Methyl lactate synthesis using batch reactive distillation: Operational challenges and strategy for enhanced performance

YesBatch reactive distillation is well known for improved conversion and separation of desired reaction products. However, for a number of reactions, the distillation can separate the reactants depending on their boiling points of them and thus not only reduces the benefit of the reactive distillation but also offers operational challenges for keeping the reactants together. Methyl lactate (ML) synthesis via the esterification of lactic acid (LA) with methanol in a reactive distillation falls into this category and perhaps that is why this process has not been explored in the past. The boiling points of the reactants (LA, methanol) are about 490 K and 337 K while those of the products (ML, water) are 417 K and 373 K respectively. Clearly in a conventional reactive distillation (batch or continuous) methanol will be separated from the LA and will reduce the conversion of LA to ML significantly. Here, first the limitations of the use of conventional batch distillation column (CBD) for the synthesis of ML is investigated in detail and a semi-batch reactive distillation (SBD) configuration is studied in detail where LA is the limiting reactant and methanol is continuously fed in excess in the reboiler allowing the reactants to be together for a longer period. However, this poses an operational challenge that the column has to be carefully controlled to avoid overflow of the reboiler at any time of the operation. In this work, the performance of SBD for the synthesis of ML is evaluated using model based optimization in which operational constraints are embedded. The results clearly demonstrate the viability of the system for the synthesis of ML

A novel split-reflux policy in batch reactive distillation for the optimum synthesis of a number of methyl esters

YesThe production of a number of methyl esters such as methyl decanoate (MeDC), methyl salicylate (MeSC), and methyl benzoate (MeBZ) by esterification reactions of several carboxylic acids such as decanoic acid (DeC), salicylic acid (ScA), and benzoic acid (BeZ) with methanol, respectively, through a reactive distillation system (batch or continuous) is cost-intensive and operationally challenging operation. It is difficult to keep the reaction species together in the reaction section due to wide boiling point differences between the reactants. Methanol (in those esterification processes) having the lowest boiling temperature in the reaction mixture can separate easily from carboxylic acid as the distillation progresses, resulting in a severe drop in the reaction conversion ratio of the acid employing batch/continuous distillation system. In order to overcome this type of challenge and to increase the overall reaction conversion, a novel split-reflux conventional batch reactive distillation configuration (sr-BRD) is proposed/studied in detail in this investigation. The optimal performance of BRD/ sr-BRD column is determined in terms of maximum achievable conversion of acids, and highest concentration of the esters produced for each chemical reaction scheme. The results for given separation tasks are compared with those obtained using conventional batch distillation (BRD) process. The optimization results clearly show that the sr-BRD process significantly improves the process efficiency, the conversion ratio of acid, and the product purity of methyl esters compared to that obtained via the BRD process

Synthesis of methyl decanoate using different types of batch reactive distillation systems

YesMethyl Decanoate (MeDC) is a Fatty Acid Methyl Ester (FAME) and is an important chemical compound with global production of 31 million tons per year. However, synthesis of methyl decanoate (MeDC) via esterification of Decanoic Acid (DeC) with methanol by reactive distillation is operationally challenging due to difficulty of keeping the reactants together in the reaction zone as methanol being the lightest component in the mixture can separate itself easily form the other reactant deteriorating significantly the conversion of DeC using either conventional batch or continuous distillation column. This is probably the main reason for not applying the conventional route for MeDC synthesis. Whether Semi-batch Distillation column (SBD) and the recently developed Integrated Conventional Batch Distillation column (i-CBD) offer the possibility of revisiting such chemical reactions for the synthesis of MeDC is the focus of this paper. The minimum energy consumption (Qtot) as the performance measure is used to evaluate the performances of each of these reactive column configurations for different range of methyl decanoate purity and the amount of product. It is observed that the use of i-CBD column provides much better performance than SBD column in terms of the production time and the maximum energy savings when excess methanol is used in the feed. However, the SBD column is found to perform better than the i-CBD column when both reactants in the feed are in equal amount. Also, the optimization results for a given separation task show that the performance of two-reflux intervals strategy is superior to the single-reflux interval in terms of operating batch time, and energy usage rate in the SBD process at equimolar ratio

Shear stress distribution within narrowly constrained structured grains and granulated powder beds

