Filtration Apparatus for Continuous Product Removal at Elevated Pressure
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Solution Overview
Problem
Current methods for producing chemicals like aminoalcohols at high pressure using catalysts and reactive gases face challenges in efficiently separating the reaction product from the catalyst and high-pressure gas, leading to hazardous and time-consuming processes, especially with unsupported base-metal catalysts like nickel or cobalt, which are difficult to filter and require venting, resulting in lost material and reduced selectivity.
Innovation Solution
A process involving a reactor system with a filtration apparatus that accumulates catalyst and uses a backpulse system to return it to the reactor, maintaining gas pressure and retaining the catalyst inside, while continuously removing the reaction product through controlled filtration and backpulse operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reactor is vented to relieve pressure and filter the catalyst to separate product from catalyst and gas, then the product can be separated from the catalyst and gas, but material is lost and time is consumed and hazards increase
Solution Approach 1:
The patent extracts the catalyst from the reaction mixture using a filter located at the reactor outlet. The filter continuously removes catalyst particles as the reaction mixture flows through the reactor, allowing product separation without venting the reactor pressure. This extraction approach maintains system pressure while achieving the necessary separation.
Solution Approach 2:
The patent introduces an intermediary filtration system that acts as a mediator between the high-pressure reaction zone and the product collection system. The filter serves as an intermediary component that enables catalyst removal while maintaining pressure integrity, avoiding the need to vent the reactor and lose valuable materials.
2Stress or pressure
If the reactor is vented to relieve pressure, then the pressure is relieved, but time is consumed and material is lost
Solution Approach 1:
The patent implements continuous filtration at the reactor outlet, allowing the separation process to occur continuously during reactor operation. This continuous action eliminates the need for periodic venting operations, maintaining both pressure integrity and continuous product removal without time losses associated with batch venting cycles.
3Productivity
If filtration of the catalyst is minimized, then time and cost are reduced and hazards are minimized, but complete separation of product from catalyst may be compromised
Solution Approach 1:
The patent applies preliminary filtration action by positioning the filter at the reactor outlet where catalyst particles are first introduced into the product stream. This preliminary separation occurs continuously as the reaction mixture exits the reactor, preventing catalyst carryover before it can contaminate the product collection system.
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 continuous removal of the reaction product from a reactor at elevated pressure without venting the gas, minimizing catalyst filtration and maintaining catalyst retention, thus reducing hazards, material loss, and operational costs, while maintaining reaction product purity over extended periods.
Implementation Method 1
reacting 2-nitro-2-methyl-1-propanol with hydrogen over a catalyst in a reactor
Implementation Method 2
Catalytic hydrogenations over heterogeneous catalysts
Implementation Method 3
filtration apparatus that accumulates catalyst and uses a backpulse system
Data Source
Figure 1
Figure 2
AI summary
Disclosed are processes and apparatuses for producing a reaction product and enabling the reaction product to be removed from a reactor operating at an elevated pressure, while simultaneously maintaining the gas pressure and retaining the catalyst inside the apparatus.