Reactive distillation, first used in the 1860s for ammonia recovery, has evolved through various applications, notably in MTBE production. The process leverages Le Chatelier’s law to optimize reaction conditions, affecting production variables like feed composition and column pressure. While it offers advantages such as improved selectivity and reduced costs, it also faces challenges related to volatility and residence time requirements.

1. REACTIVE
DISTILLATION

2. HISTORY
•Reactive distillation technique first applied for the
recovery of ammonia in the classic solvey process
during 1860s.
•Then in 1920s esterification process using
homogeneous liquid phase catalyst comes into the
picture.
•In 1970s, manufacturing of MTBE using
hetrogeneous catalyst comes into the consideration.

3. PRINCIPLE
•LeChatelier’s law:- For the reaction in equilibrium,
if any change in any process variables like
temperature, pressure or composition of reaction
mass is made, reaction move in such a direction
which will nullify the change.
A + B <--> C + D

4. CONVENTIONAL PROCESS

5. REACTIVE DISTILLATION

6. MTBE PRODUCTION USING RD
(1) Water scrubber
(2) Reactor
(3) RD column
(4) Absorber
(5) Stripper

7. EFFECT OF VARIOUS PARAMETERS ON RD OF
MTBE
(1)Effect of feed:-Increase in isobutylene percentage in feed
(a)decrease energy cost per kg of MTBE produced
(b)decrease in size of RD unit and associated equipments for
the same production rate of MTBE
(2)Effect of excess methanol:- suppress side reaction
(3)Effect of column pressure:-
(4)Effect of increasing length of reaction zone:-
(5)Effect of separation stages:-

8. Cont…..
(6)Effect of reflux ratio:-
(a)reaction zone temperature reduces
(b)concentration of ether in reaction zone reduces. It
reduces catalytic cracking of MTBE
(7)Effect of feed point:-

9. VARIOUS CONTACT DEVICES USED FOR
RD
•Tray column in which bed of catalyst is placed either
in downcomers or above the trays.
•Packed tower using random packing elements which
contain the catalyst or which may be made of the
catalyst
•Packed tower using ordered packing elements which
contain catalyst particles. In orderly packing element,
catalyst particles are sandwiched between two
supporting materials. Two types of ordered packings
are used.

10. KATMAX packing Bale packing

11. ADVANTAGES OF RD
•Shifting of equilibrium
•Reduction in plant cost
•Heat integration benefits
•Avoidance of azeotropes
•Improved selectivity

12. DISADVANTAGES OF RD
•Volatility constraints
•Residence time requirements
•Operating conditions for reaction and
distillation

13. APPLICATION OF RD
• Manufacturing of ethylacetate from ethanol
• Manufacturing of methylacetate from methnol
• Manufacturing of butyalacetate from butanol
• Manufacturing of MTBE and ETBE
• Manufacturing of benzyl chloride from toluene
• Manufacturing of ethyl propionate from ethanol
• Manufacturing of amino resins
• Selective hydrogenation of butadine of C4 stream
• Selective hydrogenation of pentadine of C5 stream
• Selective hydrogenation of hexadine of C6 stream

14. Cont….
•Thioetherification of mercaptens
•Alkylation of benzene to ethyl benzene
•Hydrodesulfurization of naptha