Modeling, simulation, and optimization of a front-end system for acetylene hydrogenation reactors

Abstract

The modeling, simulation, and dynamic optimization of an industrial reaction system for acetylene hydrogenation are discussed in the present work. The process consists of three adiabatic fixed-bed reactors, in series, with interstage cooling. These reactors are located after the compression and the caustic scrubbing sections of an ethylene plant, characterizing a front-end system; in contrast to the tail-end system where the reactors are placed after the de-ethanizer unit. The acetylene conversion and selectivity profiles for the reactors are optimized, taking into account catalyst deactivation and process constraints. A dynamic optimal temperature profile that maximizes ethylene production and meets product specifications is obtained by controlling the feed and intercoolers temperatures. An industrial acetylene hydrogenation system is used to provide the necessary data to adjust kinetics and transport parameters and to validate the approach.