A continuous molecular sieve synthesis apparatus
The continuous molecular sieve synthesis device using ultrasonic dispersing rods and multi-stage shear reactors solves the problems of long reaction cycles, high energy consumption, and uneven product quality in traditional molecular sieve production, achieving efficient and low-energy molecular sieve synthesis.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- RUNHE CATALYST (SHANDONG) CO LTD
- Filing Date
- 2025-08-26
- Publication Date
- 2026-07-21
AI Technical Summary
Traditional molecular sieve production processes suffer from problems such as long reaction cycles, high energy consumption, poor product quality consistency, and low mass transfer efficiency, making it difficult to achieve continuous production.
A continuous molecular sieve synthesis device employs a premixed reactor with an internal ultrasonic dispersing rod, a multi-stage shear reactor, and an independent heat exchange reaction chamber. Through ultrasonic dispersion, a plunger pump, fins inside the reaction tube, and three-stage temperature control, it achieves efficient mass transfer, precise temperature control, and low energy consumption for molecular sieve synthesis.
Significantly shorten crystallization time, reduce energy consumption, improve product crystallinity and particle size uniformity, reduce specific surface area loss, and enhance the production efficiency and product quality of molecular sieves.
Smart Images
Figure CN224524774U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of molecular sieve synthesis equipment technology, and in particular to a continuous molecular sieve synthesis device. Background Technology
[0002] In the industrial production of molecular sieves, the traditional production process generally employs batch high-pressure reactors for synthesis reactions. However, the traditional production process suffers from the following technical limitations, which have severely hampered the industry's efforts to reduce costs and increase efficiency: 1. Long reaction cycle and high energy consumption: Due to reliance on static heat and mass transfer, the crystallization stage of molecular sieves needs to be maintained for 72-120 hours, with steam consumption per ton of product reaching 8-12 tons, resulting in an increase in production costs of about 35%; 2. Poor product quality consistency: The uneven temperature gradient (±5℃) and concentration distribution in the reactor cause the crystallinity of the molecular sieve to fluctuate by more than 15%, and the polydispersity index (PDI) is generally greater than 0.3, which directly affects its selectivity in the MTO catalytic reaction. 3. Low mass transfer efficiency leads to side reactions: The precursor is prone to local agglomeration in laminar flow (the area with a particle size greater than 200nm accounts for more than 20%), forming an amorphous impurity phase, resulting in a loss of molecular sieve specific surface area of 50m² / g-80m² / g.
[0003] Despite existing improvements that attempt to shorten reaction time, bottlenecks remain, such as high equipment investment (over 5 million yuan per unit) and difficulty in achieving continuous production.
[0004] Therefore, developing a synthesis device that combines efficient mass transfer, precise temperature control, and low energy consumption has become a critical technical challenge that needs to be overcome in the field of molecular sieve manufacturing. Utility Model Content
[0005] The purpose of this invention is to provide a continuous molecular sieve synthesis device that can shorten the crystallization time and reduce crystallinity deviation.
[0006] The technical solution of this utility model to solve the above-mentioned technical problems is: a molecular sieve continuous synthesis device, including a premixed reaction vessel with an internal ultrasonic dispersing rod, the upper part of the premixed reaction vessel is provided with a dry material inlet pipe and a water material inlet pipe, and a twin-screw metering pump is provided on the dry material inlet pipe; the bottom of the premixed reaction vessel is connected to a multi-stage shear reactor through a discharge pipe, and a plunger pump for pumping materials into the shear reactor is provided on the discharge pipe. The multi-stage shear reactor includes several parallel reaction tubes connected in series via U-shaped connecting pipes. Each reaction tube has multiple fins along its extension direction, and the first reaction tube is connected to the discharge pipe. The reaction tubes are evenly installed in three independent heat exchange reaction chambers, and a temperature sensor is also installed inside the U-shaped connecting pipe.
[0007] As a further improvement of this utility model, a feed switch valve is provided on the dry material inlet pipe.
[0008] As a further improvement of this utility model, a feed switch valve is provided on the water inlet pipe.
[0009] As a further improvement of this utility model, a stirring motor is provided at the top of the premixed reactor, and the output end of the stirring motor is connected to a stirring shaft extending downward into the premixed reactor.
[0010] As a further improvement of this utility model, the lower end of the stirring shaft is provided with stirring blades.
[0011] As a further improvement of this utility model, the heat exchange reaction chamber is provided with a heat exchange medium inlet and a heat exchange medium outlet on both sides.
