Adiabatic Chlorine Production Process
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Solution Overview
Problem
The Deacon process for chlorine production is costly due to expensive materials and high-temperature cooling systems, leading to reactor corrosion and catalyst degradation, necessitating a more efficient and cost-effective method.
Innovation Solution
A continuous process involving a gas stream of oxygen and hydrogen chloride, passed through an adiabatic reaction zone with a catalyst, where the gas stream is divided into two streams with a controlled mass flow ratio, reducing the need for frequent catalyst replacement and minimizing cooling system leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-temperature cooling systems and expensive materials are used in the Deacon process, then chlorine production is achieved, but production costs increase and reactor corrosion occurs
Solution Approach 1:
The patent changes the temperature parameter by operating the reaction adiabatically without active cooling, allowing the reaction mixture to reach equilibrium temperatures naturally. This eliminates the need for expensive high-temperature cooling systems while maintaining chlorine production efficiency
Solution Approach 2:
The patent removes the high-temperature cooling system from the process entirely, extracting this costly component while relying on adiabatic operation and equilibrium chemistry to achieve the same production goals at lower costs
2Temperature
If high-temperature cooling systems are used, then temperature control is achieved, but cooling system leakage occurs
Solution Approach 1:
The patent removes the cooling system entirely by operating adiabatically, eliminating the source of leakage problems while maintaining temperature control through equilibrium chemistry and process design
Solution Approach 2:
The reaction system self-regulates temperature through adiabatic operation and chemical equilibrium, eliminating the need for external cooling systems that could leak
3Productivity
If high temperatures are maintained, then reaction rate is improved, but catalyst deactivation accelerates
Solution Approach 1:
The patent changes the temperature profile from constant high temperature to adiabatic equilibrium temperature, which is sufficient for the reaction but lower than what would be achieved with forced heating, thereby protecting the catalyst while maintaining productivity
Solution Approach 2:
The patent maintains continuous adiabatic operation where the reaction proceeds at equilibrium temperature without thermal shocks or excursions that would accelerate catalyst deactivation
4Object-affected harmful factors
If expensive materials like nickel and silicon carbide are used, then corrosion resistance is improved, but investment costs increase
Solution Approach 1:
The patent removes the need for expensive corrosion-resistant materials by eliminating the high-temperature cooling system that caused thermal stress and corrosion, allowing the use of simpler, cheaper materials
Solution Approach 2:
The patent changes the operating temperature profile to adiabatic equilibrium, reducing thermal gradients and stress that cause corrosion, thereby allowing the use of less expensive materials
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process enhances chlorine production efficiency, prolongs reactor lifespan, and reduces production costs by maintaining a lower equilibrium temperature and minimizing catalyst deactivation and cooling system issues.
Implementation Method 1
passing the gas stream G1 into a reaction zone Z, bringing the gas stream G1 into contact with a catalyst comprised in said reaction zone Z
Implementation Method 2
passing the gas stream G1 into a reaction zone Z, bringing the gas stream G1 into contact with a catalyst comprised in said reaction zone Z
Implementation Method 3
HCl is reacted with oxygen over a catalyst, for example copper chloride (CuCl2), Ru-based catalyst or Ce-based catalyst as disclosed in WO2007/134771 A1, WO2011/111351 A1, WO2013/004651 A1, WO 2013/060628 A1 and U.S. Pat. No. 2,418,930 A, to form chlorine and water in the gas phase at temperatures of 200 to 500° C. It is an equilibrium reaction with a slight exotherm.
Data Source
AI summary
The present invention relates to a continuous process for preparing chlorine and a production unit for carrying out said process. The present invention further relates to a use of said production unit for the continuous production of chlorine.