Jet Agitation Catalytic Reaction-Rectification Column
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Solution Overview
Problem
Traditional catalytic reaction and separation processes for producing esters and ethers, such as n-butyl acetate, are inefficient, causing equipment erosion, low conversion rates, and high production costs due to the use of sulfuric acid or solid acid catalysts, which are not reusable and require large amounts of raw materials, leading to high investment and maintenance costs.
Innovation Solution
A catalytic reaction-rectification integrated system that combines a subsonic or transonic jet agitation reaction section with a rectification column, using either solid or liquid catalysts, which increases reaction and separation efficiency, reduces energy consumption, and simplifies catalyst replacement, allowing for continuous operation and reduced equipment investment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sulfuric acid or sulfonic acid ion exchange resin is used as catalyst in traditional catalytic reaction, then the reaction can proceed, but equipment erosion occurs and catalyst cannot be reused
Solution Approach 1:
The patent replaces traditional liquid acid catalysts (sulfuric acid, sulfonic acid) with solid acid catalysts, fundamentally changing the physical state of the catalyst from liquid to solid. This substitution eliminates equipment erosion caused by liquid acids while maintaining catalytic activity, and enables catalyst reuse through filtration and recycling
Solution Approach 2:
The patent changes the physical parameter of the catalyst from liquid phase to solid phase, and optimizes particle size distribution (0.01-2mm) to balance reaction efficiency and separation ease. This parameter change enables both improved equipment durability and catalyst reusability
2Object-generated harmful factors
If solid acid catalyst and fixed-bed reaction is adopted, then equipment erosion is reduced, but the process is time-consuming and conversion rate is low (about 50%)
Solution Approach 1:
The patent replaces the static fixed-bed reactor with a dynamic jet agitation system where solid catalyst particles are suspended and continuously circulated in the reaction zone. This dynamic system enhances mass transfer between liquid reactants and solid catalyst, increasing conversion rate from 50% to over 90% while maintaining equipment durability
Solution Approach 2:
The patent uses jet agitation technology where high-velocity liquid flow creates suspension and circulation of solid catalyst particles. This hydraulic system replaces the static fixed-bed configuration, dramatically improving reaction efficiency and conversion rate while avoiding equipment erosion
3Productivity
If traditional catalytic reaction process is used, then production can be maintained, but energy consumption is high and production cost is high
Solution Approach 1:
The patent merges the reaction zone with the separation zone in an integrated reaction-separation system. The rectification column is directly connected to the reaction vessel, allowing continuous separation of products from reactants. This integration eliminates the need for separate reaction and separation operations, reducing energy consumption and increasing production efficiency
Solution Approach 2:
The patent implements continuous operation where reactants are continuously fed, reaction occurs continuously with catalyst circulation, and products are continuously separated and removed. This continuous process eliminates idle time between batches and maintains high productivity while optimizing energy utilization
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 doubles production capacity, increases conversion rates by 10%, reduces equipment damage, and lowers production costs by 30%, while ensuring safe and efficient operation with improved heat and mass transfer, and selectivity.
Implementation Method 1
The jet agitation reaction section looks like a reaction kettle, located in the middle of the catalytic reaction-rectification integrated column
Implementation Method 2
the reactants are jetted into the reaction section (6) at high speed, and the solid and the liquid in the reaction section are efficiently mixed
Implementation Method 3
After being mixed with the catalyst, the reactants are fed into the jet agitation reaction section (6) of the catalytic reaction-rectification integrated column (T-01)
Implementation Method 4
The gas emitting up from the stripping section (9) of the catalytic reaction-rectification integrated column (T-01) is led through the pipe (9-4) and the air distributor (5) back to the rectification section (4)
Data Source
AI summary
A catalytic reaction-rectification integrated process and a catalytic reaction-rectification integrated column, and the specialized device of such process is provided. The reactants are preheated and mixed with catalysts, and then fed into a jet agitation reaction section located in the middle of the catalytic reaction-rectification integrated column from a feeding inlet. The jet agitation reaction section is a kettle-like reactor located in the middle of the catalytic reaction-rectification integrated column. After pressurized by a centrifugal pump, the reactant materials are admitted into a subsonic or transonic agitator located within the reaction section. The reactant materials are ejected into the jet agitation reaction section at high speed, to efficiently mix the solid and liquid phases in the reaction section and to reinforce heat and mass transfer efficiency during the reaction. The liquid reaction mixture is separated and purified directly in the catalytic reaction-rectification integrated column.