Integrated catalytic reactor used in styrene production process
By designing an integrated catalytic reactor, a heating device is used to rapidly raise the temperature to prevent styrene polymerization, and a differential pressure gauge and dust collector are installed to prevent clogging. This achieves efficient and low-cost styrene waste gas treatment, solving the problems of large footprint and high energy consumption of traditional systems.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- NANJING YIRE ZONGLIAN ENERGY SAVING TECH CO LTD
- Filing Date
- 2025-04-21
- Publication Date
- 2026-04-14
AI Technical Summary
Traditional styrene production processes involve waste gas treatment systems that occupy large areas, consume high amounts of energy, and are prone to clogging. Existing catalytic combustion equipment is insufficient to meet the demands for high efficiency and low cost.
An integrated catalytic reactor was designed, which includes tubular and plate heat exchangers, a catalytic bed and a temperature control device. The heating device rapidly raises the temperature to prevent styrene polymerization, and a differential pressure gauge and dust collector are installed to prevent clogging, thereby achieving intelligent temperature control and waste heat recovery.
It effectively prevents styrene polymerization blockage, reduces operating costs, improves system efficiency, and achieves efficient waste gas treatment.
Smart Images
Figure CN224113924U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of catalytic reactors, and more particularly to an integrated catalytic reactor for use in the styrene production process. Background Technology
[0002] Styrene, as a crucial chemical raw material for synthetic plastics, rubber, and resins, generates waste gases during its production that pose a serious threat to the environment and human health. Traditional waste gas treatment technologies struggle to meet the demands for high efficiency, low carbon emissions, and low operating costs. Industrially used integrated catalytic combustion systems involve multiple devices, occupy a large area, and require significant investment. Furthermore, due to their complex layout, the entire system suffers from high resistance and energy consumption, making them unsuitable for small-scale chemical plants. Styrene readily polymerizes, and conventional catalytic combustion can cause equipment blockage. Therefore, waste gas is typically preheated to the catalyst's ignition temperature. This process is usually achieved through heat exchangers or electric heaters. However, the plate heat exchangers currently used in styrene catalytic combustion are prone to blockage due to styrene polymerization, increasing system resistance and reducing heat exchange performance. Utility Model Content
[0003] Purpose of the utility model: The purpose of this utility model is to provide an integrated catalytic reactor that effectively prevents styrene polymerization and has low operating costs in the styrene production process.
[0004] Technical solution: The present invention provides an integrated catalytic reactor for styrene production, comprising an inlet for introducing waste gas, a first heat exchange system connected to the inlet and capable of increasing the waste gas temperature, a second heat exchange system capable of further increasing the waste gas temperature discharged from the first heat exchange system, a first channel connecting the first heat exchange system and the second heat exchange system, a catalytic bed connected to the second heat exchange system, an outlet, and a temperature control device for adjusting the heat exchange performance of the first heat exchange system.
[0005] Furthermore, the first heat exchange system includes a tubular heat exchanger, an air inlet channel connecting to the air inlet and leading to the tubes of the tubular heat exchanger, and a heating device located outside the tubular heat exchanger to raise the temperature of the tube walls. The heating device includes a furnace located outside the tubular heat exchanger and a make-up air damper located on the furnace for controlling the amount of air entering the furnace. A burner is installed inside the furnace to burn natural gas and generate heat. The second heat exchange system includes a plate heat exchanger connected to the first channel, a second channel for sending the exhaust gas passing through the plate heat exchanger to the catalytic bed, and a third channel for discharging the exhaust gas after the catalytic reaction and connecting to the outside of the plate heat exchanger for heat exchange.
[0006] Furthermore, the temperature control device includes a first temperature sensor installed in the first channel for monitoring the temperature of the exhaust gas passing through the first channel, a second temperature sensor installed in the second channel for monitoring the temperature of the exhaust gas passing through the second channel, and a third temperature sensor installed on the inner wall of the tubular heat exchanger pipe for measuring the pipe wall temperature.
