Dimethyl Ether Production using a Reactive Distillation Process

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1 Korean Chem. Eng. Res., Vol. 42, No. 1, February, 2004, pp ( , ) Dimethyl Ether Production using a Reactive Distillation Process Younghwa Koo and Myungwan Han Department of Chemical Engineering, Chungnam National University, 220, Gung-dong, Yuseong-gu, Daejeon , Korea (Received 1 October 2003; accepted 9 December 2003).! "#$% &', -(#[6]! "#$% &. ) *"+,-!./ %5! :./;< ;=', 7 &5 C?. D EF : G HIJ>B #K L/5 MN GO, PQR EF9S. Abstract In this study, we propose a reactive distillation process for production of dimethyl ether (DME). The conventional process for the production of DME consists of one reactor and two distillation columns. The reaction-distillation hybrid process for the production of DME [6] is an interlinked system between one reactor and one distillation column. The newly proposed process for the production of DME is a reactive distillation column in which the reaction and separation occurs simultaneously and the reaction takes place on liquid phase only. This characteristics of the reactive distillation process bring about great benefits. Comparison between these three processes shows a great advantage of the proposed one over the other two processes in the reduction of energy and capital cost. We examine and analyze the effect of design and operation variables on the performance of the proposed process and provide design guides for the process. Key words: Dimethyl Ether, Methanol, Reactive Distillation 1.,!"# $%& '' ()*+, -..!"# (/ (dimethyl ether, DME) 9:, ;<= gas)&c DE& F, G AH IJ&.. K< LM 55-60N 4O"# PQR S? T&C S? U%VW -, 9:&0 ;<= >? XEY ZN0 [\ ]? ^_'A `VW Z -.. a DME bcd "e f NOx ghi& jr ] Bkl m gh+ n.. & fo DMEW! ^_p "# $%/^ "q cr+ -.[1-3]. st DME uvw xy, MTG z{, B9v& }~c!, 56 7& E ƒ V & -.. DME ˆ? EB; Š / Š ˆ= 5<u Y uœ& y 1 Ž=* (dehydration) / To whom correspondence should be addressed. mwhan@cnu.ac.kr / ˆ& -.. DMEW "# } / d 5<u E = & H R Aš 1 W } / EB (CO+H 2 ); DMEW Š xe/ ˆ& œ Y ža *Ÿ -. 'd H N + N0, Š ˆY & = &ya< =./ xe+, ªJ& «R P. n, P±A & ² ˆY ³/ & µ - ~ &.. ˆ 5 <u DME xe (?. = >.[4]. 2CH 3 OH(CH 3 ) 2 O+H 2 O Methanol DME Water st DME ªJ? DME xe ; = DMEW ¹ J / ; N 0º,C DME ªJ )+ (»? ; & ¹ J } š.. &W ²ªJd ¼ $ ½ ¾Y } / -.. À ¾d DME 5<u Á & ¹+, ÂÀ ¾d = 5<u& ¹š.. lã0 & À ¾d ¹š Á & ÂÀ ¾d.* Á +, ¹ Ä+ 44

