Film-Type Catalyst Reactor for Tertiary Amine Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional catalyst systems, such as solid catalyst slurries and fixed-bed reactors, face challenges in safety, waste management, and productivity, particularly in tertiary amination reactions where byproducts are generated, and existing reactor designs are not optimized for complex reactions like those involving alcohols and amines.
Innovation Solution
A process using a film-type catalyst in a reactor with an external circulating line and buffering tank, where the reaction solution is circulated at least 3 times per hour, allowing for efficient production of tertiary amines without the need for catalyst separation or complex mixing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a solid catalyst slurry is used in a mixing tank type reactor, then the catalyst can be utilized for the reaction, but the catalyst must be removed by filtration and the facility becomes complex
Solution Approach 1:
The catalyst is extracted from the liquid slurry form and applied as a thin film coating on the reactor interior surface. This eliminates the need for filtration operations and complex catalyst removal facilities while maintaining catalyst utilization for the amination reaction.
Solution Approach 2:
The reactor interior surface acts as an intermediary carrier for the catalyst. By coating the catalyst film on this intermediate surface, the catalyst remains in place during the reaction process, eliminating the need for complex separation facilities.
2Ease of operation
If a molded catalyst is used in a fixed-bed system, then catalyst handling and waste management are improved, but temperature control becomes troublesome and uneven liquid-gas distribution causes insufficient reaction percentage
Solution Approach 1:
The catalyst is applied as a thin film coating rather than molded into pellets or noodles. This changes the physical form parameter to allow better heat and mass transfer, improving temperature control and reaction uniformity while maintaining ease of catalyst application and handling.
Solution Approach 2:
The catalyst is applied as a thin film coating on the reactor interior surface. This thin film structure allows for uniform distribution of catalyst activity, improved heat transfer for better temperature control, and maintained ease of catalyst application compared to molded catalysts.
3Speed
If a thin film catalyst is used, then mass transfer is accelerated and pressure drop is reduced, but the reactor design becomes more complex with external circulating lines
Solution Approach 1:
The reactor serves multiple functions: it contains the reaction mixture, provides the surface for catalyst coating, and incorporates the circulation system. By making the reactor multi-functional, the design complexity from adding external circulating lines is offset by eliminating the need for separate reaction vessels and catalyst handling equipment.
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 enables high-yield production of tertiary amines with reduced byproduct formation, improved catalyst utilization, and simplified reactor maintenance, addressing the limitations of previous technologies in handling and efficiency.
Implementation Method 1
a process for producing a tertiary amine from its corresponding primary or secondary amine and an alcohol as the raw materials by using a film type catalyst
Data Source
AI summary
The present invention relates to a process for producing a tertiary amine from its corresponding primary or secondary amine and alcohol as the raw materials by using a film type catalyst. Disclosed is a process for producing a tertiary amine from an alcohol and a primary or secondary amine, which including conducting the reaction, while circulating a reaction solution at least 3 times/hour in a reactor loaded with a film type catalyst in an external circulating line ancillary to a tank.