Mathematical modeling and optimization of the dehydrogenation of ethylbenzene to form styrene

Abstract A mathematical model is developed for a styrene pilot plant reactor. The steady state version of this model was used to optimize the location of a steam injection port part way along the catalytic bed. Significant improvement in reactor performance was predicted by splitting the steam feed between the reactor inlet and the injection port. Performance was measured in terms of market value of products minus a utility cost for the steam. Studies were also carried out via computer simulation to determine optimal operating conditions. An important result was the relationship of optimal steam‐to‐ethylbenzene feed ratio to the kinetic parameters which describe the main dehydrogenation reaction. A pilot plant was constructed and operated in order to investigate experimentally the predictions of the mathematical model. Instrumentation was designed and installed so that an on‐line digital computer could acquire process measurements directly and establish operating conditions. The experimental program confirmed the improved performance by operation of the reactor with a steam injection port and the existence of an optimum of the steam‐to‐ethylbenzene feed ratio as indicated by simulation.