Kettle reactor capable of adsorbing impurities
The multi-stage stirring system and the kettle reactor with double filter screen design solve the problem of trace impurity treatment in the acrolein hydration reaction, achieve efficient impurity filtration and temperature control, and improve the reaction efficiency and economy.
Patent Information
- Application Number
- CN202510861309.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-25
- Publication Date
- 2025-09-19
AI Technical Summary
Existing autoclave reactors are difficult to effectively handle trace impurities in the acrolein hydration reaction, resulting in decreased catalyst activity, affecting reaction efficiency and cost.
It adopts a multi-stage stirring system, a double-screen graded filtration structure and a combined cooling system, combined with a rotating screen and baffle design to form a three-dimensional mixing flow field, achieving efficient impurity filtration and temperature control.
It significantly improves impurity filtration efficiency, reduces energy consumption and mixing energy consumption, extends catalyst life, and improves reaction efficiency and economy.
Smart Images
Figure CN120662245A_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the technical field of chemical equipment, and in particular to a kettle reactor capable of adsorbing impurities. Background Art
[0002] In the field of fine chemicals, efficient catalyst utilization and high product purity are key. Controlling trace impurities in reactor design is becoming increasingly important, especially in effectively removing impurities that are detrimental to catalytic reactions, to improve product quality and catalyst life.
[0003] Key technologies include filter design and reactor structure optimization. Filters effectively adsorb and filter impurities, improving catalyst utilization and playing a crucial role in achieving high-quality products.
[0004] To improve the efficiency and processing capacity of tank reactors, many researchers and engineers have attempted to integrate separation functions within the reactors. In recent years, some technical solutions have achieved solid-liquid separation by installing filters or similar devices within the tank reactors. However, existing filter designs still have shortcomings in terms of corrosion resistance, fluid flow uniformity, and filter cleaning and replacement.
[0005] Taking the acrolein hydration reaction as an example, current acrolein hydration reactors mostly use a single discharge pipe and a fixed filter, which makes it difficult to effectively handle the trace impurities generated during the reaction, resulting in a decrease in catalyst activity, affecting subsequent reactions, and increasing time and costs. Summary of the Invention
[0006] In view of the above-mentioned deficiencies in the prior art, the purpose of the present application is to provide a kettle reactor capable of adsorbing impurities, so as to solve the problem that trace impurities generated during the acrolein hydration reaction in the reactor of the prior art may lead to a decrease in catalyst activity.
[0007] In order to solve the above technical problems, this application adopts the following technical solutions: A kettle reactor capable of adsorbing impurities comprises a reactor body, the reactor body being a cylindrical structure with a closed end at one end and an open end at the other end; a reaction chamber for accommodating reactants for chemical reaction is provided in the reactor body; a reactor cover is provided at the open end, the reactor cover is detachably fixedly connected to the open end and is used to open or close the reaction chamber; a multi-stage agitator is provided in the reactor for fully stirring the materials; a feed port is provided on the reactor cover, the feed port is connected to the reaction chamber and is used to input the reaction materials into the reaction chamber; a discharge port is provided at the closed end of the reactor body, the discharge port is connected to the reaction chamber and is used to discharge the reaction products in the reaction chamber; a first discharge pipe and a second discharge pipe are provided at the discharge port, one end of the first discharge pipe is connected to the discharge port; one end of the second discharge pipe is connected to the first discharge pipe; a first filter is provided in the first discharge pipe and is detachably fixedly connected to the first discharge pipe; a second filter is provided in the second discharge pipe and is detachably fixedly connected to the second discharge pipe.
[0008] Preferably, a first discharge flange is provided on the first discharge pipe, and the first discharge flange includes two flanges I, and the flanges I are respectively fixedly connected to the first discharge pipe. The first filter is installed between the two flanges I and is detachably fixedly connected to the two flanges I.
[0009] Preferably, a second discharge flange is provided on the second discharge pipe, and the second discharge flange includes two flanges II, and the flanges II are respectively fixedly connected to the second discharge pipe. The second filter is installed between the two flanges II and is detachably fixedly connected to the two flanges II.
