3 Multitubular fixed bed reactor
2.5.4 Wall (jacket) heat exchange
2.5.5 Heat transfer by evaporation and a condenser
2.5.6 Heat transfer by coils inside the reactor
2.5.7 Microwaves heating
2.5.8 Electrical heating
2.6 Exercises
2.6.1 Industrial exercise 1: reactor types for PVC depolymerization start-up company
2.6.2 Industrial exercise 2: reactor type options for precipitation reaction
2.7 Takeaway learning points
References
Part B: Fundamentals
3. Scale-independent basics relevant for all reactors
3.1 Reaction stoichiometry and kinetics
3.1.1 Introduction
3.1.2 Reaction stoichiometry
3.1.3 Definition of reaction rate and kinetics
3.1.4 Reaction rate equations
3.1.4.1 Reaction order
3.1.4.2 Michaelis–Menten kinetics
3.1.4.3 Monod kinetics
3.1.4.4 Langmuir–Hinshelwood kinetics
3.1.4.5 First order in A and B
3.1.4.6 Reactor performance and reaction rate expressions
3.1.5 Experimental kinetics determination
3.2 Reactor performance definitions
3.2.1 Process and reactor boundaries
3.2.2 Reactor conversion
3.2.3 Integral versus differential reactor selectivity
3.2.4 Reactor production capacity
3.2.5 Process conversion and yield
3.2.6 Definitions of terms: space velocity, GHSV, WHSV, LHSV
3.2.7 Residence time and space time
3.2.8 Limiting reactant
3.3 Physical properties
3.3.1 Reaction medium density modeling
3.3.2 Physical transport properties
3.4 Reaction enthalpy
3.5 Reaction runaway behavior
3.5.1 Example from Jan’s experience
3.6 Exercises
3.7 Takeaway learning points
References
List of symbols
4. Residence time distribution and mixing theory
4.1 Residence time distribution theory
4.2 The plug flow reactor concept: PFR
4.3 The perfectly backmixed reactor: CSTR or CISTR
4.4 Intermediate macromixing
4.4.1 Tanks-in-series concept
4.4.2 Axial dispersion concept
4.5 Residence time distribution effects on conversion/selectivity
4.6 Micromixing, earliness of mixing and segregation
4.6.1 Earliness of mixing
4.6.2 Degree of segregation
4.6.3 Takeaway messages: macro- and micromixing
4.6.4 Application of RTD theory to ideal reactor type selection
4.7 RTD of real reactors
4.7.1 RTD of two- and three-phase fixed bed reactors
4.7.1.1 Wall flow and its prevention
4.7.1.2 Feed distribution lab-scale fixed beds
4.7.1.3 Feed distribution commercial-scale fixed beds
4.7.1.4 Origin of trickle-bed catalytic reactor, modeling, and scale-up
4.7.2 Residence time distribution G-L bubble columns
4.7.2.1 Liquid-phase residence time distribution
4.7.2.2 Horizontal bubble columns
4.7.3 Bubbling fluid bed residence time distributions
4.7.3.1 Solid residence time distribution
4.7.3.2 Gas phase residence time distribution
4.7.4 Residence time distribution G-L-S bubble columns and fluid beds
4.8 Exercises
4.8.1 Industrial exercise 1: RTD of a new reactor for a new process
4.8.2 Industrial exercise 2: fresh coconut drying in a fluid bed
4.8.3 Industrial exercise 3: catalyst deactivation in a three-phase slurry reactor
4.9 Takeaway learning points
References
5. Inter- and intraphase mass and heat transfer
5.1 Introduction to mass transfer
5.1.1 Mass transfer from gas phase to liquid phase to porous solid phase
5.2 Concept of transfer coefficients
5.3 Multiphase mass and heat transfer: inter- and intraphase effects
5.3.1 Exercise: mass transfer in series and/or in parallel
5.4 Mass transfer with reaction in gas–liquid reactors
5.4.1 Introduction
5.4.2 Chemical enhancement and the Hatta number
5.5 Mass transfer in heterogeneous catalysis
5.5.1 Introduction
5.5.2 Diffusion in porous catalysts
5.5.2.1 Effective diffusion
5.5.3 Consequences for catalyst performance
5.5.4 Effect on catalyst activity: Thiele modulus and the concept of effectiveness factor
5.5.5 Effect on apparent reaction orders
5.5.6 Effect on apparent activation energy
5.5.7 Effect of particle size and fluid velocity
5.5.8 Pore diffusion and catalyst design in terms of size and shapes
5.5.9 Example: the periodic table of the trilobes
5.6 Exercises
5.6.1 Industrial exercise 1: catalyst particle size and shape for the dehydration of MPC
5.6.2 Industrial exercise 2: diffusion and deactivation for bimodal pore size distribution
5.7 Takeaway learning points
References
6. Quantification of mass transfer in G-L(-S) reactors
