Three Bubble Lift Reactors for Low-Energy HCl-to-Chlorine Conversion
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Solution Overview
Problem
Existing processes for converting hydrogen chloride to chlorine using a three-reactor concept face challenges in maintaining the melt's liquidity and circulation, requiring complex systems like airlift pumps and significant temperature differences, which are energetically inefficient.
Innovation Solution
A process utilizing a reactor system with three bubble lift reactors, where a liquid melt of copper ions, alkali cations, and chloride ions is circulated through specific temperature zones to enhance the molar ratio of Cu2+:Cu+ and form chlorine efficiently, eliminating the need for airlift pumps and reducing temperature differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a three-reactor concept is used for converting hydrogen chloride to chlorine, then the chlorine production efficiency is improved, but the complexity of maintaining melt circulation increases due to requiring airlift pumps and significant temperature differences
Solution Approach 1:
The liquid melt circulates through the three bubble lift reactors autonomously based on density differences created by the chemical reactions themselves. In reactor I, oxygen bubbles increase melt density causing downward flow; in reactor II, hydrogen chloride reaction products create upward flow. This self-circulation eliminates the need for external pumps while maintaining continuous operation and improving productivity.
Solution Approach 2:
The invention optimizes temperature parameters to be much closer than conventional processes, with reactor I at 375-425°C, reactor II at 355-405°C, and reactor III at 400-450°C. This reduced temperature differential (max 75°C difference) maintains melt liquidity across all reactors without requiring complex heating/cooling systems, thereby reducing device complexity while preserving high chlorine production efficiency.
2Stability of the object's composition
If airlift pumps and significant temperature differences are used to maintain melt circulation, then the melt liquidity is maintained, but the energy consumption increases significantly
Solution Approach 1:
The system uses the chemical reactions themselves to drive melt circulation through natural convection. Oxygen introduction in reactor I creates dense melt that sinks, while hydrogen chloride reaction in reactor II generates lighter melt that rises. This reaction-driven circulation maintains melt liquidity without external energy input for pumping, dramatically reducing energy consumption.
Solution Approach 2:
The invention narrows the temperature range across reactors to 355-425°C, compared to conventional large differentials. This optimized parameter range maintains adequate melt liquidity in all three reactors simultaneously, eliminating the need for high-energy pumping while preventing thermal runaway or melt solidification issues.
3Productivity
If complex pumping systems are used for melt circulation, then the chlorine production can be maintained, but the economic advantage is reduced
Solution Approach 1:
By eliminating airlift pumps and complex circulation control systems, the invention dramatically reduces capital equipment costs and operational maintenance expenses. The self-circulating design based on reaction-driven density differences maintains continuous chlorine production capability while reducing both investment and operating costs, thereby improving economic advantage.
Solution Approach 2:
The optimized temperature parameters (375-425°C for reactor I, 355-405°C for reactor II, 400-450°C for reactor III) enable simpler reactor construction and operation compared to conventional large temperature differential systems. This parameter optimization reduces equipment complexity and operational costs while maintaining high chlorine production rates, enhancing overall economic viability.
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 achieves improved space-time-yield for chlorine production with reduced energy consumption by maintaining melt liquidity and circulation without complex pumping systems, resulting in an economically advantageous method.
Implementation Method 1
in the reaction zone i of the first bubble lift reactor I, a liquid melt comprising copper ions Cun+, alkali cations and chloride ions Cl− is contacted with oxygen (O2) at a temperature >375° C. so that the molar ratio Cu2+:Cu+ in the liquid melt increases
Implementation Method 2
the liquid melt obtained in (a) is circulated to the reaction zone ii in the second bubble lift reactor II, where the liquid melt is contacted with hydrogen chloride (HCl) at a temperature >355° C. so that water is formed
Implementation Method 3
circulating the liquid melt obtained in (b) to the reaction zone iii in the third bubble lift reactor III, which is operated at a temperature in the range from 400 to 480° C. so that chlorine (Cl2) is formed
Implementation Method 4
three bubble lift reactors I, II and III, each comprising a reaction zone i, ii and iii respectively
Data Source
AI summary
The invention relates to a process for preparation of chlorine from hydrogen chloride comprising circulating a liquid melt comprising copper ions Cun+ with n being a number in the range from 1 to 2, alkali cations and chloride ions Cl in a reactor system comprising three bubble lift reactors I, II and III, each comprising a reaction zone i, ii and iii respectively, wherein: ⋅ (a) in the reaction zone i of the first bubble lift reactor I, a liquid melt comprising copper ions Cun+, alkali cations and chloride ions Cl− is contacted with oxygen at a temperature in the range from 395 to 405° C. so that the molar ratio Cun+:Cu+ in the liquid melt increases, obtaining a liquid melt having an increased molar ratio Cun+:Cu+⋅ (b) the liquid melt obtained in (a) is circulated to the reaction zone ii in the second bubble lift reactor II, where the liquid melt is contacted with hydrogen chloride at a temperature in the range from 395 to 405° C. so that water is formed, obtaining a liquid melt being enriched in chloride anions (CI−) compared to the liquid melt obtained according to (a); ⋅ (c) circulating the liquid melt obtained in (b) to the reaction zone iii in the third bubble lift reactor III, which is operated at a temperature in the range from 420 to 430° C. so that chlorine (Cl2) is formed, wherein Cl2 is removed from the reaction zone iii and the third bubble lift reactor III respectively in gaseous form, leaving a liquid melt depleted of Cl-compared to the liquid melt obtained according to (b). The invention further relates to a reactor system comprising three bubble lift reactors I, II and III.