Steady state analysis of snowball effects for reaction–separation–recycle systems with thermally coupled distillation sequences

It is known that the steady and dynamic characteristics of processes with recycles can be significantly different from those without recycle streams. Particular attention has been given to the reactor–separator–recycle (RSR) system; because of the existence of snowball effects, a small load change can translate into a large change in the recycle flowrate, which propagates throughout the whole system. Previous works have analyzed the influence of separators on snowball effects using flash units and conventional distillation columns. This work explores the existence of snowball effects in steady state conditions under the implementation of thermally coupled distillation sequences in RSR systems. In particular, the implementation of coupled systems with side columns (sequences with side rectifiers or side strippers) is considered. A simplified process for ethylbenzene production is taken as a basis, and the effects of implementing thermally coupled systems on snowball effects are compared to those generated by conventional distillation systems.

► Snowball effects may appear in flowsheets with recycles. ► Snowball effects arise when a small load produces a large effect in the recycle. ► We analyze snowball effects in a reactor-separator-recycle system. ► The use of thermally coupled distillation systems on snowball effects is studied. ► Thermally coupled systems with side rectifier reduced both energy and snowball effects.