Chemical Engineering Research & Design, Vol.80, No.6, 587-596, 2002
Batch reactor optimization, profitability vs waste minimization
The reaction I + R --> A + 2D is carried out in a batch reactor. A is the desired speciality chemical product and D is a saleable by-product. The reaction A + R --> IMPS also occurs, where IMPS are waste products which must be treated to remove BOD before discharge into the environment. Product distribution is optimized in order to maximize profitability with respect to net product value versus feed and waste treatment costs. Initial temperature of the batch and rate of heat transfer from the vessel have been identified as the main parameters for optimization. Each reaction is exothermic, with heat of reaction of approximately 100kJ (mol R)(-1) and follows essentially elementary second order kinetics, but the rate of formation of IMPS increases more rapidly with increase in temperature than that of A. Three heat transfer configurations have been considered, for removal of heat of reaction with cooling water. (1) jacket; (2) internal coil; (3) continuous circulation with external heat exchanger. Configuration 2, with an initial batch temperature of 70-75degreesC, has been found to give the best result for overall profitability. However, Configuration 3 is preferred if increased demand for waste reduction in the light of more stringent consent limits requires that the concentration of IMPS should not exceed 0.03 mol l(-1) in the final product solution. The need for processes to meet both profitability and consent limit requirements suggests that waste minimization demands should ideally become a global target, for the whole site.