[0010] Preferably, an agitator is also provided on the reactor body, and the agitator includes a stirring rod, a first stirring paddle and a second stirring paddle. The stirring rod coincides with the axis of the reactor body, and one end of the stirring rod passes through the end of the reactor body close to the feed port and is fixedly connected to the driving end of the driving motor. The driving motor is fixedly connected to the reactor cover so that the axis of its driving end and the axis of the stirring rod coincide with the axis of the reactor body; the other end of the stirring rod extends into the reaction chamber and extends to the bottom near the reactor body; the first stirring paddle and the second stirring paddle are both located in the reaction chamber, and the first stirring paddle is arranged at a position on the stirring rod close to the driving motor and is fixedly connected to the stirring rod; the second stirring paddle is arranged at a position on the stirring rod away from the driving motor and is fixedly connected to the stirring rod.
[0011] Preferably, the first stirring paddle includes a first disc and three first blades, the first disc is mounted on the stirring rod and arranged in the horizontal direction, and is fixedly connected to the stirring rod, and the first blades are evenly spaced around the circumference of the first disc; the first blade is a sheet-like structure, and one end of the first blade is fixedly connected to the first disc, so that the plane where the first blade is located is perpendicular to the plane where the first disc is located; the second stirring paddle includes a second disc and three second blades, the second disc is mounted on the stirring rod and arranged in the horizontal direction, and is fixedly connected to the stirring rod; the second blade is a sheet-like structure, and the second blades are evenly spaced around the circumference of the second disc; wherein the second blade is arranged at an angle so that an angle of 45° is formed between the plane where the second blade is located and the horizontal plane.
[0012] Preferably, a plurality of rotating screens are provided between the first stirring paddle and the second stirring paddle. The rotating screens are sheet-like structures, evenly distributed along the circumference of the stirring rod and arranged in the vertical direction. One end of the rotating screen is fixedly connected to the stirring rod; a plurality of filter holes are provided on the rotating screen, and the aperture of the filter holes is 1-5 mm.
[0013] Preferably, a plurality of baffles are further provided inside the reaction chamber. The baffles are evenly spaced along the circumference of the reaction chamber, and one side of the baffle is fixedly connected to the inner side wall of the reaction chamber.
[0014] Preferably, a cooling jacket is provided on the outside of the reactor body, and the cooling jacket is arranged on the outside of one end of the reactor body where the discharge port is provided, and is fixedly connected to the outer wall of the reactor body, so that a cooling cavity capable of accommodating cooling water is formed between the cooling jacket and the reactor body; a cooling water inlet and a cooling water outlet are also provided on the cooling jacket, the cooling water inlet is connected to the cooling water inlet pipe, and the cooling water outlet is connected to the cooling water outlet pipe.
[0015] Preferably, a cooling coil is provided in the reaction chamber, and the cooling coil is spirally arranged around the inner wall of the reaction chamber, and the tube wall of the cooling coil is fixedly connected to the inner wall of the reaction chamber, so that the tube wall and the inner wall of the reaction chamber enclose a cooling coil inner cavity, and one end of the cooling coil inner cavity is connected to the cooling water inlet end, and the other end is connected to the cooling water outlet end.
[0016] Compared with the prior art, this application has the following beneficial effects: 1. This application has redesigned the structure of the kettle reactor in multiple dimensions. The multi-stage stirring system uses vertically set radial flow blades and 45° inclined axial flow blades to work together, and cooperates with a rotating screen with filter holes to form a three-dimensional mixing flow field, which not only enhances the shear force to break up particle agglomeration, but also optimizes the axial flow to reduce the reaction dead zone, reducing the mixing energy consumption by 20% while improving the uniformity by 25%; the double-screen graded filtration structure uses a coarse filter to intercept large particles of impurities and a fine filter to achieve fine filtration, reducing the outlet impurity concentration to 23% of the traditional design, and the filtration efficiency is as high as 99.13%; the combined cooling system integrates jacket cooling and spiral coils. The jacket quickly removes the overall reaction heat, and the coils accurately control the local temperature of the inner wall, increasing the temperature control accuracy by nearly 3 times, effectively suppressing side reactions; the flange-connected filter design can be quickly disassembled and assembled by bolts, shortening maintenance time by 70%.
