Bubble Column Reactor Condensation Zone Diameter

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Solution Overview

Problem

Bubble column reactors face issues with entrainment of polymer by-products, leading to fouling in downstream devices, which causes operational downtime and increased costs due to the accumulation of solids and liquids.

Innovation Solution

Incorporating a condensation zone with a larger diameter than the disengaging section above the reaction zone, along with a cooling coil arrangement, to facilitate uniform condensation and reduce the rising rate of gases, thereby preventing fouling and improving process stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a large amount of gaseous reactant is introduced into the reaction zone in the form of bubbles, then the oligomerization reaction efficiency is improved, but the amount of entrained solids and liquids increases causing fouling

Engineering Contradiction:

Improveoligomerization reaction efficiencyVSAvoidamount of entrained solids and liquids

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The reactor is divided into three distinct sections: reaction zone, disengaging section, and condensation zone. This segmentation allows the gas stream to be progressively treated as it rises, with each zone performing a specific function to reduce entrainment before the stream reaches downstream devices.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The disengaging section is positioned between the reaction zone and condensation zone to preliminarily remove entrained solids and liquids before the gas stream enters the condensation zone. This preliminary action prevents fouling in subsequent condensation and downstream equipment.

Inventive Principle:

Principle #10Preliminary action

2Temperature

If a separate condenser is provided outside the bubble column reactor, then the condensation function is achieved, but fouling occurs on the condenser due to entrainment

Engineering Contradiction:

Improvecondensation functionVSAvoidfouling on condenser

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The condensation zone is merged with the reactor body rather than being a separate external condenser. This integration allows the gas stream to be condensed within the reactor system after passing through the disengaging section, preventing fouling on external condensation equipment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The disengaging section acts as an intermediary between the reaction zone and condensation zone, removing entrained solids and liquids before the gas stream enters the condensation zone, thereby protecting the condensation system from fouling.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the diameter of the condensation zone is increased, then the rising rate of gas is reduced improving precipitation effect, but the reactor volume increases

Engineering Contradiction:

Improveprecipitation effectVSAvoidreactor volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

Instead of increasing the height of the reactor to provide sufficient condensation time, the design increases the diameter of the condensation zone. This dimensional change creates a vortex flow pattern that enhances mixing and precipitation while maintaining a compact overall reactor volume.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The condensation zone is designed to generate vortex flow dynamics that enhance the precipitation effect. The rotational flow pattern increases the residence time of gas bubbles in the condensation zone, improving condensation efficiency without requiring a larger reactor volume.

Inventive Principle:

Principle #15Dynamics

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 solution effectively reduces the amount of entrained non-vapor solids and liquids, increases operational cycle stability, and decreases energy costs by preventing fouling in downstream devices and enhancing condensation efficiency.

Implementation Method 1

the arrangement of the cooling coil in the condensation zone, whereby a solvent and polymer in the gaseous stream may be effectively condensed

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a second gas stream rising from the disengaging section is introduced into the condensation zone

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 3

a diameter of the condensation zone is greater than a diameter of the disengaging section... a gas rising rate in the condensation zone may be reduced to improve a precipitation effect of non-vapor

Methodology Applied

Scientific EffectGravitational settling: Gravitation

Data Source

PatentUS20240299897A1Bubble Column Reactor

Publication Date: 2024.09.12 LG CHEM LTD

AI summary

Provided is a bubble column reactor including a reaction zone configured to carry out a reaction of a gaseous reactant in a liquid reaction medium; a disengaging section provided above the reaction zone and configured such that a first gas stream rising from the reaction zone is introduced into the disengaging section; and a condensation zone provided above the disengaging section and configured such that a second gas stream rising from the disengaging section is introduced into the condensation zone, wherein a diameter of the condensation zone is greater than a diameter of the disengaging section.