2 j'y Z.[5]. Åd %Æ Ço[6]d 5<u A = ¹ ªJ& š ÈÉ œê -½ ÁEªJY Ë/ Ì Y Í.. Î "qd ½ªJY & ÈÉ œê DME xyªj "qw cr/ï.. ½W & / DMEW xy/. = >? Ì' Y Z.. /0 Ìd = ½ ¼ ÐY _* r/ Ñ Ì = ÉÒ Y sór ]h - š.. a Pd,0 fo %x/ ÔY ¹ } -, & P j' `V,, ÕY -.. Ëš ½ªJ Ì j'y ²ªJ Ö -½ÁEªJ= W Ž/ Ø/Ï Ù ªJ Ú & ½ªJ E Û Ü Y } Ø/ ± Ö ÝÞ ßY ÍVà /Ï.. 2. ½ªJd 5<u? Ù 5 <u? %Ô N?. = >.. 2CH 3 OH(CH 3 ) 2 O + H 2 O V? r = k f a 2 a a DME H2O MeOH âã -.. d r? äq Vd j h 1 &C, a i E i å_vw 0âæ.. V d œp [7] VP K eq K eq = exp T &, k f = exp h T &C `V T j çè(kelvin)&.. &f } š 1 Rohm & Haas Co. éye ê.ªe (Amberlyst 15 wet, moisture content 53 wt%)&.[7]. & 1 } `V 120 o C &/ +, -, Ëš ½ ë nn0, st $%+ - 1 [8] & } E Y &ÑdV `dv } - fo V Y l & /Ï <u A DMEW xy/ ªJd Ëš ½ªJ= ²ªJ Ö -½ÁEªJ = Ö Ì W k}w Ž/ r/ï.. a ½ªJ ÙÙ Ú ì, # í îj, ½, ¾ ïð, j!½i, 5<u # ñv ƒ& ªJ E Û Ü Y òó.. ²ªJ= -½ÁEªJ ô& ÙÙ 7.6 m, m &.. ²ªJ= -½ÁEªJ l¹ ½ªJ # î i? 5<u Kmol/hr, 2.5 Kmol/hr _ /.. } š ½¾? k¼ ¾PN; õ W 1jN, t W ö jn /Ï.. ªJk} ASPEN PLUSW } /ÏNC, } š kø? ù¹ ˆ úy & NRTL&..? kû jd,0, Ù j? /@ œ PÊ -NC, Ù žò Á & š. J/Ï.[9].. ²ªJ, -½ÁEªJ l¹ ½ªJ Ýü/Ï ²ªJ? Fig. 1(a) 0âý þ& DME xy xegh ¹JW ¼ $ ½¾N qe+, -.. ¹ Jš Û 5<u? tñ+ ¹š? ÿ ¹š.. # 5<u î? ÈÉ 5<u= ½¾(T-2)d ¹š Û 5<u& Á +, Ô (E-1) Ô (E-2) A +, ý,c.. xe? Ô (E-2) Ù+, ¼ $ ½¾(T-1, T-2) ( À ½¾(T-1)N ý, À ½¾(T-1) ¾Jd DMEW Í.. ¾Ó ghš Û 5<u= & ¼ À ½¾(T-2)N ý, Û 5<u? ; ¹š.. ¹š Û 5<u? tñ+? Ù (E- 4) Ù+, ÿ ¹š Fig. 1(b) 0âæ /0 ½¾N qe+c Û 5<u? ½¾ (P;d ½ gh+, tñš.. # î? ÈÉ 5<u= ½¾(T-1)d ¹š Û 5 <u& Á +, Ô (E-1) Ô (E-2) A +, ý,c.. xe? Ô (E-2) Ù +, ½¾(T-1)N ý, xyš DME? ½¾(T-1) ¾Jd ÍY - ¾Ód Í? Ù (E-3) Ù+, ÿ ¹ š ½ªJ Fig. 1(c) DMExy = xe ¹JW _ * /0 ½¾(T-1)d,0Và qe+, -.. # í 5 <u? ¾( N î+, DME & xeš.. xeš DME? ¹ J+, ¾P;d DMEW ÍY -, ¾/; d Y ÍY -.. & Í,c? Ù (E-1) Ù +, ÿ ¹š.. Ëš ½ ªJ k} Y Table 1 0âý Fig. 2 ²ªJ, -½ÁEªJ l¹ Î "q ½ª J kiy /Ï.. ²ªJ? -½ÁEªJ. m ¼ g ) Y -, -½ÁEªJ * ½ªJ PQi k+ Y -.. &. = >? Ø& /.. &,0C = ½ /0 ½¾d &,Ñd * xe+ Ô? Ô Y ½/ } +, ¹ š.. P ²ªJ= -½ÁEªJ xe + Ô `V / Ü Y 3.. a ½ªJ Ô& A Ô } +, `V ÚA, + fo `V,, Õ& / š.. a = ½ _*,0d * ]? `VdV V S Ò & S V ¹ Y * & š.. Ì W / Table 2 Ù Ì ÝÞ / 0âý.. Fig. 1d ²ªJ? /0 ¼$ ½¾N &,, -½ÁEªJ? /0 /0 ½¾N &,.. ì, -½ÁEªJ? Ì Ñd ²ª J /0 ½¾Y Ý/ nv š. Ì'& -.. Ñ ½ªJ ½¾ /0 = ½ k¼ &, C ½¾ V -½ÁEªJ. Ð? Y -.. Korean Chem. Eng. Res., Vol. 42, No. 1, February, 2004

