Développement d’une méthodologie pour la conduite en sécurité d’un réacteur continu et intensifié

Abstract : Today, the chemical industry has to deal with new challenges. In addition to produce more and faster, safer and cleaner production must be performed. Process intensification can be considered as a method that allows to prevent and reduce risks related to major industrial accidents. Indeed significant progress has been reached in the development of new reactor technologies: today, miniaturised and continuous processes are being developed to attain better heat transfer and safer conditions compared to traditional batch or semi-batch operations. These performances authorise to modify operating conditions by employing higher concentrations and using less solvent and reaction volumes. In this field, new prototypes of “heat-exchanger/reactors” are a good illustration: built like a plate heat-exchanger, internal plates are designed in order to carry out chemical synthesis. But these new concepts of reactor design being less familiar than traditional ones, research work is necessary not only to assess their feasibility and potentialities but also to evaluate their efficiency and intrinsic characteristics. The aim of the study, sponsored by CNRS and INERIS, was therefore to develop a methodology in order to carry out safely an exothermic reaction in an intensified continuous reactor. It was established on a case study: the transposition of the esterification between propionic anhydride and 2-butanol in a new prototype of heat-exchanger/reactor, called Open Plate Reactor and developed by Alfa Laval. The approach was divided in three steps. In a first part, experimental data obtained by calorimetry allow to determine the potential hazard of the compounds as well as the reaction and a kinetic model is validated. In a second stage a dedicated software model is used to calculate optimal operating conditions for safe control. Experiments are then achieved to test these conditions. In the last step, the inherently safer behaviour of the reactor is evaluated in the case of probable malfunctions (fluids shutdown) due to the thermal inertia of the apparatus. Finally, the evolution of the temperature profiles is obtained by dynamic simulation. To complete this approach, INERIS has been involved since 2003, in the IMPULSE project, and works with several partners in order to develop a new risk analysis methodology dedicated to microreactor, intensified process and multiscale equipments.
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Wassila Benaissa, Douglas Carson, Michel Demissy. Développement d’une méthodologie pour la conduite en sécurité d’un réacteur continu et intensifié. Rapport Scientifique INERIS, 2008, 2007-2008, pp.93-97. ⟨ineris-01869207⟩

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