[0017] 2. This application also sets a rotating screen and baffles in the kettle reactor. The rotating screen and the circumferentially arranged baffles produce a synergistic anti-blocking effect. The baffles convert the tangential flow into axial flow, dispersing the impact of the material; the rotating screen generates dynamic shear force during stirring, so that a slurry with a solid content of 15% can run continuously for 10 hours without clogging, breaking the 5% solid content limit of the traditional static filter; the tilted setting of the second blade can induce a chaotic mixing flow pattern, increase the turbulent dissipation rate by 30%, increase the mixing efficiency of non-Newtonian fluids by 40%, and significantly accelerate the reaction kinetics. In addition to temperature control, the cooling coil can also reduce the reactor wall temperature, reduce the deposition rate of heat-sensitive substances by 120%, and significantly extend the reaction cycle of the reaction raw materials, especially biological reactions; the two-stage filtration also brings economic benefits. The coarse filter protection extends the life of the fine filter by 3 times, reduces the replacement cost by 60%, and the graded pressure drop design reduces energy consumption by 25%.
[0018] 3. This application transforms passive components into a dynamic collaborative system - the rotating screen simultaneously performs stirring and pre-filtration functions, the multi-stage blade combination solves the mixing problem while optimizing energy transfer, and the dual cooling paths unexpectedly suppress scale formation during the temperature control process; these design structures enable the reactor to efficiently process complex material systems such as high solid content and heat sensitivity, providing a new solution for the chemical and pharmaceutical fields that combines engineering practicality and economy. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Figure 1 This is a schematic diagram of the structure of a tank reactor that can adsorb impurities.
[0020] Figure 2 Schematic diagram of the structure of the cooling coil.
[0021] In the figure: reactor body 1, reactor cover 2, feed port 3, discharge port 4, first discharge pipe 5, second discharge pipe 6, first filter screen 7, second filter screen 8, stirring rod 9, drive motor 10, first disc 11, first paddle 12, second disc 13, second paddle 14, rotating screen 22, baffle 15, cooling jacket 16, cooling water inlet 17, cooling water outlet 18, cooling coil 19, cooling water inlet end 20, cooling water outlet end 21. DETAILED DESCRIPTION
[0022] This application will provide a clear and complete description of the technical solutions in the embodiments of this application in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of this application, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on this application are within the scope of protection of this application.
[0023] Unless otherwise indicated in specific cases in this application, the numerical ranges listed herein include the upper and lower limits, as well as all integers and fractions within the range, and are not limited to the specific values listed when defining the range.
[0024] The present application provides a tank reactor capable of adsorbing impurities, such as Figure 1 As shown, the kettle reactor includes a reactor body, which is a cylindrical barrel-shaped structure with a closed end at one end and an open end at the other end; a reaction chamber for accommodating reactants for chemical reaction is provided in the reactor body; a reactor cover is provided at the open end, and the reactor cover is detachably and fixedly connected to the open end for opening or closing the reaction chamber; a feed port is provided on the reactor cover, and the feed port is connected to the reaction chamber for inputting reaction materials into the reaction chamber; a discharge port is provided at the closed end of the reactor body, and the discharge port is connected to the reaction chamber for discharging the reaction products in the reaction chamber; a first discharge pipe and a second discharge pipe are provided at the discharge port, one end of the first discharge pipe is connected to the discharge port; one end of the second discharge pipe is connected to the first discharge pipe; a first filter screen is provided in the first discharge pipe, and the first filter screen is detachably and fixedly connected to the first discharge pipe; a second filter screen is provided in the second discharge pipe, and the second filter screen is detachably and fixedly connected to the second discharge pipe. The first filter screen and the second filter screen are both made of 304 stainless steel with a porosity ratio of 0.4-0.6.
[0025] A first discharge pipe is provided with a first discharge flange, comprising two flanges I, each of which is fixedly connected to the first discharge pipe. The first filter is mounted between the two flanges I and is removably fixedly connected to the two flanges I. A second discharge pipe is provided with a second discharge flange, comprising two flanges II, each of which is fixedly connected to the second discharge pipe. The second filter is mounted between the two flanges II and is removably fixedly connected to the two flanges II.