6.1 Introduction
6.2 Mass transfer coefficients and Sherwood numbers
6.3 Quantified mass transfer two- and three-phase bubble columns
6.3.1 Gas–liquid mass transfer in horizontal bubble columns
6.3.2 Liquid–solid mass transfer in three-phase bubble columns
6.3.3 Shear rate distribution commercial scale on bubbles and droplet size distribution
6.3.4 Particle (catalyst) breakage and attrition
6.4 G-L-S mass transfer in trickle-bed reactors
6.5 Process intensification methods for interface transfer
6.5.1 Rotating reactors
6.5.2 Other process intensified reactors
6.6 Exercises
6.7 Takeaway learning points
References
7. Heat management
7.1 Introduction
7.2 Theory nonisothermal behavior reactors
7.2.1 Nonisothermal backmixed reactor
7.2.2 Nonisothermal tubular reactor
7.2.3 Reactor design to avoid temperature runaway
7.2.3.1 Adiabatic reactors
7.2.3.2 Wall-cooled/heated multitubular two- and three-phase fixed bed reactors
7.2.4 Quantified heat transfer for two- and three-phase slurry and fluid bed reactors
7.2.4.1 Introduction
7.2.4.2 Quantified heat transfer two- and three-phase bubble columns
7.2.4.3 Bubble column two- and three-phase heat transfer
7.2.4.4 Gas–solid fluid bed heat transfer
7.2.5 Mechanically stirred reactor heat transfer
7.3 Reactor operation and dynamic behavior
7.4 Exercises
7.5 Takeaway learning points
References
8. Multiphase reactor modeling
8.1 Introduction
8.2 Models for and two- and three-phase fixed bed reactors
8.2.1 Adiabatic versus nonadiabatic
8.2.2 Pseudo-homogeneous models
8.2.3 Heterogeneous models
8.2.4 CFD models
8.3 Models for trickle-bed reactors
8.3.1 Co-current trickle-bed
8.3.2 Adiabatic trickle-bed
8.3.3 Multitubular heat exchange trickle-bed
8.3.4 Countercurrent trickle-bed flow
8.4 Models for bubble columns
8.4.1 Models for G/L bubble columns
8.4.2 CFD models for G/L/S (slurry) bubble columns
8.5 Models for fluid beds
8.5.1 Models for G/S fluid beds
8.5.2 CFD models for L/S fluid beds
8.5.3 CFD models for three-phase mechanically stirred fed-batch reactors
8.6 Exercises
8.6.1 Industrial exercise 1: trickle-bed reactor
8.7 Takeaway learning points
References
Part C: Stage-gate innovation methods
9. Stage-gate innovation methods
9.1 Introduction
9.2 Innovation stages overview
9.2.1 Discovery stage
9.2.2 Concept stage
9.2.3 Feasibility stage
9.2.4 Development stage
9.2.5 Engineering procurement construction stage
9.2.6 Operation stage
9.2.7 Abandon stage
9.3 Takeaway learning points
References
References
10. Multiphase reactor selection
10.1 Introduction
10.2 Critical review some academic methods reactor selection
10.2.1 Reactor family tree selection
10.2.2 Three-level multiphase reactor selection method
10.3 Reactor selection method when scale-up risk is low for reactor types considered
10.4 Introduction to industrial reactor selection and its practice
10.4.1 Introduction
10.4.2 Ideation stage reactor type selection
10.4.2.1 Ideation stage reactor families to choose from
10.4.3 The power of reactor selection in the ideation stage: Shell shale fluid bed case
10.5 Reactor type selection in the various innovation stages
10.5.1 Concept phase reactor selection
10.5.1.1 Stepwise selection
10.5.1.2 Industry cases with large-scale solid processing
10.5.1.3 Reactor selection criteria in concept stage
10.5.1.3.1 Selection criteria
10.5.2 Feasibility stage reactor selection
10.5.2.1 Introduction
10.5.2.2 Reactor selection by value of information analysis
10.5.2.3 Example case reactor selection
10.5.3 Development stage front-end engineering design reactor selection
10.5.4 Engineering procurement construction (EPC) stage reactor selection
10.6 Exercises
10.6.1 Industrial exercise 1: reactor type selection in ideation stage
10.6.2 Industrial exercise 2: reactor selection concept stage
10.6.3 Industrial exercise 3: reactor family-type selection ideation stage
10.7 Takeaway learning points
11 New reaction systems through all innovation stages
11.1 Introduction
11.2 Ideation stage (also called discovery stage, or early research stage)
11.2.1 Ideation stage design
11.2.2 Ideation stage modeling
11.2.3 Ideation stage proof of principle experiments
11.3 Concept stage (also called research stage)
11.3.1 Concept design
