Optimization of the catalyst service life based on the coupling of reactor and heat exchanger network

Abstract

A systematic method is proposed for targeting the optimal catalyst service life, considering the catalyst deactivation and coupling integration of HEN and reactor. Relations among the reactor’s conversion, inlet/outlet temperature, energy consumption, average product cost, and catalyst activity are determined based on the catalyst deactivation kinetics, energy balance, and the migration of the composite curves. The Reactor-HEN coupling diagram is constructed to illustrate the variation curves of these indexes with catalyst activity/catalyst regeneration activity and target the optimal regeneration activity. The optimal catalyst service time is further determined considering the catalyst deactivation dynamics. A practical process with benzene hydrogenation to cyclohexene is studied. The optimal regeneration activity of the Ru-Zn-B/ZrO2 catalyst is determined to be 0.42, and the optimal service life is 1.32 y. The proposed method is efficient, and the results can guide the design and operation of the production processes.