3 46 Fig. 1. Three Processes for the Production of Dimethyl Ether from Methanol: (a) Conventional Process R-1. Reactor E-1. Methanol Pre-heater T-1. DME Tower E-2. Reactor Cooler T-2. Methanol Tower E-3. DME Cooler P-1. Feed Pump E-4. Waste Water Cooler; (b) Reaction-Distillation Hybrid Process R-1. Reactor E-1. Methanol Pre-heater T-1. Methanol Tower E-2. Reactor Cooler E-3. Waste Water Cooler; (c) Reactive Distillation Process T-1. Reactive distillation column E-1. Waste Water Cooler. Table 1. Simulation input for the proposed reactive distillation column Input Component MeOH kmol/hr H kmol/hr Temperature 25 o C Pressure 30 atm Distillation column T-1 Total number stages 30 Condenser Partial-Vapor-Liquid Reflux ratio 3 Feed stage 15 Pressure top 25 atm bottom 25 atm Holdup Total 80 kmol ½ªJ? ªJ& N ²ªJ= - ½ÁEªJd P. ¾ý & / ½¾ Š, t l¹ õ Ð Ì =W ÍY -.. & õ t d ) / V / š Fig. 2. Comparison of heat duties between conventional, reaction-distillation hybrid, and the proposed reactive distillation process # îj J? Üd V S +V à / 'd &,.. Î ªJd 5<u & ½¾ îš.. Fig. 3? # îj xe ñ

4 Table 2. Equipment dimensions of the three processes Process Reactor Distillation column T-1 T-2 Conventional D = 0.72 m L = 7.6 m D = 0.79 m Total stage = 24 D = 0.87 m Total stage = 28 Reaction- Distillation Hybrid D = 0.75 m L = m D = m Total stage = Reactive Distillation none D = m Total stage = 30 VW 0âý.. # îy ( j 10-15j }& î*y f S? ñvw ÍY -.. &? Fig. 4 5d 0âá > & ý;v Ü VW Ñ 12jN #W î* Y f Ì Ð? Üd &!,0. jn î* Y f. ¹ J } + Ü& + Y -.. & Ò V S xe ñv S 0«Y" -.. ¾ P; 5jN #W î*y & ¾/; #d,0 Y -.. & ¾P; 5jN îš 5<u? DME Á $Ø+, V ] a ¾P; `V ]N Fig. 3. Effect of feed stage on the product purities. & åea+ %/ N xùš.. Œd & 5<u? ¾/; /é/ `V S? Üd / + N.. ¾ /; 20jN #W î*y 20j & 5<u Fig. 4. Mole fraction profiles for different feed stages: (a) feed stage-5; (b) feed stage-12; (c) feed stage-15; (d) feed stage-20. Korean Chem. Eng. Res., Vol. 42, No. 1, February, 2004

5 48 Fig. 5. Reaction rate profiles for different feed stages: (a) feed stage-5; (b) feed stage-12; (c) feed stage-15; (d) feed stage-20. V e '( )Œ & 5<u& A+, ¾ P; &_/ 5<u& ¾Ò! +, Ü& ¾Ò! / š.. & Œ *? ÜN ¹J )+ ½j& / +, xe ñv +, š.. #î? Ü,jN î * & -.. >? ǹ P 5<u? Ü & î *Ñ S? ñv Ò Y ÍY - Y ¾ ïð DME xe ñvw Fig. 6 0âý.. ïð& 25 atm &/ f xe ñv ddr +, Y atm &P xe ñv m J/ + Y -þ& & ªJ ïð? 25 atm &PN. Y atm m 100% ñvw Í Y -.. &? ïðy S&Ñ `V P// Ò & + fo&.. Fig. 7 0âá >& ¾ ïð `V 0â0C, & Œ V +, ¾ (0d `VÚA 0â0 š.. & N & Üd j EÚA µ fo&.. ¾ ïð ¾ 1 ¼2W 3/ Ì P/š ïð Fig. 6. Effect of pressures on the product purities. 5 -, / Ì /0, Åd 6š 7JH Ü / ½¾ j, ¾ Ö j!½iy -.. Œd ïðú H'Y Z..

