Continuous flow reactor

Abstract

The utility model discloses a continuous flow reactor which comprises a motor, a stirrer, two end reaction discs with heat exchange cavities at two ends of the reactor, a plurality of middle reaction discs with heat exchange cavities in the middle of the reactor, material inlet and outlet runners, connecting pipes, a detection instrument and a support connecting part, the two reaction discs which are connected together form a reaction cavity; materials simultaneously and continuously enter a reaction cavity of the reactor through a connecting pipe, react under stirring and mixing of a stirrer driven by a motor and flow into a hole channel in the center of the reactor; and meanwhile, a cooling or heating medium enters the heat exchange cavity through the connecting pipe for heat exchange. Compared with the prior art, the novel structural design can achieve better reaction stirring and mixing effects and has a very good heat transfer effect, so that the reaction safety is improved, and very good economical efficiency is achieved; due to the fact that the flow channel of the reactor is relatively large, the reactor has higher applicability.

Description

Technical Field

[0001] This utility model belongs to the field of biochemical, petroleum and chemical equipment, and in particular a continuous flow reactor. Background Technology

[0002] In the field of chemical engineering, many chemical reactions involve the mixing of liquids with liquids (including fluid slurries). Since most reactants are flammable or explosive, improper reaction control poses a risk of runaway explosions. This places high demands on reaction safety control, leading to a search for safe and efficient reactors. Currently, many reactors are available on the market, including batch reactors, tubular reactors, microchannel reactors, and other specially designed reactors. Whether batch or continuous flow, reactors used in chemical engineering must address two main challenges to achieve safe production: ensuring thorough mixing of reactants for complete reaction, and promptly removing the large amount of heat released during the reaction. Current reactors on the market have shortcomings in both aspects. Due to limitations in existing reactor structures, either the mixing degree of raw materials is insufficient to meet the requirements of thorough mixing, or the speed and capacity of heat removal are inadequate, resulting in difficulties in controlling the reaction temperature. Commonly used batch reactors suffer from poor mixing and slow heat transfer due to the large amount of material inside and the low stirring speed. Tubular reactors, lacking stirring components, have even worse mixing, and even with static mixing components, the effect may not meet expectations, and the heat transfer is not ideal. Microchannel reactors excel in heat transfer, but they encounter the problem of particles in the slurry clogging the flow channels, which greatly limits their application range. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides a continuous flow reactor that appears as a cylindrical or tubular reactor. Its novel structural design achieves significantly better reaction stirring and mixing effects and excellent heat transfer compared to existing reactors, thereby improving reaction safety and economic efficiency. The relatively large flow channel of this reactor enhances its applicability. Furthermore, its modular nature allows for the addition of modules to meet reaction capacity requirements, improving its convenience.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0005] A continuous flow reactor includes a motor, a stirrer, two end reaction plates with heat exchange chambers at both ends of the reactor, multiple intermediate reaction plates with heat exchange chambers in the middle of the reactor, inlet and outlet channels and connecting pipes, detection instruments, supporting and connecting components, etc.

[0006] The overall structure of the reactor is a combination of a main body consisting of an end reaction plate connected to multiple intermediate reaction plates and then to another end reaction plate, plus a stirrer and a motor. The reaction plates are modularly designed; that is, the end reaction plate is connected to multiple intermediate reaction plates and then to another end reaction plate, and the stirrer runs through all the reaction plates.

[0007] The reaction disks (including the middle reaction disk and the end reaction disks) are circular and have the same diameter. Each reaction disk is a module and each reaction disk is equipped with a heat exchange chamber. When the reaction disks are connected together, they form a reaction chamber. Multiple reaction disks connected together will form multiple reaction chambers. The heat exchange chambers and reaction chambers are not interconnected, forming an alternating arrangement of heat exchange chambers and reaction chambers. That is, one heat exchange chamber is connected to one reaction chamber, then another heat exchange chamber, and then another reaction chamber, and this sequence is repeated continuously. Each reaction disk has a hole at its center to form a channel for material flow.

