Differential Recycle Reactor With Dividing Wall For Uniform Flow
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Solution Overview
Problem
Common differential recycle reactors face challenges in achieving homogeneous flow and temperature profiles, leading to non-uniform reaction conditions and high pressure losses.
Innovation Solution
A differential recycle reactor design featuring two reactor tubes connected by bent tubes to form a closed loop, with a catalyst placed in one tube and a product withdrawal point ensuring components flow through the catalyst before extraction, and a dividing wall for heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single reactor tube with annular duct is used, then the device complexity is reduced, but the flow uniformity and temperature profile homogeneity deteriorate
Solution Approach 1:
The reactor is divided into two separate reactor tubes (first reactor tube and second reactor tube) instead of using a single tube with annular duct. Each tube has its own catalyst bed and flow path, which segments the flow distribution problem and improves flow uniformity across the catalyst beds while maintaining manageable device complexity
Solution Approach 2:
Each reactor tube is equipped with dedicated flow distribution mechanisms and heating/cooling elements tailored to its specific requirements. The first and second reactor tubes can have different local conditions optimized for their respective catalyst beds, achieving better local flow uniformity and temperature control
2Stability of the object's composition
If high recirculation ratio is used to achieve intensive mixing, then the continuously stirred tank reactor mode is achieved, but the pressure losses increase
Solution Approach 1:
A heat exchanger is introduced as an intermediary device to manage thermal energy in the recirculating fluid. The heat exchanger allows for efficient heat transfer between the recirculating fluid and the reactor walls or cooling medium, enabling better temperature control and reducing the energy required to maintain the desired recirculation conditions, thereby reducing overall pressure losses
Solution Approach 2:
The reactor operates by changing parameters such as recirculation flow rate, temperature, and pressure to optimize the balance between mixing intensity and pressure losses. By dynamically adjusting these parameters, the system can achieve the required continuously stirred tank reactor mode while minimizing energy losses
3Device complexity
If conventional jet loop reactor design is used, then the device complexity is low, but the temperature profile uniformity deteriorates
Solution Approach 1:
The heating and cooling functions are merged into the reactor wall structure itself, with heating elements and cooling channels integrated directly into the first and second reactor tubes. This allows for simultaneous or alternating heating and cooling of different sections of the reactor, achieving uniform temperature profiles across the catalyst beds without adding significant external complexity
Solution Approach 2:
The reactor system performs preliminary heating or cooling of the recirculating fluid before it enters the catalyst beds through the first and second reactor tubes. This preliminary thermal conditioning ensures that the fluid enters the catalyst beds at the optimal temperature, maintaining uniform temperature profiles and preventing hot spots or cold zones
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 design achieves a constant and homogeneous flow through the catalyst, allowing for precise kinetic measurements and reducing pressure losses, while also maintaining a uniform temperature profile.
Implementation Method 1
The reactor tubes are separated by a dividing wall
Implementation Method 2
a reactant feed with a nozzle through which a reactant stream is injected into one of the reactor tubes
Implementation Method 3
a catalyst can be placed in the second of the reactor tubes
Data Source
Figure 1
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Figure 3
AI summary
The invention relates to a differential recycle reactor comprising two reactor tubes (3, 5) which are connected at each end with a bent tube (9, 11), forming a closed loop, a reactant feed with a nozzle (37) through which a reactant stream is injected into a first of the reactor tubes (3), and a product withdrawal point (38), wherein a catalyst can be placed in a second of the reactor tubes (5), the product withdrawal point (38) being located such that components being injected into the reactor (1) flow at least one time through the catalyst before reaching the product withdrawal point (38), wherein the reactor tubes (3, 5) are holes formed in a housing (6) and separated by a dividing wall (7).