6 49 Fig. 7. Column temperature profiles for different pressures: (a) pressure-20; (b) pressure-23; (c) pressure-25; (d) pressure ! Ëš ½¾d ½ ¹W éa*ÿ '( )Œ, Û Y tñ* Üd VW * & å EA+Và.. ì ½ à = ¹= _* / ñv Ò &.. Fig. 8 ½ªJ ½ ¾P, ¾Ó ñvw 0âý.. ½ 3 & P f ñv S +0 ½ 2.5 &/d ñv R +, Y -.. Fig. 9d ½W * Ñ ¾P Û 5<u& ¾(0 ÜN &_/ Ò & / Y -.. lã0 ½ ¾ý i W Û.. & Œ i& /. ê Š ¾& } +, / Ì / j'y Z.. Fig. 10? ½ ïð ñvúaw 0âæ &.. ½ªJd ½ Ö ïð& 8 Œ Ö ¹ å EA+, ñv / Y -.. ì ¼ Ú W H A Ú d H R 8 Œ ªJY HA*Ÿ " #$ %& ¾ý j!½i ªJ E Û Ü Y }/Ï.. Table 3 Fig. 8. Effect of reflux ratio on product purities.? j 9 Œ j!½iy ÚA* Y f :=W... &f Case 1? Ò!j(2-29j)!½iY J/ 80 kmol & Case 2 ½¾ P; 4j= /; 4j j!½iy 30 kmol / ( ; j(6-25j) j!½iy 100 kmol Korean Chem. Eng. Res., Vol. 42, No. 1, February, 2004

7 50 Fig. 9. Reaction rate profiles for different reflux ratios: (a) RR-2; (b) RR-2.5; (c) RR-3.5; (d) RR-4. Table 3. Effect of holdup distribution in the column on DME purity Stage range Hold-up (kmol) Each stage Total stage DME Purity (%) Case Case Case Case Fig. 10. Effect of reflux ratio and pressure on DME purity. &.. Case 3= 4 ½¾ 5<u ;îjy.n / P ;(2-15j) /;(16-29j) j!½iy ÚA*. &.. Ù Ò! j!½i? 2,240 kmol J/.. Case 1= Case := xe DME ñv p& 0 nó( j j!½ iy *. Case 2 < -? ñvw ÍY -.. ì Fig. 11 (a), (b)d Case 2 Case 1. H? j d &,0C 0= jd ¹J +. ñv Y ÍY -.. Case 3= 4W := Case 3 x E DME ñv S 0â>.. &? Fig. 11 (c), (d)w Žd -þ& ¾/; j!½iy * Y f Ò & - fo&œ Y " -.. &?! 5<u&

8 51 Fig. 11. Reaction rate profiles for different holdup distributions: (a) Case 1; (b) Case 2; (c) Case 3; (d) Case 4. î+ñ #îj /; 5<u V / fo & Ü j!½i Ò 0â0 N xùš.. &Pd &!,0 Ü j!½iy * Ò 0= jy ¹ J } + / ñva &, í - Y ò -.. Œd ½¾ ÝÞ* jy ÝÞ/ Ò Y *, ½j? j Ð ÝÞ/ Y -.. lã0 &f jy /? =V ïðé/w %/ fo j!½i? Y ' () *+, -. î # ñv Œ xe+ DME ñv Û Ü Y ò ó.. Table 4 0âý þ& î 5<u ñv 99-50% }& d òó.. &f ¾Pi? ÙÙ ñvd 99% f # ( 5<u žò xe+ DME AN Þy/ :J/ Ï.. Table 4 0âæ >& 5<u ñv +,ŒV Ò & +, n ñvw - Y " -.. Œd Ëš ½ªJd & Bñ 8š ÓñV 5<uY # } -.. Table 4. Effect of feed purity on DME product purity Feed methanol purity (%) Distillation rate (kmol/hr) 5. Product DME Purity (%) more-than more-than more-than more-than more-than more-than c IJ $%& )q+ -NC ² 4O"#W! - p d C Î Çod /0 Ìd = ½ ¼ Ð Y _* r/ Ì = ÉÒ Y - ÈÉ ½ªJY Ë/Ï.. Ëš ªJ? 45678W xy/ -, ²ªJ= -½ÁEªJ W - Y " -.. a ½ªJ ) Ú & ªJE Korean Chem. Eng. Res., Vol. 42, No. 1, February, 2004

