On-line estimation and identification of a nonlinear, distributed-parameter process: The dehydrogenation of ethylbenzene to form styrene in a tubular, fixed-bed, catalytic reactor

The industrial production of styrene monomer is achieved via the dehydrogenation of ethylbenzene in the presence of steam over a metal oxide catalyst at a temperature around 600°C. The goal of this investigation was to develop and demonstrate an online scheme for estimation of process variables and identification of the dehydrogenation reaction parameters using a distributed-parameter, Kalman filter. This technique was first tested by computer simulation and accurately estimated the process states. Reaction parameters were identified well also, although they proved to be more sensitive to process noise than the state variables. A pilot plant and digital computer system were constructed in order to investigate experimentally the on-line identification scheme. The filter proved effective in estimating process variables. As the simulation predicted, the experimental identification of dehydrogenation reaction parameters was sensitive to process noise; however, the identified parameters are shown to be of potential use in optimization of the reactor operating conditions.

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