Catalytic Reactive-Rectification Column With Separate Gas Removal
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Solution Overview
Problem
Existing chemical reactors suffer from low selectivity and conversion of target products, requiring multiple catalysts and separate devices, leading to substantial size, power consumption, and inefficiencies.
Innovation Solution
A device with a reaction zone comprising multiple catalytic sections stacked one under the other, each with a feed channel and overflow well, allowing liquid flow between sections and separate gas removal, utilizing a distributor and distribution chamber to optimize liquid-gas interaction and reduce catalyst volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate devices are used for different catalytic reactions, then each reaction can be optimized independently, but the overall system size and power consumption increase substantially
Solution Approach 1:
The patent combines multiple catalytic reaction sections into a single integrated device with stacked sections (S1, S2, S3) that can perform different catalytic reactions simultaneously. The sections share common structural elements including the housing (1), distribution chamber (2), and liquid circulation system, thereby reducing overall system size while maintaining independent optimization capability for each reaction type.
Solution Approach 2:
The device incorporates multiple catalytic sections within one unit that can accommodate different catalysts and perform various catalytic reactions. The universal design allows the same structural framework to support diverse chemical transformations, eliminating the need for separate dedicated devices for each reaction while preserving reaction-specific optimization.
2Reliability
If multiple separate devices are used for different catalytic reactions, then each reaction can be optimized independently, but power consumption increases substantially
Solution Approach 1:
The patent combines multiple catalytic reaction sections into a single integrated device with stacked sections (S1, S2, S3) that can perform different catalytic reactions simultaneously. The sections share common structural elements including the housing (1), distribution chamber (2), and liquid circulation system, thereby reducing overall system size while maintaining independent optimization capability for each reaction type.
Solution Approach 2:
The device incorporates multiple catalytic sections within one unit that can accommodate different catalysts and perform various catalytic reactions. The universal design allows the same structural framework to support diverse chemical transformations, eliminating the need for separate dedicated devices for each reaction while preserving reaction-specific optimization.
3Productivity
If liquid flows through multiple sections sequentially, then residence time can be extended for better conversion, but the risk of gas phase mixing between sections increases
Solution Approach 1:
The device divides the reaction zone into multiple stacked sections (S1, S2, S3) separated by distribution chambers and overflow wells. Each section contains its own catalyst bed and is hydraulically connected to the next section through controlled overflow channels. This segmentation allows extended residence time through sequential flow while maintaining physical barriers that prevent gas phase mixing between sections, thus preserving selectivity.
Solution Approach 2:
The distribution chamber and overflow well structure acts as an intermediary between sections. Liquid flows from one section to the next through this intermediary structure, which allows liquid phase transfer while blocking gas phase passage. This intermediary mechanism enables extended conversion time without compromising section isolation and selectivity.
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
Improves target product yield and selectivity, reduces heat losses, and minimizes catalyst usage by optimizing residence time and heat utilization, while allowing flexible catalyst arrangement for various processes.
Implementation Method 1
the liquid present therein forms a hydraulic seal so that the gaseous phase present in the section cannot enter the feed channel
Implementation Method 2
a device for performing chemical reactions over a fixed bed of catalyst
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A catalytic reactive rectification column for performing chemical reactions, in which one starting substance is in the liquid phase and one product is in the gaseous phase. The column comprises a reaction zone which includes at least two catalytic sections, each section having a feed channel and an overflow well which simultaneously acts as the feed channel for the next section, such that liquid from each section passes into the overflow well of this section and via it enters the lower part of the next section, the reaction zone being designed to permit removal of the gaseous products of each section, bypassing the remaining sections. Application to the hydromerization of benzene and the isomerization of paraffins.