Integrated Fixed Bed and Jet Floating Bed Reactor Process
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Solution Overview
Problem
Integrated reaction and separation systems face challenges with long reaction times, low conversion rates, and high energy consumption due to the limitations of fixed bed reactors, as well as difficulties in catalyst regeneration and mixing of reactants in existing industrial processes.
Innovation Solution
An integrated process coupling fixed bed reactors with jet floating bed reactors and a separating unit, where preliminary reactions occur in the fixed bed reactor followed by intensified reactions in the jet floating bed reactor, with subsequent separation of products, allowing for reduced reaction time, extended catalyst life, and lower energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed bed reactor is used for liquid-solid catalytic reaction, then structure is simple and catalyst mechanical loss is small, but reaction efficiency is relatively low and heat transfer is poor
Solution Approach 1:
The patent combines fixed bed reactor and jet floating bed reactor into an integrated system where the fixed bed reactor performs preliminary reaction and the jet floating bed reactor performs intensified reaction. This merging allows the system to maintain structural simplicity while achieving high reaction efficiency through the complementary strengths of both reactor types.
2Ease of operation
If fixed bed reactor is used, then catalyst replacement is difficult, but if fluidized bed reactor is used, then catalyst can be regenerated frequently
Solution Approach 1:
The patent segments the reaction process into two distinct stages performed in separate reactor units: preliminary reaction in fixed bed reactor and intensified reaction in jet floating bed reactor. This segmentation allows each reactor type to operate optimally for its specific function, with the fixed bed providing stable catalyst support and the jet floating bed enabling efficient catalyst-c reactant mixing and heat transfer.
3Reliability
If fixed bed reactor is used, then fluid and catalyst contact is effective, but mixing of two-phase reactants is difficult
Solution Approach 1:
The integrated reactor system merges the effective fluid-catalyst contact of fixed bed reactor with the superior two-phase mixing capability of jet floating bed reactor. The preliminary reaction in fixed bed ensures good contact, while the subsequent intensified reaction in jet floating bed achieves thorough mixing of oil and water phases through high-velocity fluid circulation.
4Productivity
If reaction time is extended to achieve high conversion rate in fixed bed reactor, then conversion rate improves, but equipment volume increases and energy consumption increases
Solution Approach 1:
The patent applies preliminary action by performing the preliminary reaction stage in the fixed bed reactor before proceeding to the intensified reaction stage in the jet floating bed reactor. This staged approach allows the system to achieve high conversion rates more quickly than a single fixed bed reactor would require, reducing both equipment volume and energy consumption while maintaining effective conversion.
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 shortens reaction time, reduces energy consumption, and extends catalyst service life by combining the advantages of both reactor types, enhancing conversion rates and product separation efficiency.
Implementation Method 1
Its operating principle is use of high velocity mobile phase to suck other phases, generating intense stirring effect, promoting close contact among phases
Implementation Method 2
heat exchanger E-1 (for heating)
Data Source
Figure 1
AI summary
This invention relates to a process of integrated system formed by coupling of fixed bed, jetting floating bed, and separating unit, aimed to provide a new process and equipment of higher efficiency, which integrates multi-type reactors and separation. In this invention, reaction materials will undergo preliminary reaction in fixed bed reactor and intensified reaction in jetting floating bed reactor, and then separation in the subsequent separation system. Unreacted materials will be returned to the raw material intermediate storage tank for mixing with fresh materials, as raw materials for continued reaction. During this process, materials first pass the fixed bed reactor once to achieve certain conversion rate, and then enter the jetting floating bed reactor for intensified reaction. When the product reaches required concentration, the materials will enter subsequent separation equipment for separation. During the whole process, fixed bed reactor, jetting floating bed reactor, and subsequent separation system are coupled, so that the flow path is more integrated, reaction time is greatly shortened, and process energy consumption is further lowered.