Hydroformylation Reactor Aqueous Phase Control
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Solution Overview
Problem
In the hydroformylation of olefins with 6 to 20 carbon atoms, the inaccurate determination of the aqueous phase level in the reactor leads to operational disruptions, affecting the yield of crude hydroformylation products due to insufficient or excessive aqueous phase removal, which can cause temperature peaks and catalyst decomposition.
Innovation Solution
A continuous process where the flow rate of the aqueous phase stream from the reactor bottom is controlled based on temperature measurements at specific points within the reactor or in lines leading from the bottom, allowing for precise regulation and automation to maintain stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the aqueous phase level is determined using conventional methods, then the process operation is simple, but the measurement precision is insufficient leading to operational disruptions
Solution Approach 1:
The patent implements a feedback control system where the aqueous phase level is continuously measured and the measurement value is fed back to automatically control the discharge flow rate. This closed-loop feedback mechanism resolves the contradiction by providing precise measurement (improving parameter 28) while using automated control to simplify operation (compensating for increased device complexity in parameter 36).
Solution Approach 2:
The patent replaces manual visual assessment or simple level indicators with automated measurement systems that use physical principles (such as density differences, electrical properties, or optical methods) to detect aqueous phase level. This substitution of mechanical/manual methods with automated sensing technologies improves measurement precision (parameter 28) while the automation reduces operational complexity (addressing parameter 36).
2Reliability
If excessive aqueous phase is removed from the reactor, then the aqueous phase level is controlled, but temperature peaks occur causing catalyst decomposition
Solution Approach 1:
The feedback control system continuously monitors aqueous phase level and adjusts the discharge flow rate in real-time to maintain optimal levels. This prevents both excessive removal (which causes temperature peaks) and insufficient removal (which disrupts operation), thereby improving reliability (parameter 27) while maintaining temperature stability (addressing parameter 17).
Solution Approach 2:
The system uses the natural density difference between aqueous and organic phases to enable automatic phase separation and level detection without external intervention. The aqueous phase automatically settles and can be discharged based on level detection, allowing the system to self-regulate (improving parameter 27) while avoiding temperature excursions (addressing parameter 17).
3Productivity
If insufficient aqueous phase is removed from the reactor, then catalyst decomposition is avoided, but operational disruptions occur reducing productivity
Solution Approach 1:
The automated feedback control system continuously adjusts the aqueous phase discharge rate to maintain optimal levels, ensuring continuous stable operation (improving parameter 27) and preventing operational disruptions that would reduce productivity (addressing parameter 39).
Solution Approach 2:
The system dynamically changes the discharge flow rate parameter based on real-time aqueous phase level measurements. By adjusting this parameter continuously, the system maintains optimal aqueous phase levels to prevent disruptions (improving parameter 27) while maximizing productivity (addressing parameter 39).
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 ensures stable, continuous operation by accurately controlling the aqueous phase removal, reducing process interruptions and increasing the yield of crude hydroformylation products while minimizing maintenance efforts.
Implementation Method 1
If the aqueous phase separates from the organic phase and separates in the bottom space of the reactor
Implementation Method 2
the flow rate of the second stream is controlled in accordance with a temperature which is measured at a point in the bottom of the reactor or in a line leading from the bottom
Implementation Method 3
The cobalt catalyst is destroyed oxidatively and the central atom is formally transferred from the oxidation state -1 to +2
Data Source
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AI summary
The invention relates to the hydroformylation of olefins having 6 to 20 carbon atoms in the presence of a cobalt catalyst in the presence of an aqueous phase being mixed in a reactor, wherein a first current containing hydroformylation products is drawn on the head of the reactor and a second current containing an aqueous phase is drawn from the sump of the reactor. The flow rate of the second current is controlled according to a temperature which is measured at a location in the sump of the reactor or in a line leading out of the sump. The yield of raw hydroformylation product is increased as a consequence of stable continuous operation.