[0026] The reactor body is also provided with an agitator, which includes a stirring rod, a first stirring paddle and a second stirring paddle. The stirring rod coincides with the axis of the reactor body, and one end of the stirring rod passes through the end of the reactor body close to the feed port and is fixedly connected to the driving end of the drive motor. The drive motor is fixedly connected to the reactor cover so that the axis of its driving end and the axis of the stirring rod coincide with the axis of the reactor body; the other end of the stirring rod extends into the reaction chamber and extends to the bottom near the reactor body. The first stirring paddle and the second stirring paddle are both located in the reaction chamber, and the first stirring paddle is arranged at a position on the stirring rod close to the drive motor and is fixedly connected to the stirring rod. The second stirring paddle is arranged at a position on the stirring rod away from the drive motor and is fixedly connected to the stirring rod. The drive motor can simultaneously drive the first stirring paddle and the second stirring paddle to rotate around the axis of their driving ends.
[0027] The first stirring paddle includes a first disc and three first blades. The first disc is mounted on the stirring rod and is arranged in the horizontal direction and is fixedly connected to it. The first blades are evenly spaced around the circumference of the first disc. The first blade is a sheet-like structure. One end of the first blade is fixedly connected to the first disc so that the plane where the first blade is located is perpendicular to the plane where the first disc is located, thereby forming a radial flow blade structure for the first stirring paddle. The second stirring paddle includes a second disc and three second blades. The second disc is mounted on the stirring rod and is arranged in the horizontal direction and is fixedly connected to it. The second blade is a sheet-like structure. The second blades are evenly spaced around the circumference of the second disc. The second blade is tilted so that an angle of 45° is formed between the plane where the second blade is located and the horizontal plane. The second blade can simultaneously generate axial flow and radial flow during stirring. This combined flow can achieve a good mixing effect. Among them, the diameters of the first and second blades are 2 / 3-1 times their respective radii, and the length of the second blade is greater than that of the first blade, ensuring that the second blade can fully stir the reaction liquid at the bottom of the reaction chamber to ensure sufficient reaction; at the same time, the straight-line distance between the bottom of the second blade and the liquid surface of the reaction liquid is 1 / 2-2 / 3 of the liquid level of the reaction liquid, ensuring that the second blade can stir and mix the reaction liquid at the bottom of the reaction chamber, avoiding the increase in viscosity of the reaction liquid at the bottom of the reaction chamber due to the increase in product, thereby causing incomplete reaction. The multi-stage stirring system used in this application can significantly improve the mixing efficiency. By combining the first stirring paddle (radial flow) and the second stirring paddle (45° inclined axial flow) with a rotating screen, a three-dimensional mixing flow field is formed: the vertical disc design of the first blade generates strong shear force to break up agglomerated particles; the 45° inclination angle of the second blade optimizes axial flow and reduces the dead zone at the bottom of the reactor (the 45° inclination maximizes the material throwing angle). Compared with single-stage stirring, the energy consumption is reduced by 20% while the mixing uniformity is increased by 25%, which is particularly suitable for liquid-liquid heterogeneous reactions.
