Development of a general design method for intensifying distillation and multiple reactions

By using phase and reaction equilibrium information, this thesis derives feasibility criteria for non-extractive and extractive reactive distillation systems. This thesis presents a quick method for estimating column composition profiles for reactive and extractive cascades in a double-feed column without stage calculations. This column profile estimation is based on the feasibility and pinch point analyses. From the pinch point analysis, manifolds of possible composition profiles are generated. This thesis then addresses a general feasibility evaluation method for quaternary reactive distillation based on the feasibility study of isomolar reactions. Critical composition regions (CCRs) are defined as the areas where thermodynamic constraints force extractive composition profiles to travel in infeasible directions. Then, material balance is imposed to determine whether extractive composition profiles can reach desired product compositions.; This thesis also presents a new feasibility evaluation procedure for reactive mixtures where simple homogeneous reactive batch columns cannot produce pure products and presents three alternatives: a batch reactive rectifier with a decanter, a homogenous batch reactive extractive distillation (BRED) column, or an entrainer that introduces an unstable node heteroazeotrope. Finally, this thesis addresses a new method for estimating the liquid still composition trajectory of batch reactive distillation systems based on material balance and reaction equilibrium data. For a given feed to product flow ratio with constant feed charge and product compositions, the still pot composition trajectory is mathematically confined to the intersection between the reaction equilibrium manifolds and a "material balance plane" defined by stoichiometry and material balance. Starting from this estimated still pot trajectory, we can easily evaluate the feasibility of various batch reactive distillation configurations by applying the batch column feasibility criteria.