[0012] Beneficial effects Compared with the prior art, the advantages of the molecular sieve continuous synthesis device of this utility model are as follows: Compared to traditional molecular sieve production using intermittent high-pressure reactors, this continuous molecular sieve synthesis device, through the combination of ultrasonic dispersing rods, plunger pumps, finned reactor tubes, and three independent heat exchange reaction chambers, can significantly shorten crystallization time and reduce energy consumption. Simultaneously, by controlling the feed through a twin-screw metering pump, along with the finned reactor tubes and three independent heat exchange reaction chambers, it can reduce fluctuations in molecular sieve crystallinity and the polydispersity index (PDI). Furthermore, the combination of ultrasonic dispersing rods, plunger pumps, and finned reactor tubes can also reduce the loss of specific surface area of the molecular sieve.
[0013] The present invention will become clearer from the following description and in conjunction with the accompanying drawings, which are used to explain the embodiments of the present invention. Attached Figure Description
[0014] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0015] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the heat exchange reaction chamber of this utility model.
[0016] Wherein: 1-Premixed reactor; 11-Stirring shaft; 12-Stirring blade; 13-Stirring motor; 14-Ultrasonic dispersing rod; 15-Dry material inlet pipe; 17-Twin screw metering pump; 16-Water material inlet pipe; 18-Feed switch valve; 2-Discharge pipe; 3-Plunger pump; 4-Multi-stage shear reactor; 41-Heat exchange reaction chamber; 42-Heat exchange medium inlet; 43-Heat exchange medium outlet; 44-Reaction pipe; 45-U-shaped connecting pipe; 46-Temperature sensor. Detailed Implementation
[0017] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.
[0018] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; of course, they can also refer to a mechanical connection or an electrical connection; furthermore, they can refer to a direct connection, an indirect connection through an intermediate medium, or a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0019] Embodiments of the present invention will now be described with reference to the accompanying drawings.
[0020] Example: The specific embodiments of this utility model are as follows: Figure 1-2 As shown, a continuous molecular sieve synthesis apparatus includes a premixing reactor 1 with an internal ultrasonic dispersing rod 14. The premixing reactor 1 has a dry material inlet pipe 15 and a water material inlet pipe 16 at its upper part, and a twin-screw metering pump 17 is installed on the dry material inlet pipe 15. Meanwhile, the bottom of the premixing reactor 1 is connected to a multi-stage shear reactor 4 via a discharge pipe 2, and a plunger pump 3 for pumping materials into the shear reactor 4 is installed on the discharge pipe 2.
[0021] The multi-stage shear reactor 4 includes several parallel reaction tubes 44 connected in series via U-shaped connecting pipes 45. Multi-stage fins are welded inside each reaction tube 44 along its extension direction, and the first reaction tube 44 is connected to the discharge pipe 2. The reaction tubes 44 are evenly installed in three independent heat exchange reaction chambers 41 arranged sequentially along the material conveying direction, and temperature sensors 46 are also installed inside the U-shaped connecting pipes 45. Heat exchange medium inlets 42 and outlets 43 are respectively located on both sides of each heat exchange reaction chamber 41. The temperature sensors 46 detect the material temperature and transmit the information to the controller. The controller then controls the temperature of the heat exchange medium in the heat exchange reaction chamber 41, ultimately ensuring the material reaches the desired temperature. This forms three independent temperature control jackets.
[0022] In this embodiment, along the material conveying direction, the temperature inside the reaction tube 44 in the first-stage heat exchange reaction chamber 41 is controlled at 100±5℃, which is the heating and nucleation range; the temperature inside the reaction tube 44 in the second-stage heat exchange reaction chamber 41 is controlled at 130℃-150℃, which is the crystallization and forming stage; and the temperature inside the reaction tube 44 in the third-stage heat exchange reaction chamber 41 is controlled at 90℃, which is the cooling and discharging stage.
[0023] In use, the raw materials are first transported to the premixing reactor 1 for premixing; then, the colloid obtained by premixing the raw materials is sent to the multi-stage shear reactor 4 at a flow rate of 5L / min through the discharge pipe 2 and the plunger pump 3 for reaction; after that, the material is discharged from the last reaction pipe 44 in the third-stage heat exchange reaction chamber 41; finally, the discharged slurry is filtered by a filter press, and the filter cake enters the spray dryer, where the molecular sieve product is obtained after a period of time.