[0008] The intermediate reaction disks with heat exchange chambers in the middle section have the following structure for a single intermediate reaction disk: one side is a concave disc-shaped or planar disc-shaped structure, which is connected to the corresponding concave disc structure of the previous reaction disk by a flange to form a cavity as a reaction space (i.e., reaction chamber). In the middle is a cavity (called heat exchange chamber) for the flow of cooling or heating media (such as water, steam, etc.). The other side is a concave disc-shaped structure backing onto the heat exchange chamber. This disc-shaped structure is connected to the next reaction disk module by a flange.

[0009] The two end reaction plates with heat exchange chambers have the following structure: the end reaction plate closer to the motor has a heat exchange chamber on one side, along with corresponding seals, support connectors, and an outlet pipe; the other side has a concave disc-shaped structure connected to the flange of the intermediate reaction plate. The other end reaction plate farther from the motor has the following structure: the end reaction plate has a heat exchange chamber on one side, along with corresponding seals or shaft support connectors and an outlet pipe; the other side has a flat disc-shaped or concave disc-shaped structure connected to the flange of the intermediate reaction plate.

[0010] The motor is a drive device connected to the stirrer.

[0011] The stirrer is a structure with a main shaft passing through all reaction chambers and heat exchange chambers and having multiple layers of stirring blades on it. Each layer of stirring blades is located in a reaction chamber and rotates with the main shaft to stir the reaction materials in its respective chamber. The main shaft of the stirrer has a support and sealing component on the side near the motor to ensure that it operates smoothly without shaking. The other end of the main shaft can be fixed or not, depending on the size of the reactor and the smoothness of the stirrer's operation. If the reactor is large and the main shaft of the stirrer is too long and the shaking is too great, then the other end must also be fixed. This patent application chooses to describe the other end as fixed as well.

[0012] The other end of the stirring shaft can be fixed or not, depending on the size of the reactor and the smoothness of the stirring operation. If the reactor size is small, it generally does not need to be fixed. If the reactor size is large and the stirring shaft is too long and the shaking is too great, then the other end should also be fixed. Preferably, the other end should also be fixed.

[0013] The material enters the reactor's reaction chamber continuously through the connecting pipe, reacts under the stirring and mixing of the motor-driven agitator, and flows into the channel in the center of the reactor. All the material in the reaction chamber converges in the channel in the center of the reactor and then flows out from the outlet pipe at one end of the reactor. At the same time, the cooling or heating medium enters the heat exchange chamber through the connecting pipe for heat exchange. Each reaction plate is equipped with a detection instrument that can detect the temperature and pressure inside the reaction chamber as needed.

[0014] The material inlet and outlet channels and pipes include a material inlet pipe on the outer edge of each reaction plate for material to enter the reaction chamber, an opening in the center of each reaction plate for material to flow, a central hole-shaped flow channel in the end reaction plate connected to the material outlet pipe, and a pipe for entering and exiting hot and cold media on the outer edge of the heat exchange chamber on each reaction plate.

[0015] The detection instruments are provided on each reaction plate as needed to detect the temperature, pressure, etc. inside the reaction chamber, in order to monitor the state of the reactor.

[0016] Furthermore, due to its modular design, the overall structure of the reactor can be combined with other modules. The reactor structure can be as small as two end reaction plates combined together. The reactor structure in the attached drawings of this patent application is illustrated by taking two end reaction plates plus two intermediate reaction plates as an example. If it is necessary to further increase the output, the number of intermediate reaction plates can be increased directly. Theoretically, as long as the manufacturing material can meet the strength requirements, the number of intermediate reaction plates can be increased indefinitely.

[0017] Furthermore, the impeller can be a straight blade impeller, an oblique blade impeller, or other suitable types of blades. The number of blades can be a single blade impeller, a two-blade impeller, a three-blade impeller, a four-blade impeller, or other multi-blade impellers. The figure in this patent application shows a three-blade impeller.

[0018] Furthermore, depending on the needs, the reactor can be positioned vertically or horizontally.

[0019] Furthermore, depending on the needs, appropriate instruments can be added or removed from the reactor to meet monitoring requirements.