[0007] Preferably, differential pressure gauges are installed at the air inlet and outlet of the first heat exchange system. When the pressure difference between the two points is large, it indicates that the tubular heat exchanger is blocked. Differential pressure gauges are also installed at the air inlet and outlet of the second heat exchange system. When the pressure difference between the two points is large, it indicates that the plate heat exchanger is blocked. A dust collector is installed in the first channel. When the pressure difference is large, the dust collector can be cleaned to ensure the overall resistance of the system.
[0008] Beneficial effects: Compared with the prior art, the present invention has the following advantages: (1) The first heat exchange system uses a tubular heat exchanger to exchange heat with the low-temperature waste gas entering the tube, and the temperature is rapidly raised to above the polymerization temperature of styrene, so that the polystyrene decomposes and does not block the tubular heat exchanger. It also increases the temperature of the waste gas entering the plate heat exchanger and reduces the risk of styrene polymerization and blockage on the plate heat exchanger; (2) The clean high-temperature flue gas after the catalytic reaction of the catalytic bed acts on the plate heat exchanger, recovers waste heat, and reduces operating costs; (3) A temperature control device is set up to monitor the temperature in real time, adjust the output of the burner and the opening of the make-up air door, and realize intelligent control; (4) A differential pressure gauge and a removable dust collector are provided to prevent polystyrene from entering the plate heat exchanger and blocking the plate heat exchanger. Attached Figure Description
[0009] Figure 1 This is a front view of the present invention;
[0010] Figure 2 This is a top view of the present invention; Detailed Implementation
[0011] The technical solution of this utility model will be further described below with reference to the accompanying drawings.
[0012] As shown in the figure, the integrated catalytic reactor for styrene production according to this utility model includes an inlet 1, a first heat exchange system, a first channel 2, a second heat exchange system, a catalytic bed 3, a temperature control device, and an outlet. The first heat exchange system includes an inlet channel 4, a tubular heat exchanger 5, and a heating device. The second heat exchange system includes a plate heat exchanger 6, a second channel 7, and a third channel 8. Waste gas from the styrene production process enters the integrated catalytic reactor through the inlet, passes through the inlet channel, and enters the tubes of the tubular heat exchanger. The inlet is located at the top of the catalytic reactor, and the tubular heat exchanger is located on one side of the inlet. The tubular heat exchanger uses a U-shaped tube. Differential pressure gauges are installed at the inlet and outlet of the tubular heat exchanger. When the pressure difference between the two points is large, it indicates a blockage inside the tube. The tubular heat exchanger can be disassembled and cleaned by soaking in an alkaline solution. A heating device is installed at the inlet of the exhaust gas into the tubular heat exchanger. This device includes a furnace 9 located along one side of the outer surface of the heat exchanger, with a make-up air damper 10 to control the amount of air entering the furnace. Inside the furnace is a burner 11, a proportionally adjustable burner whose output is adjusted according to a signal from a temperature control device. The burner burns the natural gas outside the tubes of the tubular heat exchanger to generate heat, raising the temperature of the tube walls and exchanging heat with the exhaust gas passing through the heat exchanger. This rapidly raises the temperature of the low-temperature exhaust gas entering from the inlet to above the polymerization temperature of styrene, preventing polystyrene decomposition and effectively avoiding blockage of the tubular heat exchanger. To discharge the liquid generated during the catalytic reactor process, drain ports 12 are installed at the lower ends of both the inlet channel and the first channel. These drain ports can also discharge waste liquid generated during the cleaning of the tubular heat exchanger.
[0013] The plate heat exchanger and catalytic bed are located on the other side of the air inlet. The tubular heat exchanger is connected to the plate heat exchanger via a first channel. A dust collector 13 is installed in the first channel. The dust collector is detachable, and differential pressure gauges are installed before and after the dust collector. When the pressure difference is large, the dust collector can be cleaned to ensure the overall system resistance. Differential pressure gauges are also installed at the air inlet and outlet of the plate heat exchanger. A large pressure difference at both locations indicates blockage inside the plate heat exchanger. The plate heat exchanger and the catalytic bed are connected via a second channel. Exhaust gas from the tubular heat exchanger enters the plate heat exchanger through the first channel. The plates of the plate heat exchanger are designed with raised dots, resulting in better heat transfer performance and less clogging, leading to superior heat exchange efficiency. Then, it enters the catalytic bed through the second channel. The catalyst lowers the activation energy of the reaction, while simultaneously enriching reactant molecules on the catalyst surface, increasing the reaction rate and enabling flameless combustion at a lower ignition temperature. At this point, the exhaust gas is oxidized into clean, high-temperature flue gas. This clean, high-temperature flue gas enters the plate heat exchanger through a third channel, where it exchanges heat with the exhaust gas again before being discharged through the outlet. The exhaust gas, having reached its ignition temperature after heat exchange, enters the catalytic bed, and this cycle repeats, maximizing waste heat recovery and reducing operating costs. Flanges connect the various components of the catalytic reactor for sealing purposes.
