Gas-Liquid Bubbling Bed Reactor for Carbonate Synthesis
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Solution Overview
Problem
Existing gas-liquid reactors for synthesizing carbonate face issues such as insufficient reaction of raw materials, low conversion efficiency, gas binding of pumps, and difficulty in accurately determining the liquid level, leading to fluctuations and potential 'full-tank' states.
Innovation Solution
A gas-liquid bubbling bed reactor system is introduced, featuring a liquid distributor, gas distributor, catalyst bed layer, and catalyst support plate, with a heterogeneous catalyst. This system includes a sub-reactor connected in series, allowing for efficient mixing and reaction of alkylene oxide and carbon dioxide, and a separation unit for purifying the carbonate product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional gas-liquid reactor is used for carbonate synthesis, then the reaction can proceed, but the conversion efficiency of carbon dioxide and alkylene oxide is insufficient and raw materials are not fully reacted
Solution Approach 1:
The reactor is divided into multiple segments with catalyst beds distributed throughout, creating multiple reaction zones. This segmentation allows for better contact between gas and liquid phases at different locations, improving overall conversion efficiency and ensuring more complete reaction of carbon dioxide and alkylene oxide.
Solution Approach 2:
The liquid phase is pre-saturated with carbon dioxide gas before entering the catalyst bed through a gas-liquid mixing section. This preliminary action ensures that the liquid contains sufficient dissolved CO2 to react with alkylene oxide in the catalyst bed, improving conversion efficiency and reducing unreacted materials.
2Productivity
If carbon dioxide gas is introduced into the reactor, then the reaction can proceed, but gas binding occurs in the circulating pump
Solution Approach 1:
The gas binding problem is resolved by extracting the gas-liquid mixture from the pump circulation line and introducing it directly into the reactor at a point where gas can be properly distributed. This removes the harmful effect of gas binding in the pump while maintaining the necessary reaction conditions.
Solution Approach 2:
A gas-liquid mixing section acts as an intermediary between the gas inlet and the catalyst bed. This intermediary zone allows carbon dioxide to be properly mixed with the liquid phase before reaching the reaction zone, enabling reaction progress without causing gas binding in pumping equipment.
3Ease of operation
If a traditional liquid level measurement method is used, then the liquid level can be monitored, but the liquid level fluctuates greatly and accurate determination is difficult
Solution Approach 1:
Traditional mechanical liquid level measurement methods are replaced with a more advanced sensing system that can accurately measure liquid level despite gas-liquid fluctuations. This substitution eliminates the measurement errors caused by mechanical sensitivity to gas bubbles and flow turbulence.
4Productivity
If a homogeneous catalyst system is used, then the reaction can proceed smoothly, but product separation is difficult and large amounts of catalyst are consumed
Solution Approach 1:
The catalyst system is changed from homogeneous to heterogeneous, representing a fundamental parameter change in the catalyst's physical state. This change allows the catalyst to be easily separated from the product stream through filtration or decantation, simplifying the separation process while maintaining catalytic activity and enabling catalyst reuse.
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
The system enhances the conversion efficiency of carbon dioxide and alkylene oxide, improves the yield and purity of carbonate, prevents gas binding in pumps, and stabilizes the reaction operation, ultimately leading to efficient and high-yield carbonate synthesis.
Implementation Method 1
a catalyst bed layer and a catalyst support plate, preferably the catalyst bed is loaded with a heterogeneous catalyst
Implementation Method 2
gas-liquid bubbling bed reactor
Data Source
Figure 1~2
AI summary
The present invention discloses a gas-liquid bubbling bed reactor, comprising a liquid distributor, a gas distributor located below the liquid distributor, a catalyst bed layer and a catalyst support plate, and an optional interception screen, wherein the top of the reactor is provided with a gas outlet, the reactor is provided with a feed inlet connected to the liquid distributor, a gas inlet connected to the gas distributor, the bottom is provided with a discharge outlet. The present invention further provides a reaction system, which comprises the gas-liquid bubbling bed reactor as the main reactor and a sub-reactor. Through the system and the process of the present invention, the problems of the low conversion rate, the gas binding of the circulating pump, the unstable operation, the low yield of electronic-grade products, and the like in the carbonate synthesis process are solved purposedly targetedly, and the present invention can be applied to related industrial production.