[0020] Furthermore, the reactor is currently designed with flange connections between the reaction discs. If necessary, the flange connection can be changed to welding or other feasible methods.

[0021] Furthermore, the reactor has material outlets at both ends. In practical applications, only one outlet can be used, and the outlet at the other end can be used as a backup. In the example of this application, the outlet furthest from the motor end is selected as the material outlet.

[0022] Furthermore, due to its scientifically sound structure, and especially its excellent mixing and heat exchange effects, the reactor described in this application can also be used as a mixer for a variety of materials.

[0023] The structural design of the reaction disk consists of multiple intermediate reaction disks with heat exchange chambers in the middle. The structure of a single intermediate reaction disk is as follows: one side is a flat or concave disc-shaped structure, which is connected to the corresponding concave disc structure of the previous reaction disk by a flange to form a cavity as a reaction space, i.e., a reaction chamber. The middle part of the cavity is a cavity for the flow of cooling or heating media, including water and steam. The cavity is called a heat exchange chamber, and the other side is a concave disc-shaped structure backing onto the heat exchange chamber. This concave disc-shaped structure is connected to the next reaction disk module by a flange.

[0024] The two end reaction plates with heat exchange chambers have the following structure: the end reaction plate closer to the motor has a heat exchange chamber on one side, along with corresponding seals and an outlet pipe, which is connected to the motor via a fixed bracket; the other side is a concave disc-shaped structure connected to the intermediate reaction plate via a flange. The other end reaction plate farther from the motor has the following structure: a heat exchange chamber on one side, along with corresponding seals, an outlet pipe, and a shaft support; the other side is a flat disc-shaped or concave disc-shaped structure connected to the intermediate reaction plate via a flange.

[0025] The design of the heat exchange medium flow channel involves the heat exchange medium continuously entering and exiting the heat exchange cavity simultaneously from the pipe on the outer edge of the heat exchange cavity of the reaction plate, where it undergoes heat exchange for cooling or heating. This structural design allows the heat exchange medium in the heat exchange cavity of the middle reaction plate to simultaneously exchange heat with the reactants in the reaction cavities on both sides.

[0026] The working principle of this utility model is as follows:

[0027] Under normal circumstances, the reaction raw materials are connected to the material inlet of the reactor through pipelines and enter each reaction chamber simultaneously and continuously. After being strongly stirred by the agitator, the raw materials entering the reaction chamber are fully mixed and react in the reaction chamber. At the same time, they flow towards the center of the chamber and into the inner channel in the center of the reaction plate. The inner holes of all the reaction plates are connected. The reacted materials in each reaction chamber converge in the central channel and flow along the central channel of the agitator shaft to the outlet pipes at both ends of the reactor. They flow out from the outlet pipe at one end of the reactor (the other outlet pipes can be used as backups) and leave the reactor to obtain the reaction products.

[0028] The above describes the material flow direction under normal circumstances. Under special circumstances, the material flow direction can be adjusted.

[0029] The heat exchange medium inside the heat exchange chamber is also connected to a cold source or a heat source through pipes entering and exiting its outer edge. While the raw materials enter the reaction chamber to react, the heat exchange medium also enters and exits the heat exchange chamber and flows, bringing in heat or taking away reaction heat through heat exchange between the reaction plate walls.

[0030] The temperature or pressure during the reaction process can be detected and observed by the pressure gauge and insertion thermometer set on the outer edge of the reaction plate. As needed, various adjustment measures can be taken to keep the reactor operating parameters within the required range and ensure the normal and safe operation of the reactor.

[0031] Compared with the prior art, the advantages and beneficial effects of this utility model are as follows:

[0032] 1. In this utility model, the material in the reactor simultaneously enters the narrow reaction chamber from the outer edge of each reaction plate and flows towards the center. After converging, it is discharged from the flow channel in the center of the entire reactor. This flow channel design is novel and has not been seen in existing reactor technology. This new design makes the reactor flow channel shorter, more compact and reasonable, reduces the volume of the reaction unit, greatly increases safety, and helps to significantly reduce the size of the reactor.