[0028] Between the first and second stirring paddles, multiple rotating screens are positioned. These are sheet-like structures, evenly spaced around the circumference of the stirring rod and arranged vertically. One end of each rotating screen is fixedly connected to the stirring rod. The rotating screens are equipped with multiple filter holes with a diameter of 1-5 mm, which dynamically filter during stirring, achieving simultaneous mixing and pre-separation. The rotating screens are coated with an anti-fouling and anti-corrosion coating, which promotes uniform distribution of the material without affecting stirring and helps prevent solid particles from settling at the bottom. Multiple baffles are also positioned within the reaction chamber, evenly spaced around the circumference. One side of each baffle is fixedly connected to the inner wall of the reaction chamber. When the reaction liquid in the reaction chamber is stirred, impurities are flung to a position close to the inner wall of the reaction chamber due to the stirring. The baffles act to collect the impurities at the discharge port and deposit them on the filter screen in the first or second discharge pipe, preventing them from affecting the reaction in the reaction chamber. In actual application, the present application found that the rotating screen generates dynamic shear force during stirring, and the baffles arranged along the circumference of the reaction chamber can convert the tangential flow into axial flow. The two produce a synergistic anti-blocking effect and disperse the impact of materials. In actual application, the rotating screen generates dynamic shear force during stirring, allowing a slurry with a solid content of 15% to run continuously for 10 hours without clogging, breaking the 5% solid content limit of traditional static filters; the 45° design of the inclined blades unexpectedly triggers a chaotic mixing flow pattern, increasing the turbulence dissipation rate by 30% and the mixing efficiency of non-Newtonian fluids by 40%. It not only solves the original bottom mixing problem, but also significantly accelerates the reaction kinetics, making the chemical reaction rate faster and the reaction more complete.
[0029] A cooling jacket is provided on the outside of the reactor body. The cooling jacket is provided on the outside of one end of the reactor body where the discharge port is provided, and is fixedly connected to the outer wall of the reactor body, so that a cooling chamber capable of accommodating cooling water is formed between the cooling jacket and the reactor body. A cooling water inlet and a cooling water outlet are also provided on the cooling jacket. The cooling water inlet is connected to the cooling water inlet pipe, and the cooling water outlet is connected to the cooling water outlet pipe. A cooling coil is provided in the reaction chamber, such as Figure 2 As shown, in order to more accurately show the location of the cooling coil, Figure 2 The baffle structure is removed. The cooling coil is spirally arranged around the inner wall of the reaction chamber. The cooling coil wall is fixedly connected to the inner wall of the reaction chamber, forming a cooling coil lumen. One end of the cooling coil lumen is connected to the cooling water inlet, and the other end is connected to the cooling water outlet. In addition to controlling the temperature, the cooling coil also reduces the temperature of the inner wall of the reaction chamber. During biological reactions, the deposition rate of heat-sensitive substances such as proteins can be reduced by 120%, significantly extending the reaction cycle.
[0030] A thermometer mounting hole for mounting a thermometer is provided on the kettle cover, so that the thermometer can detect the reaction temperature in the reaction chamber; a pressure gauge mounting hole for mounting a pressure gauge is provided on the kettle cover, so that the pressure gauge can detect the pressure in the reaction chamber.
[0031] When a cooling coil and a baffle are simultaneously provided in the reactor, an opening for accommodating the cooling coil is provided on the side of the baffle connected to the inner wall of the reaction chamber. The shape of the opening is consistent with the outer shape of the cooling coil, ensuring that the positions of the cooling coil and the baffle do not affect each other, while also ensuring that the baffle and the cooling coil play their due roles.
[0032] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application and not to limit the technical solutions. Those skilled in the art should understand that modifications or equivalent replacements of the technical solutions of the present application that do not depart from the purpose and scope of the technical solutions of the present application should be included in the scope of the claims of the present application.
Claims
1. A tank reactor capable of adsorbing impurities, characterized in that: The invention comprises a reactor body (1), wherein the reactor body is a cylindrical structure with one end being a closed end and the other end being an open end; a reaction chamber for accommodating reactants for chemical reaction is provided in the reactor body; a reactor cover (2) is provided at the open end, wherein the reactor cover is detachably fixedly connected to the open end and is used to open or close the reaction chamber; a multi-stage stirrer is provided in the reactor for fully stirring the materials; a feed port (3) is provided on the reactor cover, wherein the feed port is connected to the reaction chamber and is used to input the reaction materials into the reaction chamber; a discharge port (4) is provided at the closed end of the reactor body, wherein the discharge port is connected to the reaction chamber and is used to discharge the reaction products in the reaction chamber; A first discharge pipe (5) and a second discharge pipe (6) are provided at the discharge port, one end of the first discharge pipe is connected to the discharge port; one end of the second discharge pipe is connected to the first discharge pipe; A first filter screen (7) is provided in the first discharge pipe, and the first filter screen is detachably fixedly connected to the first discharge pipe; a second filter screen (8) is provided in the second discharge pipe, and the second filter screen is detachably fixedly connected to the second discharge pipe.
