De-entrainer for Vapor Phase Fluorination Catalyst Protection
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Solution Overview
Problem
The existing manufacturing process for producing 2,3,3-tetrafluoropropene (HFO-1234yf) faces catalyst deactivation issues due to unvaporized feed entrainment, leading to yield loss and economic disadvantages in the conversion of 1,1,2,3-tetrachloropropene (1230xa) to 2-chloro-3,3,3-trifluoropropene (1233xf).
Innovation Solution
A reactor system incorporating a de-entrainer, such as a knock-out pot or packed tower, is used to separate vaporous and liquid phases of 1230xa, ensuring the catalyst contacts only the vaporous feed, thereby extending catalyst life and stability by preventing liquid feed entrainment and oligomer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vapor phase fluorination is used to convert 1230xa to 1233xf, then reaction efficiency is improved, but catalyst deactivation occurs due to liquid feed entrainment
Solution Approach 1:
A de-entrainer is installed between the vaporizer and reactor to remove liquid feed entrainment before the vapor enters the reactor. This preliminary separation action prevents liquid droplets from reaching the catalyst bed, thereby preventing catalyst deactivation while maintaining continuous vapor phase fluorination operation.
Solution Approach 2:
The de-entrainer acts as an intermediary device between the vaporizer and reactor. It receives the vapor stream containing liquid entrainment, separates the liquid droplets through coalescence or impingement, and delivers a cleaned vapor stream to the reactor, protecting the catalyst from liquid damage.
2Productivity
If continuous operation is maintained to improve productivity, then yield increases, but catalyst deactivation leads to yield loss
Solution Approach 1:
The de-entrainer converts the harmful effect of liquid feed entrainment into a beneficial separation process. By capturing and removing liquid droplets that would otherwise damage the catalyst, the device transforms a potential source of catalyst deactivation and yield loss into a protective function that enables sustained high-yield production.
3Speed
If vaporizer temperature is increased to improve vaporization efficiency, then feed vaporization is improved, but liquid feed entrainment increases
Solution Approach 1:
The de-entrainer extracts and removes liquid feed droplets from the vapor stream. By taking out the harmful liquid entrainment that forms during high-temperature vaporization, the device allows the vaporizer to operate at optimal temperatures for efficient vaporization without suffering from the negative consequences of liquid carryover.
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 significantly prolongs catalyst life, improves reaction selectivity, and enhances the overall yield of 1233xf, maintaining high conversion and selectivity rates over extended operation times, as demonstrated by continuous operation examples.
Implementation Method 1
separating the vaporous 1230xa from the liquid 1230xa, in e.g. a de-entrainer
Implementation Method 2
The starting material is vaporised using a vaporiser which is then fed to the vapor phase reactor
Data Source
AI summary
The invention relates to the use of a liquid- vapor separator such as a de-entrainer to remove an unvaporized portion of a feed, e.g. 1,1,2,3-tetrachloropropene (1230xa), to a catalytic vapor phase fluorination reaction where e.g. 2-chloro-3,3,3,-trifluoropropene (1233xf) is produced. The invention extends the life of the catalyst.