Catalytic Oxidation Gas Feed Control for Explosion Range Avoidance

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Solution Overview

Problem

Existing methods for catalytic gas-phase oxidation reactions struggle to safely change the composition of reaction gases near the explosion range, which is crucial for maximizing production capability while ensuring catalyst life and avoiding reducing atmospheres.

Innovation Solution

Adjusting the feed rates of the material to be oxidized and molecular oxygen to change the gas composition along a non-linear path that avoids the explosion range, using intermediate points to ensure safety and optimize production conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the composition of reaction gas is changed to maximize production capability, then productivity is improved, but the risk of entering the explosion range increases

Engineering Contradiction:

Improveproduction capabilityVSAvoidsafety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary calculation of the composition change path before actually changing the reaction gas composition. By computing the entire path from composition A to composition B and verifying it stays outside the explosion range beforehand, the system ensures safety before execution, resolving the contradiction between maximizing productivity through composition changes and maintaining safety.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system introduces an intermediate composition path as a mediator between the initial and target compositions. Instead of directly changing from composition A to B, the system calculates and follows a predetermined intermediate path that passes through multiple intermediate compositions, ensuring each step remains outside the explosion range while achieving the desired compositional change for improved productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the gas composition is kept near the explosion range, then productivity is improved, but catalyst life is reduced due to reducing atmosphere

Engineering Contradiction:

Improveproduction capabilityVSAvoidcatalyst life

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The system changes the compositional parameters of the reaction gas in a controlled manner along a predetermined path. By adjusting the composition parameters step-by-step through calculated intermediate points rather than making abrupt changes, the system maintains productivity while avoiding conditions that would create a reducing atmosphere harmful to the catalyst.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If fixed composition points are set for safety, then reliability is improved, but adaptability to changing production demands is reduced

Engineering Contradiction:

ImprovesafetyVSAvoidcompositional flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The system transitions from static fixed composition points to a dynamic composition change approach. Instead of being constrained to predetermined fixed composition levels, the system dynamically calculates and follows optimized composition paths that adapt to different production demands while maintaining safety constraints, thereby improving both adaptability and reliability.

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

Enables safe and efficient changes in reaction conditions, maximizing production capability by avoiding the explosion range and maintaining catalyst integrity, even when operating near hazardous compositional thresholds.

Implementation Method 1

a catalytic gas-phase oxidation reaction in which a material to be oxidized and a gas containing molecular oxygen are mixed and the resultant mixture is supplied to a catalytic gas-phase oxidation reactor

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

catalytic gas-phase oxidation reaction in which a material to be oxidized and a gas containing molecular oxygen are mixed

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS9493386B2Method for supplying reaction gases in catalytic vapor phase oxidation process

Publication Date: 2016.11.15 MITSUBISHI CHEM CORP

AI summary

A method for supplying reaction gases in which at least a material to be oxidized and a gas containing molecular oxygen are mixed and the resultant mixture is supplied to a catalytic gas-phase oxidation reactor, characterized in that, a feed rate of the material to be oxidized and a feed rate of the gas containing molecular oxygen are adjusted so that when a composition of a gas at the inlet of the catalytic gas-phase oxidation reactor is changed from a composition A point [the concentration of the material to be oxidized: R(a), and the concentration of oxygen: O(a)] represented by plotting a concentration of the material to be oxidized and a concentration of oxygen in the gas at said inlet to a composition B point [R(b) and O(b)] [the composition A point and the composition B point are compositions outside an explosion range, and R(a)≠R(b) and O(a)≠O(b)], compositions on the way of the change from the composition A point to the composition B point fall outside the explosion range.