[0024] Compared to the long reaction cycle and high energy consumption of traditional molecular sieve production, this continuous molecular sieve synthesis device utilizes ultrasonic waves emitted by the ultrasonic dispersion rod 14 to generate micro-explosion shock waves, forcing the precursor to disperse to the nanoscale, eliminating amorphous phase nucleation sites, and thus shortening the crystallization induction period. Furthermore, the plunger pump 3 generates high pressure, which, combined with the multi-stage fins within the reaction tube 44, creates vortices in the material, compressing the diffusion distance from millimeters to micrometers. This significantly increases the crystal growth rate, thereby drastically shortening the crystallization time and reducing energy consumption. Simultaneously, three independent heat exchange reaction chambers 41 allow for precise temperature control in stages, further reducing energy consumption.
[0025] To address the issue of inconsistent product quality in traditional molecular sieve production, this continuous molecular sieve synthesis device first uses a twin-screw metering pump 17 to precisely control the feed, reducing feed errors. Then, through three independent heat exchange reaction chambers 41, it achieves three-stage targeted temperature control: the first stage (100±0.5℃) precisely triggers synchronous nucleation across the entire process; the second stage (130℃-150℃) accelerates surface reactions, shifting crystal growth from diffusion-controlled to reaction-controlled; and the third stage (90℃ rapid cooling) freezes crystal size and inhibits coarsening. Combined with forced micro-mixing through multi-stage fins within the reaction tube 44—where the material undergoes hundreds of rotations per second—this homogenizes the temperature / concentration field. Therefore, this device effectively reduces fluctuations in molecular sieve crystallinity and the polydispersity index (PDI).
[0026] Furthermore, this continuous molecular sieve synthesis device addresses the shortcomings of traditional molecular sieve production, such as low mass transfer efficiency and side reactions. First, it uses an ultrasonic dispersing rod 14 to continuously pulverize aggregates larger than 100 nm, thereby eliminating amorphous phases at the source. Then, it utilizes the combination of a plunger pump 3 and multi-stage fins within the reaction tube 44 to generate a continuously acting turbulent field, preventing material particle agglomeration and improving the mass transfer coefficient. As a result, this device also reduces the specific surface area loss of the molecular sieve.
[0027] In this embodiment, a feed switch valve 18 is provided on the dry material inlet pipe 15 to control the feeding. Similarly, a feed switch valve 18 is also provided on the water material inlet pipe 16. At the same time, in order to realize the stirring of materials in the premixing reactor 1, a stirring motor 13 is provided on the top of the premixing reactor 1. The output end of the stirring motor 13 is driven to a stirring shaft 11 extending downward into the premixing reactor 1. The lower end of the stirring shaft 11 is provided with stirring blades 12.
[0028] The present invention has been described above in conjunction with the preferred embodiments, but the present invention is not limited to the embodiments disclosed above, but should cover various modifications and equivalent combinations made in accordance with the essence of the present invention.
Claims
1. A continuous molecular sieve synthesis apparatus, characterized in that, The premixed reactor (1) includes an ultrasonic dispersing rod (14) inside. The upper part of the premixed reactor (1) is provided with a dry material inlet pipe (15) and a water material inlet pipe (16). A twin-screw metering pump (17) is provided on the dry material inlet pipe (15). The bottom of the premixed reactor (1) is connected to a multi-stage shear reactor (4) through a discharge pipe (2). A plunger pump (3) for pumping materials into the shear reactor (4) is provided on the discharge pipe (2). The multi-stage shear reactor (4) includes several parallel reaction tubes (44) connected in series via U-shaped connecting pipes (45). The reaction tubes (44) are provided with multi-stage fins along their extension direction. The first reaction tube (44) is connected to the discharge pipe (2). The reaction tubes (44) are evenly installed in three independent heat exchange reaction chambers (41). A temperature sensor (46) is also provided in the U-shaped connecting pipe (45).
2. The continuous molecular sieve synthesis apparatus according to claim 1, characterized in that, The dry material inlet pipe (15) is equipped with a feed switch valve (18).
3. The continuous molecular sieve synthesis apparatus according to claim 1 or 2, characterized in that, The water inlet pipe (16) is equipped with an inlet switch valve (18).
4. The continuous molecular sieve synthesis apparatus according to claim 1, characterized in that, The premixed reactor (1) is equipped with a stirring motor (13) at the top, and the output end of the stirring motor (13) is connected to a stirring shaft (11) extending downward into the premixed reactor (1).
5. The continuous molecular sieve synthesis apparatus according to claim 4, characterized in that, The stirring shaft (11) is provided with stirring blades (12) at its lower end.
6. The continuous molecular sieve synthesis apparatus according to claim 1, characterized in that, The heat exchange reaction chamber (41) is provided with a heat exchange medium inlet (42) and a heat exchange medium outlet (43) on both sides.