An experimental study is presented here to understand the stress transmission characteristics under different geometrical arrangements of particulates inside a narrow chamber subjected to axial compression loading. The multi-grain systems considered here are face-centred, simple cubic and poly-dispersed structures, as well as inclusions embedded inside seeded, unseeded and cohesive powder bed of Durcal (calcium carbonate). The distribution of the maximum shear stress, direction of the major principal stress and shear stress concentration factor were obtained using photo stress analysis tomography (PSAT). The results show that the maximum shear stress distribution in the simple cubic structure is chain-like and self-repetitive, i.e, a single grain behaviour is representative of the whole system. This is not the case in the case of other granular packing. In the case of the inclusion surrounded by powder media, the maximum shear stress distribution in the inclusion occurs through ring-like structures, which are different from those observed in the structured granular packing. This tendency increases for an increase in the cohesivity of the surrounding particulates. In the granular systems, the direction of the major principal stress is mostly orthogonal to the direction of loading except in some particles in the random granular packing. In the case of inclusion surrounded by Durcal particulates, the directional of the major principal stress acts along the direction of the axial loading except in the ring region where this tends to be oblique to the direction of axial loading. Estimates of the shear stress concentration factor (k) show that, k tends to be independent of the structural arrangement of granular packing at higher load levels. In the case of inclusion surrounded by powder bed, k for the seeded granulated particulate bed is mostly independent of the external load levels. In the case of unseeded particulate (granulated) bed, a fluctuation in k is observed with the loading level. This suggests that the seeded granules could distribute stresses in a stable manner without much change in the nature of shear stress-transmitting fabric of the particulate contacts under external loading. An increase in the cohesion of particulate bed results in more plastic deformation as shown by the differential shear stress concentration factor. The results reported in this study show the usefulness of optical stress analysis to shed some scientific lights on unravelling some of the complexities of particulate systems under different structural arrangements of grains and surrounding conditions of the inclusions in particulate media

Estimation of Dulling Rate and Bit Tooth Wear Using Drilling Parameters and Rock Abrasiveness

NoOptimisation of the drilling operations is becoming increasingly important as it can significantly reduce the oil well development cost. One of the major objectives in oil well drilling is to increase the penetration rate by selecting the optimum drilling bit based on offset wells data, and adjust the drilling factors to keep the bit in good condition during the operation. At the same time, it is important to predict the bit wear and the time to pull out the bit out of hole to prevent fishing jobs. Numerous models have been suggested in the literature for predicting the time to pull the bit out to surface rather than predict or estimate the bit wear rate. Majority of the available models are largely empirical and can be applied for limited conditions, and do not include all the drilling parameters such as the formation abrasiveness and bit hydraulic. In this paper, a new approach is presented to improve the drill bit wear estimation that consists of a combination of both Bourgoyne and Young (BY) drilling rate model and theory of empirical relation for the effects of rotary speed (RPM), and weight on bit (WOB) on drilling arte (ROP) and rate of tooth wear. In addition to the drilling parameters, the formation abrasiveness and the effect of the jet impact force of the mud have also been accounted to estimate the bit wear. The proposed model enables estimation of the rock abrasiveness, and that lead to calculate the dynamic dulling rate of the bit while drilling that used in more accurate to assess the bit tooth wear compared with the mechanical specific energy (MSE). Then the estimated dulling rate at the depth of pulling out is used to determine the dull grade of the bit. The technique is validated in five wells located in two different oil fields in Libya. All studied wells in this showed a good agreement between the actual bit tooth wear and the estimated bit tooth wear

Revamping of an acid gas absorption unit: An industrial case study

YesThis work evaluates the efficiency of the aqueous mixture of Methyl Diethanolamine (MDEA) and Diethanolamine (DEA) at various mass concentrations to remove CO2 and H2S from natural gas in an industrial sweetening unit in Fajr Jam Gas Refining Company located in the south of Iran and gives recommendations for modifying the process. The sweetening unit includes absorber and desorption towers, flash drum, lean and rich amine exchanger, kettle type reboiler and a reflux drum. The considered process is simulated by Promax simulator (version 3.2) taking into account operational constraints and sustainability of the environment. The validity of simulation has been evaluated by comparison between simulation results and the plant data. The main objective of this work is the modification of natural gas sweetening unit to achieve lower energy consumption. Thus, the effect of amine circulating rate and MDEA to DEA ratio on steam consumption in the regeneration tower, CO2 and H2S concentration in the treated gas, and the acid gas loadings have been investigated. Therefore, substitution of DEA solvent in the unit with the aqueous mixture of DEA and MDEA is proposed. In the examined cases, the mass concentration of MDEA and DEA lies between 15 and 45 wt% and 0–30 wt%, respectively, with the reference cases having MDEA 0 wt% and DEA 31.6 wt%. The results show that in the proposed cases of alternative mixtures including cases 1 (MDEA15 wt% and DEA 30 wt%), 2 (MDEA 20 wt% and DEA 25 wt%), and 3 (MDEA 25 wt% and DEA 20 wt%) the amount of reduction in amine circulation rate are between 11.1%v/v and 19.4%v/v compared to the original amine circulation rate. Likewise, steam consumption decreases between 24.4 %wt/wt and 27 %wt/wt. Influence of anti-foam injection for the different cases were also studied and it was found that anti-foam with the concentration of 5000 ppmv is more suitable for the optimum operation and is a more cost effective

