Plug Flow Reactor (PFR) Design for the Production of 100,000 tons per year of Cumene from the Catalytic Alkylation of Propylene and Benzene

Abstract

In a bid to meet the ever-growing global demand for cumene based on its wide range of industrial applications and economic importance, the research considered the design of a plug-flow reactor (PFR) for the production of 100,000 tons of cumene per year from the catalytic alkylation of propylene and benzene. The PFR design models were developed by performing the mass and energy balance over the reactor at steady-state operation. The steady-state PFR performance models were simulated using the MATLAB R2023a version at an initial feed and operating temperature of 481.10 K and 483 K with varying fractional conversions from 0 to 0.95 at 0.05 intervals. At a maximum fractional conversion of 0.95, the PFR design specification for volume, height, diameter, space time, space velocity, quantity of heat generated, and quantity of heat generated per unit volume of the reactor was 19.7707 m3, 4.6523 m, 2.3261 m, 3.8766 s, 0.2580 s-1, 1.8035 J/s, and 0.03448 J/sm3, respectively. The profile behavior of the PFR functional parameters at changes in fractional conversion is in agreement with the trend for PFR operation at steady-state conditions, as shown in Figures 2–10. The evaluation of the PFR yearly production dependent on the reactor volume stood at $2,049.838. The article has shown that PFR is a suitable reaction medium for the catalytic alkylation process for optimum production of cumene and sustainability.