Advanced Reactor and Separation Technologies for the Production of Base Chemicals and Polymers

Teacher(s)

De Wilde Juray; Luis Alconero Patricia; Mignon Denis;

Language

English
> French-friendly

Main themes

a) (Petro)chemicals & Polymers:
Refining and petrochemicals: After an introduction and overview of refining and the (petro)chemical industry, three specific processes are studied in detail, analyzing as well the flow-sheets, thermodynamic, kinetic and eventual catalytic aspects, the reactor concepts, aspects related to the separation and purification of reactants and products, the energy requirements and the environmental impact, and the process safety. In the context of process intensification, advanced reactor technologies and their modeling are also dealt with.
Polymerization processes: after a general introduction to polymerization processes, the various types of processes are reviewed and illustrated at hand of industrial examples.  A special emphasis is put on the production processes of polymers produced in large amounts worldwide, such as polyethylene (HDPE, LDPE), polypropylene (PP), polystyrene (GPPS, HIPS), PVC.  Some specific problems, such as the control of polymerization reactors are also addressed.
b) Advanced Separation Technologies:
Separation technologies are the cornerstone in the industry since they contribute with around 75% of the production cost. In addition to simple distillation, absorption or extraction, more complex techniques are required for challenging separations. The following advanced separation techniques will be addressed during the second part of the course:

• Enhanced Distillation (Extractive Distillation ; Salt Distillation ; Pressure-Swing Distillation ; Homogeneous Azeotropic Distillation ; Heterogeneous Azeotropic Distillation ; Reactive Distillation).
• Batch Distillation (Differential Distillation ; Binary Batch Rectification ; Batch Stripping and Complex Batch Distillation).
• Membrane Separations (Gas Permeation and pervaporation ; Membrane contactors).

Learning outcomes

At the end of this learning unit, the student is able to :

AA1.1, AA1.2 AA2.2 AA3.1 AA6.1, AA6.2, AA6.3, AA6.4 Specific AA - JDW Part: Innovative reactor technologies: Three examples (structured catalytic reactors, high-G rotating fluidized bed, plasma reactor), operating principle, theoretical analysis, modeling, specific applications, critical analysis. Processes using complex reactors: Three examples of processes using a complex reactor, process flow-sheet, detailed description of the different stages, catalyst/reactor specificity, safety and environmental aspects.

Content

Part A:
- Introduction and overview of refining and the (petro)chemical industry. Three example processes are studied in detail, e.g.:

• Hydrocracking;
• Phtalic acid anhydride;
• Fischer-Tropsch.

Advanced reactor technologies for process intensification and their modeling.
- Introduction to polymerization processes:

• Suspension Polymerization
• Emulsion Polymerization
• Step-Growth Polymerization
• Coordination Polymerization
• Free-Radical Polymerization: Homogeneous Systems
• Free-Radical Polymerization: Heterogeneous Systems
• Control of Polymerization Reactors
• Identification of emissions: water, air, waste

Part B:
- Advance Separation Techniques :
Enhanced Distillation :

• Extractive Distillation ;
• Salt Distillation ;
• Pressure-Swing Distillation ;
• Homogeneous Azeotropic Distillation ;
• Heterogeneous Azeotropic Distillation ;
• Reactive Distillation

Batch Distillation :

• Differential Distillation ;
• Binary Batch Rectification ;
• Batch Stripping and Complex Batch Distillation

Membrane Separations :

• Gas Permeation and pervaporation ;
• Membrane contactors (membrane-based absorption; membrane distillation; membrane crystallization)

Teaching methods

This course combines ex-cathedra teaching and projects/exercises with tutoring.  Depending on the circumstances, the lectures and the practical sessions can be organized in presential and/or in remote mode.
Processes for the production of (petro)chemicals and advanced reactor technologies:
The theoretical courses are ex-cathedra. The students are encouraged to ask questions. During the course, the students are asked to read, analyze and question a number of scientific papers. Practical sessions are given in the form of exercise sessions.
Advance Separation Processes:
Theoretical classes are complemented with exercises sessions and laboratory.

Evaluation methods

The students will be individually graded based on the objectives indicated above. The exam is an oral defense/discussion with or without a written preparation.  Depending on the circumstances, the examination can be organized in presential or in remote mode. The part taught by each teacher normally counts for a third of the total mark, unless specified otherwise during the course. However, if a deep deficiency (<=8/20) is found for one or more parts of the course, the total mark will represent a failure at the examination and be reduced to 8/20 as a maximum.

Other information

This course requires basic knowledge in organic chemistry and chemical engineering (chemistry, thermodynamics, kinetics, reactor design and transport phenomena, polymer chemistry, fluid-fluid separation).

Online resources

Resources in Moodle

Bibliography

Les notes de cours sont fournies aux étudiants ou disponibles via Moodle.
Reference books:
- Separation Process Principles by Seader, J. D., Henley, Ernest J., Roper, D. Keith. Published by Wiley,2010, Binding: Hardcover 3rd Edition.

Faculty or entity

> FYKI