Comparative Techno-Economic Analysis of Carbon Capture Processes: Pre-Combustion, Post-Combustion, and Oxy-Fuel Combustion Operations

YesEvaluation of economic aspects is one of the main milestones that affect taking rapid actions in dealing with GHGs mitigation; in particular, avoiding CO2 emissions from large source points, such as power plants. In the present study, three kinds of capturing solutions for coal power plants as the most common source of electricity generation have been studied from technical and economic standpoints. Aspen HYSYS (ver.11) has been used to simulate the overall processes, calculate the battery limit, and assess required equipment. The Taylor scoring method has been utilized to calculate the costliness indexes, assessing the capital and investment costs of a 230 MW power plant using anthracite coal with and without post-combustion, pre-combustion, and oxy-fuel combustion CO2 capture technologies. Comparing the costs and the levelized cost of electricity, it was found that pre-combustion is more costly, to the extent that the total investment for it is approximately 1.6 times higher than the oxy-fuel process. Finally, post-combustion, in terms of maturity and cost-effectiveness, seems to be more attractive, since the capital cost and indirect costs are less. Most importantly, this can be applied to the existing plants without major disruption to the current operation of the plants

Prevalence and risk factors of complication of endotracheal extubation in teaching hospitals affiliated with Jahrom University of medical science

Endotracheal intubation is to maintain a safe open airway to prevent pulmonary aspiration by administrating general anesthesia. Endotracheal tube, as a foreign body, can stimulate the patients’ airway during the emergence from general anesthesia and cause various reactions and complications immediately or within a multi-day delay.The present study intended to determine the prevalence and associated risk factors of the complications of endotracheal extubation (removal of endotracheal tube / ETT) within 24 hrs. since the surgery. To this end, a descriptive research was conducted on 200 adult candidates for elective and emergency surgery of endotracheal intubation by administrating general anesthesia. Data about the intended associated risk factors and complications were respectively collected in operating room (OR) and within 24 hrs. since surgery and were recorded in the questionnaire. The results indicated that the prevalent complications were sore throat (%21), cough (%12.5) and hoarseness (%15.5). There was not any case of dysphagia and bloody sputum (blood-streaked expectorant). Also, there was a significant relationship between sore throat and the type of surgery (P˂0.001). On the other hand, there was not any statistically significant relationship between sore throat and other associated risk factors (sex, age, weight, type of surgery and size of endotracheal tube). Likewise, not any significant relationship was observed between cough, hoarseness and the intended risk factors. To conclude, the present study found that the type of surgery has a significant effect on the incidence of sore throat within 24 hrs. since the surgical operation; thus, raising awareness of these risk factors and taking proper actions, particularly during intubation, can reduce the incidence of complications, in particular sore throat, and improve patients’ satisfaction.Keywords: General Anesthesia; Intubation; Complication

Investigation about profitability improvement for synthesis of benzyl acetate in different types of batch distillation columns

YesIn this work, for the first time, the synthesis of benzyl acetate via the esterification of acetic acid and benzyl alcohol is investigated in the reactive distillation system using a middle vessel (MVD), inverted (IBD), and conventional batch reactive distillation columns. The measurement of the performance of these column schemes is determined in terms of profitability through minimization of the batch time for a defined separation task. The control variables (reboil ratio for MVD, IBD columns) and (reflux ratio in case of CBD column) are considered as piecewise constants over batch time. The optimization results obviously indicate that the CBD system is a more attractive process in terms of batch time reduction, and maximum achievable yearly profit as compared to the MVD, and IBD operations