[0014] The temperature control device monitors the temperature, transmits signals to the burner, and adjusts the burner's output. It includes a first temperature sensor 14 located in the first channel, a second temperature sensor 15 located in the second channel, and a third temperature sensor 16 located on the inner wall of the tubular heat exchanger pipes. The first temperature sensor ensures that the temperature of the exhaust gas entering the first channel is higher than the styrene polymerization temperature. When the temperature detected by the first temperature sensor is lower than the styrene polymerization temperature, the burner output is increased, increasing the natural gas flow into the furnace; when the temperature detected by the first temperature sensor is higher than the styrene polymerization temperature, the burner output is decreased. The second temperature sensor ensures that the temperature of the exhaust gas about to enter the catalytic bed is higher than the ignition temperature of styrene. When the temperature detected by the second temperature sensor is lower than the ignition temperature, the burner output is increased; when the temperature detected by the second temperature sensor is higher than the ignition temperature, the burner output is decreased. The third temperature sensor ensures that the wall temperature of the tubular heat exchanger exceeds the polystyrene decomposition temperature. When the temperature detected by the third temperature sensor is lower than the polystyrene decomposition temperature, the make-up air damper opening is decreased; when the temperature detected by the third temperature sensor is higher than the polystyrene decomposition temperature, the make-up air damper opening is increased.
Claims
1. An integrated catalytic reactor for styrene production, comprising an inlet for introducing waste gas, a catalytic bed, and an outlet, characterized in that, It also includes a first heat exchange system connected to the air inlet and capable of increasing the exhaust gas temperature, a second heat exchange system capable of further increasing the exhaust gas temperature discharged from the first heat exchange system, a first channel connecting the first heat exchange system and the second heat exchange system, and a temperature control device for adjusting the heat exchange performance of the first heat exchange system, wherein the catalytic bed is connected to the second heat exchange system.
2. The integrated catalytic reactor according to claim 1, characterized in that, The first heat exchange system includes a tubular heat exchanger, an air inlet channel that connects to the air inlet and leads to the inside of the tubular heat exchanger tubes, and a heating device located outside the tubular heat exchanger that raises the temperature of the tube wall of the tubular heat exchanger.
3. The integrated catalytic reactor according to claim 1, characterized in that, The second heat exchange system includes a plate heat exchanger connected to the first channel, a second channel for sending the exhaust gas passing through the plate heat exchanger to the catalytic bed, and a third channel for discharging the exhaust gas after the catalytic reaction and connected to the outside of the plate heat exchanger for heat exchange.
4. The integrated catalytic reactor according to claim 1, characterized in that, The temperature control device includes a first temperature sensor installed in a first channel for monitoring the temperature of exhaust gas passing through the first channel, a second temperature sensor installed in a second channel for monitoring the temperature of exhaust gas passing through the second channel, and a third temperature sensor installed on the inner wall of the tubular heat exchanger pipe for measuring the pipe wall temperature.
5. The integrated catalytic reactor according to claim 2, characterized in that, The heating device includes a furnace located outside the tubular heat exchanger and a make-up air damper located on the furnace for controlling the amount of air entering the furnace. A burner is installed inside the furnace.
6. The integrated catalytic reactor according to claim 1, characterized in that, A dust collector is installed in the first channel.
7. The integrated catalytic reactor according to claim 1, characterized in that, Differential pressure gauges are installed at the air inlet and outlet positions of the first heat exchange system and the air inlet and outlet positions of the second heat exchange system, respectively.