Hydroformylation Reactor Distributor Plate for Olefin Conversion
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Solution Overview
Problem
Conventional hydroformylation and hydrogenation processes face limitations in reaction efficiency due to inadequate contact between olefins and synthesis gas, leading to reduced selectivity and increased side reactions such as esterification, acetal formation, and etherification.
Innovation Solution
An apparatus comprising a hydroformylation reactor with a nozzle and distributor plate to enhance gas-liquid contact and a hydrogenation reactor with dual catalyst layers to suppress side reactions, promoting efficient production of alcohols from olefins by forming micro-bubbles and optimizing catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional stirring or circulation methods are used in hydroformylation reactor, then the reactor structure is simple and easy to operate, but the contact surface area between olefins and synthesis gas is insufficient, leading to reduced reaction efficiency
Solution Approach 1:
The invention utilizes gas-liquid phase interaction by introducing synthesis gas as gas bubbles into the liquid reaction mixture. The gas-liquid contact process enhances mass transfer and reaction efficiency without requiring complex mechanical stirring mechanisms, thereby resolving the contradiction between productivity improvement and device complexity.
2Manufacturing precision
If longer residence time or multiple reactors in series are used to achieve satisfactory product conversion, then the required product level is achieved, but the process complexity and equipment investment increase
Solution Approach 1:
The invention changes the reaction parameters by optimizing gas flow rate, liquid circulation rate, and reactor temperature to achieve high conversion efficiency in a single reactor. This approach avoids the need for multiple reactors in series or extended residence times, thereby reducing process complexity while maintaining satisfactory product conversion levels.
3Reliability
If conventional hydrogenation catalysts are used, then the catalyst structure is simple, but side reactions such as esterification, acetal formation, and etherification occur, reducing selectivity
Solution Approach 1:
The invention employs a composite catalyst system combining nickel and copper catalysts in specific proportions. This composite catalyst structure enhances selectivity by suppressing unwanted side reactions while maintaining catalytic activity, resolving the contradiction between improving reliability and managing device complexity.
4Speed
If vapor phase hydrogenation is used to perform the reaction, then the reaction rate is fast, but esterification and other side reactions are generated, reducing selectivity
Solution Approach 1:
The invention changes the phase parameter from vapor phase to liquid phase hydrogenation. This parameter change slows the reaction rate slightly but dramatically improves selectivity by suppressing esterification and other side reactions, thereby resolving the contradiction between speed and reliability.
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 apparatus significantly improves reaction efficiency and selectivity by increasing the contact surface area and controlling catalyst activity, resulting in enhanced production of alcohols while reducing unwanted side reactions.
Implementation Method 1
spraying olefins and a synthesis gas (CO/H2) into a solution of catalyst mixture... forming micro-bubbles
Implementation Method 2
a part of these gases being dispersed in the form of gas bubbles in the reaction liquid
Implementation Method 3
a distributor plate for converting a flow of the olefins and the synthesis gas (CO/H2)
Implementation Method 4
converting a flow of the olefins and the synthesis gas... enhancing gas-liquid contact
Implementation Method 5
a nickel catalyst layer having a high activity... a copper catalyst layer having a low activity... producing alcohols by adding hydrogen to the recovered aldehydes
Implementation Method 6
hydrogenation reactor for producing alcohols by adding hydrogen to the recovered aldehydes
Implementation Method 7
a circulation line for circulating the reaction mixture... continuously circulates the reaction mixture
Data Source
Figure 1(a)~1(b)
Figure 2~3(c)
Figure 4(a)~4(e)
AI summary
The present invention relates to an apparatus for producing alcohols from olefins, comprising: a hydroformylation reactor wherein aldehydes are produced from olefins; a catalyst/aldehydes separator; a hydrogenation reactor wherein the aldehydes are hydrogenated to produce alcohols; and a distillation column. The hydroformylation reactor is equipped with a distributor plate, which has a broad contact surface for providing sufficient reaction area for reactants such as olefins and synthesis gas, and allows the reaction mixture to circulate and mix sufficiently, which contribute to excellent efficiency in terms of production of aldehydes. In addition, the hydrogenation reactor suppresses sub-reactions to improve the production yield of alcohols.