11.3.1.1 Optimization target for concept design
11.3.1.2 Reactor concept design in relation to process concept design
11.3.1.3 Feed composition design
11.3.1.4 Single-pass reactor conversion design
11.3.1.5 Residence time distribution design
11.3.1.6 Product removal from reaction phase
11.3.1.7 Reactor conditions, pressure, and temperature selection for highest selectivity
11.3.1.8 Operation mode batch versus continuous
11.3.1.9 Process intensification as a concept design method
11.3.2 Concept modeling
11.3.3 Experimental validation
11.4 Feasibility stage design (also called first part of development
11.4.1 Introduction
11.4.2 Reactor development plan overview
11.4.3 Critical performance factors for commercial-scale reactors
11.4.3.1 Feed distribution
11.4.3.2 Feed distribution fixed bed reactors
11.4.3.3 Feed distribution fluid bed and slurry reactors
11.4.3.4 Closing remark on feed distribution
11.4.3.5 Residence time distribution and mixing
11.4.3.6 Mass transfer
11.4.3.7 Heat management and transfer
11.4.3.8 Critical performance factors for easy to scale up reactor types
11.4.3.9 Critical performance factor for hard to scale up reactor types
11.4.4 Reactor scale-up methods and applications
11.4.4.1 Brute force scale-up method
11.4.4.2 Dimensionless number scale-up method
11.4.4.3 Dimensional analysis and scale-up method
11.4.4.4 Model-based scale-up method
11.4.4.5 Empirical scale-up method
11.4.4.6 Hybrid empirical-model-based scale-up method
11.4.4.7 No-scale-up method
11.4.4.8 Avoiding scale-up uncertainties by design
11.4.4.9 Modeling plan
11.4.4.10 Reactor test facilities: various scales
11.4.4.11 Flow chemistry microstructured reactor
11.4.4.12 Laboratory test setup
11.4.4.13 Micro-plant, bench scale
11.4.4.14 Mini-plant
11.4.4.15 Pilot plant
11.4.4.16 Demo plant
11.4.5 Cold flow test rigs
11.4.5.1 Flow pattern detection methods
11.5 Development stage
11.5.1 Introduction
11.5.2 Pilot plant and test program execution
11.5.3 Front-end engineering design
11.5.3.1 Critical aspects for commercial-scale design to be addressed in EPC stage
11.6 Engineering, procurement, and construction (EPC) stage (also called execution stage)
11.6.1 Contractor choice and co-operation
11.6.2 Reactor procurement and construction
11.6.3 Commissioning
11.7 Start-up and normal operation (also called demonstration stage)
11.8 Exercises
11.8.1 Industrial exercise: glucose to ethylene glycol
11.8.1.1 Context
11.8.1.2 Experimental setup
11.9 Takeaway learning points
References
Part D: Education
12. Education guidelines
12.1 Introduction
12.2 Challenges in chemical reaction engineering education
12.2.1 From Jan’s recollection
12.2.2 From René’s recollection
12.2.3 CRE as a language game linked to teaching
12.3 Guidelines to use this book in academic education
12.4 Guidelines to use this book in industry
12.5 Education options for industry practitioners
12.5.1 Learning course: industrial chemical reaction engineering and process concept design for nonchemical engineers
12.5.2 Hands-on course: industrial reaction engineering and conceptual process design
12.5.3 Course program
12.6 Position of reaction engineering in chemical engineering curriculum
12.7 Takeaway learning points
References
13. Industrial cases
13.1 Introduction
13.2 Gas-to-liquid (GTL) Shell case
13.2.1 Introduction to GTL case
13.2.2 A consecutive or a parallel reaction?
13.2.3 Flory–Schulz distributions
13.2.4 Why Shell experts “like” fixed bed reactors for GTL?
References: gas-to-liquid (GTL)
13.3 Ethyl benzene peroxidation reactor (EBHP)
13.3.1 Introduction to the case
13.3.2 Reaction description
13.3.3 The liquid-phase RTD experiments
13.3.4 Results of the liquid-phase RTD experiments
13.3.5 Results of the gas phase RTD experiments
13.3.6 Commercial plant improvements
13.3.7 Takeaway learning points
References: ethyl benzene peroxidation reactor
13.4 A new catalyst shape: pressure drop and packing density
13.4.1 Introduction
13.4.2 Initial evaluation
13.4.3 Experimental results
13.4.4 Takeaway learning points
References: ethyl benzene peroxidation reactor
13.5 Heavy residue oil upgrading: reactor type selections and development
13.5.1 Heavy residue upgrading introduction
