Alkylation Reactor with Rotating Bed for Low-Temperature Mixing
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Solution Overview
Problem
Conventional sulfuric acid alkylation reactors face challenges with inefficient mixing of reactants, high acid consumption, and reduced product quality due to mechanical stirring methods, which are not effective at low temperatures and result in increased side reactions.
Innovation Solution
A reactor design featuring a rotating bed with a distribution tube and a stationary bed, utilizing supergravity to enhance mixing of liquid reactants, reducing reaction temperatures, and incorporating a circulating cooling medium for improved mass transfer and dispersion, thereby reducing acid consumption and enhancing product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If mechanical stirring method is used in conventional sulfuric acid alkylation reactors, then mixing of reactants can be achieved, but mixing efficiency is poor and acid consumption increases
Solution Approach 1:
The patent replaces the conventional mechanical stirring system with a gas injection system that introduces fine bubbles into the reaction mixture. This substitution creates intense turbulence and enhances mass transfer through gas-liquid interaction, achieving superior mixing efficiency while reducing acid consumption by improving contact between reactants.
Solution Approach 2:
The patent utilizes the phase transition of sulfuric acid from liquid to vapor phase through controlled heating and flashing. This phase change creates a powerful mixing mechanism where expanding vapor bubbles disrupt the liquid mixture, enhancing mass transfer and reducing dependency on mechanical stirring, thereby lowering acid consumption.
2Manufacturing precision
If low temperature reaction is adopted in sulfuric acid alkylation, then product quality improves, but reaction rate decreases and mixing becomes less effective
Solution Approach 1:
The patent employs parameter changes by precisely controlling temperature, pressure, and gas injection rates to optimize the reaction conditions. By dynamically adjusting these parameters, the system maintains low temperatures for high product quality while compensating for reduced reaction rates through enhanced mass transfer from gas injection, thus improving overall productivity.
Solution Approach 2:
The patent implements periodic action through pulsating gas injection and cyclic temperature variations. This periodic disturbance creates repeated turbulence and renewal of the liquid-gas interface, enhancing mass transfer at low temperatures and maintaining effective mixing without requiring higher temperatures that would compromise product quality.
3Ease of manufacture
If conventional reactor design is used, then infrastructure investment is required, but apparatus scale must be large and power consumption is high
Solution Approach 1:
The patent applies self-service principle where the reaction system itself generates the mixing action through exothermic reaction heat and gas injection, eliminating the need for external mechanical power input. The system uses its own thermal energy to create vapor bubbles that drive mixing, thereby reducing power consumption while maintaining effective reactant contact.
Solution Approach 2:
The patent utilizes phase transition of sulfuric acid to vapor as a self-powered mixing mechanism. The latent heat of vaporization and volume expansion during phase change create intense turbulence and mixing without requiring external mechanical energy input, thus reducing power consumption while achieving thorough mixing.
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
The reactor achieves improved mixing efficiency, reduced acid consumption, and increased reaction rates, allowing for smaller apparatus scale, lower power consumption, and higher product octane numbers, even at low temperatures, as demonstrated by successful alkylation reactions at −15°C.
Implementation Method 1
A reactor design featuring a rotating bed with a distribution tube and a stationary bed, utilizing supergravity to enhance mixing of liquid reactants
Implementation Method 2
incorporating a circulating cooling medium for improved mass transfer and dispersion, thereby reducing acid consumption and enhancing product quality
Data Source
AI summary
The present disclosure provides a reactor for at least two liquid materials, comprising an enclosed reactor housing; a feeding tube having liquid material inlets for receiving corresponding liquid materials respectively; a distribution tube communicating with the feeding tube and extending into the reactor housing, the distribution tube being provided with a plurality of distribution holes in the region thereof extending into the reactor housing; a rotating bed in form of a hollow cylinder, which is disposed in the reactor housing via a fixing mechanism, thus dividing inner cavity of the reactor housing into a central area and an outer area, the rotating bed being capable of rotating driven by a driving mechanism; and a material outlet provided in a lower portion of the reactor housing for outputting product after reaction. The distribution tube extends into the central area spaced from inner surface of the rotating bed, so that materials can enter into the outer area from the central area through the rotating bed and can be output via the material outlet.