9 52 Û Ü Y }/ ± Ö ÝÞ ßY Í.. P ²ªJ= -½ÁEªJ? * %Ô Ô& R uœ,/, É Ñ N * Ô& A Ô } +, `V ÚA D / n +,,/ E.. a * %x+ Ô? sô& F Ô A Ü Y, ½ & š.. lã ²ªJ= -½ÁEªJ ê =W ÍY -.. ½ªJ? = ¹ _*,0 œ'& &_ / ]? `VdV S? Ò Y ÍY ½ªJ E? # îj, ïð, ½, Ò!j, j9 j!½i ÚA l¹ î 5<u ñv Ü Y 3.. #îj, ¾ ïð Ö ½ ªJE Ü Y GHÑ N ¾ P; î* I ÜY ZVà :J+,.. ïð= ½ P š >& ïð= ½ J à ñv / N 0 â>nc & ïð= ½i 5<u Ò 82 ¹ JW å/ / fo&.. j!½i * Y * Ò Y *C & Œ ) ¾ý j W *Ÿ - Ì'Y 0!½i j ïð KL& µ Y 3.. ¾ý j!½i Ü? Üd j!½iy * * Y * Ò Y S& ¹ J 0= j & & + / S? ñvw ÍY -.. a ½¾ ÝÞ* jy ÝÞ/ Ò Y *, ½jY j. Ð Ý Þ/ ½¾ ÝÞV xù -.. 5<u Bñ & 8š ¾P iy /Ñ 5<u ñv ]? V S? ñv Y ÍY -.. & "q ¹ªj MNcO=(2002EID03P ) r+ P).. "q }W QR).. 1. McCandless, J. C., Dimethyl Ether Powered Engine, U.S. Patent No. 5,626,294(1997). 2. Kim, J. W., Sim, K. S. and Han, S. D., Dimethyl Ether as a Diesel Fuel Alternative, Energy Engg. J., 7(2), (1998). 3.Choi, J. W., Lee, S. H., Sim, K. S., Kim, J. W. and Kim, S. H., Direct Synthesis of Dimethyl Ether from Syngas in a Slurry Phase and Gas Phase Reactor, Energy Engg. J., 10(1), 49-54(2001). 4. Jun, K. W. and Roh, H. S., Traditional DME Production Technology and Domestic Status of the DME Technology, NICE, 20(5), (2002). 5. Turton, R., Bailie, R. C., Whiting, W. B. and Shaeiwitz, J. A., Production of Dimethyl Ether (DME) via the Dehydration of Methanol, Analysis, Synthesis and Design of Chemical Processes, Appendix B., Prentice Hall PTR, (1998). 6. Koo, Y. H. and Han, M., Dimethyl Ether Production using a Reaction-Distillation Hybrid Process, HWAHAK KONGHAK, 41(5), (2003). 7. Song, W., Venimadhavan, G., Manning, J. M., Malone, M. F. and Doherty, M. F., Measurement of Residue Curve Maps and Heterogeneous Kinetics in methyl Acetate Synthesis, Ind. Eng. Chem. Res., 37, (1998). 8. Kim, B. K., Koh, J. C., Kim, B. S. and Han, M., A Study of Liquid Phase Dimethyl Ether Formation using a New Catalyst, KIChE Annual Meeting, October, Seoul(2003). 9. Aspen Plus User Guide, Version 11.1, Aspen Technology, Inc

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