13.5.2 Heavy residue upgrading reaction chemistry
13.5.2.1 Reactor type options
13.5.3 Shell bunker flow selection and the development to commercial scale
13.5.3.1 Shell hydrogenation trickle-bed moving-bed reactor selection
13.5.3.2 Shell hydrogenation trickle-bed moving-bed (bunker) reactor development
13.5.3.3 Bunker reactor development
13.5.3.4 First demonstration reactor, Gothenburg
13.5.3.5 Development
13.5.3.6 Second demonstration process
13.5.3.7 Commercial-scale design and operation
13.5.3.8 Conclusions – Shell bunker reactor selection and commercialization
13.5.4 LC-FINING™ residue hydrocracking in three-phase slurry-ebullated-bed reactor
13.5.4.1 Reactor type selection
13.5.4.2 Reactor development and commercial-scale applications
13.5.4.3 Conclusion on three-phase ebullated-bed reactor
13.5.5 Heavy oil upgrading by coking with Exxon Flexicoker fluid bed
13.5.5.1 Reactor system
13.5.5.2 Reactor selection
13.5.5.3 Reactor development to commercialization
13.5.6 Reactor type comparison – heavy petroleum upgrade
13.5.7 Exercises
13.5.7.1 Exercises on reaction systems
13.5.7.2 Exercises on thermodynamic calculations
13.5.8 Takeaway learning points
References: a new catalyst shape
13.6 Reactor stability in an adiabatic trickle-bed reactor
References: heavy residue oil upgrading
13.7 Three-phase slurry-reactive distillation
13.7.1 Introduction
13.7.2 Takeaway learning points
References: three-phase slurry reactive distillation
13.8 Fluid bed retorting shale oil
13.8.1 Project starting points
13.8.2 Reaction kinetics, reactors, and process concept selections
13.8.3 Shale characteristics
13.8.4 Process concept
13.8.5 Process conditions
13.8.6 Process research items
13.8.7 Takeaway learning points
References: fluid bed retorting of shale
14. Education case study: polyolefin CRE and scale-up
14.1 Introduction
14.2 Discovery-stage reactor family selection
14.3 Concept stage
14.3.1 Scale-independent basics
14.3.2 Chemistry and stoichiometry of the reaction
14.3.2.1 Kinetics
14.3.3 Heat of reactions
14.3.3.1 Heat of propagation reactions
14.3.3.2 Heat of hydrogenation reactions
14.3.4 Physical properties
14.3.5 Reaction engineering concept design
14.3.5.1 Polymer and particle formation
14.3.5.2 Gas phase residence time distribution and concept design choices
14.3.6 Solid-phase residence time distribution
14.3.7 Mass transfer limitations and concept design choices
14.3.8 Heat transfer limitations and concept design
14.3.8.1 Particle heat transfer limitation
14.3.8.2 Heat transfer limitation-aggregated polymer particles
14.3.8.3 Heat and temperature management reactor
14.3.8.4 Choice of particle size related to fluidization class behavior and G/S separation
14.3.8.5 Overall reaction engineering concept design
14.3.8.6 Molecular weight distribution control
14.3.8.7 Polymer yield on catalyst
14.3.8.8 Reliable design for scale-up and operation
14.3.8.9 Lowest cost of investment and catalyst per ton of product
14.3.8.10 Final concept design summary
14.3.9 Modeling for reactor sizing
14.4 Feasibility stage
14.4.1 Introduction
14.4.2 Commercial-scale design in feasibility stage
14.4.2.1 Introduction: commercial-scale design
14.4.2.2 Safe, healthy, environmental, economic, technically feasible, and sustainable (SHEETS criteria)
14.4.2.3 Feed distribution
14.4.2.4 Catalyst feed distribution
14.4.2.5 Residence time distribution gas phase
14.4.2.6 Residence time distribution solids
14.4.2.7 Shear rate distribution and impulse transfer
14.4.2.8 Mass transfer
14.4.2.9 Heat transfer
14.4.2.10 Design to combat electrostatic charging
14.4.2.11 Gas–solid separation
14.5 Development stage
14.5.1 Pilot plant design
14.5.1.1 Purpose
14.5.1.2 Pilot plant and mock-up model design
14.5.1.3 Mock-up model design
14.5.2 Economics commercial scale, pilot plant and mock-up model
14.5.3 Risks and value of information assessment
14.5.4 Development: front-end engineering design
14.6 Commercial-scale implementation (EPC and start-up)
14.7 Exercises
14.7.1 Exercise 1: Thiele modulus description and calculation for polyolefin catalyst
14.7.2 Exercise 2: temperature catalyst particle
14.7.3 Exercise 3: polyethylene reactor design
14.8 Takeaway learning points
14.9 List of symbols
References
Index