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Waste minimization in reactor design is an effective approach for pollution control, when compared to the traditional practice of the end-of-pipe treatment. Reactor degree of backmixing and operating conditions are important factors that determine the performance of chemical process, including environmental impact. For the purpose of waste minimization, two modeling methods were used for simulating the performance of the acrylonitrile production reactor, based on the ammoxidation of propylene. The effect of residence time, temperature, degree of backmixing on the steady-state propylene conversion, and production of waste were determined. The tanks-in-series model and the axial dispersion model were used to account for the degree of backmixing. The two main by-products in the acrylonitrile process are acetonitrile and hydrogen cyanide, which are both highly toxic waste. Extensive reactor backmixing reduces propylene conversion, especially at high temperature and residence time. Minimum acetonitrile production is favored by low residence time, high to moderate temperature, and no backmixing. Minimum hydrogen cyanide production is favored by low residence time, low temperature, and no backmixing. At 450 °C, the percentage of increase in the selectivity of acrylonitrile, with respect to hydrogen cyanide at plug-flow reactor conditions, as compared to a continuous stirred tank reactor, is 87.1, 74.3, 50.9, 30.4, and 12.4% at a residence time of 1, 2, 4, 6, and 8 s, respectively. The reactor degree of backmixing and operating conditions are important factors that affect the environmental friendliness of the acrylonitrile production process.

Acrylonitrile Process Enhancement through Waste Minimization: Effect of Reaction Conditions and Degree of Backmixing