[0033] 2. In this utility model, the heat exchange effect of the reactor is significantly improved compared to other industrial reactors. This is because the stirring speed of the agitator designed in this patent application is much higher than that of existing industrial reactors. For example, due to the large capacity, large size of the agitator, and mechanical vibration, the stirring speed of a typical batch reactor is limited to about 80-150 rpm. However, due to the reasonable design structure and the small size of the reactor and agitator, the stirring speed designed in this patent application can reach thousands of rpm. The strong stirring can greatly enhance the heat exchange effect of the reactor wall, making it easier to control the reaction temperature, which also improves safety.

[0034] 3. In this invention, the mixing effect of the reactor is significantly improved compared to other industrial reactors. Within each narrow, small-sized reaction chamber, the powerful action of the stirring blades results in a material mixing effect many times better than other types of industrial reactors, even comparable to or better than laboratory-level mixing. This leads to a more uniform microscopic state of the reaction, greatly enhancing reaction stability and improving the safety of the chemical reaction. This novel design has not been seen in existing reactor technologies.

[0035] 4. In this invention, the heat exchange medium in the heat exchange chamber of each intermediate reaction disc can simultaneously exchange heat with the reaction in the reaction chambers on both sides. This novel design has not been seen in existing reactor technologies. The disc-shaped heat exchange surface not only increases the heat exchange area and improves the heat exchange effect, but also makes the reactor structure compact and small, greatly reducing the reactor size and saving equipment costs and investment.

[0036] 5. The reactor size of this invention is between that of a microchannel reactor, a batch reactor, and a tubular reactor. It can be used for slurry reactions, unlike microchannels which will become clogged when they encounter slurry, thus greatly improving its applicability to various reactions. Due to its smaller size, it also has less material storage capacity than batch reactors or tubular reactors, making it safer and easier to control in production.

[0037] 6. The reactor of this utility model has a novel structure, high safety, small overall size, reasonable design, and is more economical and suitable for industrial production. Attached Figure Description

[0038] Figure 1 This is a structural schematic diagram (cross-sectional view) of an embodiment of the present utility model;

[0039] Figure 2 yes Figure 1 Sectional view of AA in the middle;

[0040] The main components shown in the diagram are: 1. Motor; 2. Stirring shaft; 3. End reaction plate; 4. 5. Intermediate reaction plate; 6. End reaction plate; 7. Stirring paddle; 8. Support and related accessories. Detailed Implementation

[0041] The present invention will be further described below with reference to the accompanying drawings and embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the present invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the present invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0042] A continuous flow reactor includes 1. an electric motor; 2. a stirring shaft; 3. an end reaction plate; 4. an intermediate reaction plate; 5. an end reaction plate; 6. an end reaction plate; 7. a stirring paddle (each reaction chamber has a stirring paddle); 8. a support frame and related accessories.

[0043] Motor 1 is fixed to bracket 8 and connected to the reactor. Simultaneously, the coupling of motor 1 is connected to stirring shaft 2 to drive the stirring shaft and impeller 7 to rotate. Reactant M1 enters the reaction chamber containing impeller 7 through material inlet pipes N1, N3, and N5. Reactant M2 simultaneously enters the reaction chamber through inlet pipes N2, N4, and N6. Note: The reaction chamber has a spare inlet pipe, such as N19, for adding more reactants. Reactants M1 and M2 react within the reaction chamber through stirring and flow towards the central channel. Reactants from multiple reaction chambers converge in the central channel and finally flow to the outlet pipe at one end of the reactor, for example, exiting through inlet N17. Inlets N15, N16, and N18 are spare ports. During the reaction process, through… Figure 2 Pressure gauge P and temperature gauge T, installed on the outer wall of the reaction pan, are used to monitor the pressure and temperature inside the reactor.

[0044] The cooling medium or heating medium C1 simultaneously enters the reactor heat exchange chamber through the inlet pipes N7, N9, N11, and N13 on the outer edge of the heat exchange chamber, and flows out from the outlets N8, N10, N12, and N14, removing the heat that needs to be removed during the reaction or bringing in the heat required for the reaction. The flow direction of the cold and hot media can be reversed as needed.