2. The tank reactor according to claim 1, wherein A first discharge flange is provided on the first discharge pipe, and the first discharge flange includes two flanges I, and the flanges I are fixedly connected to the first discharge pipe respectively. The first filter is installed between the two flanges I and is detachably fixedly connected to the two flanges I.
3. The tank reactor according to claim 1, wherein A second discharge flange is provided on the second discharge pipe. The second discharge flange includes two flanges II. The flanges II are fixedly connected to the second discharge pipe respectively. The second filter is installed between the two flanges II and is detachably fixedly connected to the two flanges II.
4. The tank reactor according to claim 1, wherein The reactor body is also provided with an agitator, comprising a stirring rod (9), a first stirring paddle and a second stirring paddle, wherein the stirring rod coincides with the axis of the reactor body, and one end of the stirring rod passes through the end of the reactor body close to the feed port and is fixedly connected to the driving end of the driving motor (10), and the driving motor is fixedly connected to the reactor cover so that the axis of its driving end and the axis of the stirring rod coincide with the axis of the reactor body; the other end of the stirring rod extends into the reaction chamber and extends to the bottom of the reactor body; the first stirring paddle and the second stirring paddle are both located in the reaction chamber, and the first stirring paddle is arranged at a position on the stirring rod close to the driving motor and is fixedly connected to the stirring rod; the second stirring paddle is arranged at a position on the stirring rod away from the driving motor and is fixedly connected to the stirring rod.
5. The tank reactor according to claim 4, characterized in that: The first stirring paddle comprises a first disc (11) and three first blades (12), the first disc is mounted on the stirring rod and arranged in the horizontal direction and fixedly connected thereto, and the first blades are evenly spaced around the circumference of the first disc; the first blade is a sheet-like structure, one end of the first blade is fixedly connected to the first disc, so that the plane where the first blade is located is perpendicular to the plane where the first disc is located; the second stirring paddle comprises a second disc (13) and three second blades (14), the second disc is mounted on the stirring rod and arranged in the horizontal direction and fixedly connected thereto; the second blade is a sheet-like structure, and the second blades are evenly spaced around the circumference of the second disc; wherein the second blade is tilted so that an angle is formed between the plane where the second blade is located and the horizontal plane, and the angle is 45°.
6. The tank reactor according to claim 1, characterized in that: A plurality of rotating screens (22) are further provided between the first stirring paddle and the second stirring paddle. The rotating screens are sheet-like structures, are evenly distributed along the circumference of the stirring rod and are arranged in the vertical direction. One end of the rotating screen is fixedly connected to the stirring rod. The rotating screen is provided with a plurality of filter holes, and the aperture of the filter holes is 1-5 mm.
7. The tank reactor according to claim 1, characterized in that: A plurality of baffles (15) are also provided inside the reaction chamber. The baffles are evenly spaced along the circumference of the reaction chamber, and one side of the baffle is fixedly connected to the inner side wall of the reaction chamber.
8. The tank reactor according to claim 1, characterized in that: A cooling jacket (16) is provided on the outside of the reactor body. The cooling jacket is provided on the outside of one end of the reactor body where the discharge port is provided, and is fixedly connected to the outer wall of the reactor body, so that a cooling chamber capable of accommodating cooling water is formed between the cooling jacket and the reactor body. A cooling water inlet (17) and a cooling water outlet (18) are also provided on the cooling jacket. The cooling water inlet is connected to a cooling water inlet pipe, and the cooling water outlet is connected to a cooling water outlet pipe.
9. The tank reactor according to claim 1, characterized in that: A cooling coil (19) is provided in the reaction chamber. The cooling coil is spirally arranged around the inner wall of the reaction chamber, and the tube wall of the cooling coil is fixedly connected to the inner wall of the reaction chamber, so that the tube wall and the inner wall of the reaction chamber enclose an inner cavity of the cooling coil. One end of the inner cavity of the cooling coil is connected to the cooling water inlet end (20), and the other end is connected to the cooling water outlet end (21).