Design a new column including an evaporator and a refeed system to increase the capacity by 30% taking into account the wastewater streams of additional plants.
Design a simulation model based on the insights of the laboratory tests. Adapt the data of the chemical and physical properties of substances to the test results. Conduct sensitivity analyses to optimise the product treatment and refeed of recycling streams. Create an adjusted simulation model based on the results of the sensitivity analyses.
Identify the right amount of cooling water to avoid any catalyst deactivation due to the high thermal load.
The required temperatures to thermally deactivate the catalyst couldn’t be reached in the model, not even using the current amounts of cooling water.
Following customer feedback we discovered that also the uncooled part of the heat exchanger (calotte at the inflow) was filled with the catalyst. Another modelling based on adjusted conditions showed a significant temperature peak in the uncooled part of the reactor.