| In this thesis, we show how to synthesize reactive distillation systems, which are representative process units with integrated functionality since reaction and separation occur simultaneously in one piece of equipment. Our main approach to solutions is to visualize the reactive separation systems in the original composition space so that we can really understand the interaction between reaction and separation.;We derive a reactive lever rule by using the linear combinations of untransformed composition vectors. When generating design alternatives for reactive systems in the original composition space, the reactive lever rule automatically upholds material balance constraints. This reactive lever rule represents the extent of reaction and the product flowrates on two parallel lines if a reaction does not change the total number of moles.;Extending the principles of the reactive lever rule, we adapted the Ponchon-Savarit and the McCabe-Thiele methods to design binary reactive distillation columns. By sketching these two diagrams, we can obtain numerous design insights for binary reactive distillation. Among them, two main contributions are: (1) we can determine how to locate reaction zones inside a column to create a synergistic effect of reaction and separation, and (2) we can understand that binary reactive distillation cannot circumvent an azeotrope under total reflux.;Based on these visualization methods for binary reacting systems, we extend tray-by-tray calculations into ternary and quaternary reacting systems. The visualization of tray-by-tray calculations for a reaction zone enables us to evaluate the feasibility of a reactive distillation column and to optimally locate reactive stages with ternary isomolar and non-isomolar reactions. Specifically for the MTBE (methyl tert-butyl ether) production system, the feed and rectifying reaction sections circumvent the iso-butene-methanol azeotrope in a single-feed column. Finally we visualize Eastman Chemicals' methyl acetate production system by deriving projection equations. The most significant result from this visualization is that there is an optimal operating range of the reflux ratio. Below or above this range, the overall reaction conversion decreases. |
