The nonlinear behavior of the heat-integrated plug-flow reactor; consisting
of a feed-effluent hear exchanger (FEHE) furnace, adiabatic tubular reacto
r, and steam generator is studied considering a first-order irreversible, e
xothermic, adiabatic reaction. Bifurcation theory is used to analyze the re
lationships among design, reaction thermodynamics and kinetics, and state m
ultiplicity and stability. Hysteresis, isola and boundary limit varieties a
re computed, and the influence of the activation energy, reaction heat and
FEHE efficiency on the multiplicity region is studied. The double-Hopf and
double-zero bifurcation points divide parameter space in regions with diffe
rent dynamic behavior. State multiplicity, isolated branches, and oscillato
ry behavior may occur for realistic values of model parameters. A design pr
ocedure is proposed to ensure a desired multiplicity pattern and a stable p
oint of operation and to avoid high sensitivity. The procedure was applied
to three reaction systems with different kinetic and thermodynamic characte
ristics.