Alkylbenzene Hydroperoxide Production via Segmented Oxygen Bubbles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing alkylbenzene oxidation processes face challenges in achieving high yields due to insufficient mass transfer area between the alkylbenzene liquid phase and the oxidant gas phase, leading to reduced product yield, increased capital and processing costs, and formation of undesirable byproducts.
Innovation Solution
A flow reactor system with a sparger that introduces oxygen-containing gas bubbles serially into the reaction channel, maintaining a specific bubble size and residence time to prevent coalescence, thereby enhancing mass transfer efficiency and product yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional spargers with multiple apertures are used to introduce oxygen-containing gas into the liquid phase, then gas introduction efficiency is improved, but bubble coalescence occurs reducing mass transfer area and product yield
Solution Approach 1:
The sparger is designed with multiple apertures arranged such that gas is introduced in a segmented manner, creating discrete bubbles that maintain separation throughout the liquid phase. This segmentation prevents bubble coalescence while maintaining efficient gas introduction, thereby preserving mass transfer area and maximizing product yield
Solution Approach 2:
The sparger creates localized gas introduction zones with specific aperture distributions. By optimizing the local aperture arrangement and spacing, the system maintains small bubble sizes in critical mass transfer zones while managing overall gas flow rates, thus preserving mass transfer area where it is most needed
2Productivity
If larger reactors are used to increase mass transfer area, then product yield is improved, but capital cost and equipment size increase
Solution Approach 1:
The invention changes the bubble size parameter and gas distribution pattern to maintain small, dispersed bubbles throughout the liquid phase. This parameter optimization maximizes the mass transfer area within the existing reactor volume, achieving high product yield without increasing reactor size or capital cost
3Productivity
If conventional gas introduction methods are used, then equipment complexity is reduced, but mass transfer efficiency decreases leading to higher processing costs
Solution Approach 1:
The sparger design allows the liquid flow itself to maintain bubble dispersion through its velocity and direction. The system uses the existing liquid flow characteristics to prevent bubble coalescence without requiring additional active control mechanisms, thereby achieving high mass transfer efficiency with minimal added complexity
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 approach increases the product yield of alkylbenzene hydroperoxide, reduces capital and processing costs, and minimizes byproduct formation by optimizing the mass transfer between the liquid and gas phases.
Implementation Method 1
insufficient mass transfer area between an alkylbenzene liquid phase and an oxidant gas phase can further reduce the product yield
Implementation Method 2
an inlet sparger configured to flow gas bubbles comprising the oxygen-containing gas within the liquid flow
Data Source
AI summary
An apparatus for oxidation of a C8-C12 alkylbenzene reactant to a C8-C12 alkylbenzene hydroperoxide product, the reactor can comprise: a flow reactor comprising a reactant inlet, an oxidate product outlet, wherein the reactor is configured to provide a liquid flow from the reactant inlet to the product outlet, a gas inlet configured to introduce an oxygen-containing gas into the reactor, and an inlet sparger configured to flow gas bubbles comprising the oxygen-containing gas within the liquid flow, and wherein: the inlet sparger is configured to flow the gas bubbles having a diameter of 1.0 mm to 5.0 mm over a gas bubble residence time from 1 to 200 seconds, and/or the inlet sparger configured to flow the gas bubbles such that greater than or equal to 80% of the gas bubbles do not coalesce into larger bubbles over a gas bubble residence time of 1 to 200 seconds.