Claims

1. A continuous flow reactor characterized in that It comprises a motor, a stirrer, two end reaction discs with heat exchange cavities, a plurality of middle reaction discs with heat exchange cavities, flow channels and connecting pipes for feeding and discharging materials, detecting instruments and supporting and connecting components.

2. The continuous flow reactor according to claim 1, characterized in that The overall structure of the reactor is a combination of one end reaction disc, a plurality of middle reaction discs and another end reaction disc as the main body, plus the stirrer and the motor, wherein the reaction discs are modularly designed.

3. The continuous flow reactor of claim 1, wherein The reaction disc comprises an end reaction disc and a middle reaction disc, one reaction disc is one module, each reaction disc is attached with a heat exchange cavity, two connected reaction discs form a reaction cavity, and a plurality of connected reaction discs form a plurality of reaction cavities.

4. The continuous flow reactor of claim 1, wherein The material continuously enters the reaction cavities of the reactor through the connecting pipes, and is mixed and reacted under the stirring of the motor-driven stirrer, and then flows into the hole in the center of the reactor, and the materials in all the reaction cavities flow together in the flow channel in the center of the reactor and then flow out of the outlet pipe at one end of the reactor.

5. The continuous flow reactor of claim 1, wherein The detecting instruments for detecting the temperature and pressure in the reaction cavity are arranged on each reaction disc as needed.

6. The continuous flow reactor of claim 1, wherein The connection mode of the reaction disc is flange connection or welding. The design of the reaction material flow channel is that the material continuously enters the reaction cavities of the reactor through the connecting pipes on the outer edge of the reaction disc, is mixed and reacted in the reaction cavity, and then flows into the hole in the center of the reactor, and the materials in all the reaction cavities flow together in the hole in the center of the reactor and then flow out of the outlet pipe at any end of the reactor. The design of the heat exchange medium flow channel is that the heat exchange medium continuously enters and exits the heat exchange cavity through the connecting pipes on the outer edge of the reaction disc, and is cooled or heated for heat exchange, so that the heat exchange medium in the heat exchange cavity of the middle reaction disc can simultaneously exchange heat with the reaction materials in the reaction cavities on both sides thereof.

7. The continuous flow reactor of claim 1, wherein The structure design of its reaction disc: the middle reaction disc with multiple heat exchange cavities, the structure of a single middle reaction disc is: one side is a flat disc or a concave disc structure, which is connected with the corresponding concave disc structure of the previous reaction disc by flange to form a cavity as a reaction space, i.e. a reaction cavity, and the middle part is a cavity for cooling or heating medium flow; the cavity is called a heat exchange cavity, and the other side is a concave disc structure with a heat exchange cavity, which is connected with the next reaction disc module by flange; The structure of the two end reaction discs with heat exchange cavities: the structure of the end reaction disc close to the motor is: the end side is a heat exchange cavity with corresponding sealing elements and outlet connecting pipes, which is connected with the motor through a fixed support, and the other side is a concave disc structure connected with the middle reaction disc by flange; the structure of the other end reaction disc away from the motor is: the end side is a heat exchange cavity with corresponding sealing elements, outlet connecting pipes and shaft support elements, and the other side is a flat disc or a concave disc structure connected with the middle reaction disc by flange.

8. The continuous flow reactor of claim 1, wherein The stirrer is a main shaft passing through all the reaction cavities and heat exchange cavities with multiple layers of stirring paddles, each layer of stirring paddles is located in a reaction cavity, and all the stirring paddles rotate with the main shaft to stir the reaction materials in the respective cavities; the main shaft of the stirrer has support fixing elements and sealing components on the side close to the motor to ensure stable operation during operation, and the end of the other side of the stirring main shaft can be fixed or not.

9. The continuous flow reactor of claim 8, wherein, The end of the other side of the stirring main shaft is also fixed.

10. The continuous flow reactor of claim 1, wherein The stirring paddles are straight blade paddles, inclined blade paddles or curved blade paddles, and the number of paddle blades is single blade, two blades, three blades or four blades.

11. The continuous flow reactor of claim 1, wherein The reactor can be placed vertically or horizontally.

Images