Multi-phase Loop Reactor with Segmented Separation
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Solution Overview
Problem
Existing multiphase loop reactors face challenges with scalability and phase separation complexity, limited specific output due to space-consuming phase separation, and fouling issues in membrane processes, which hinder long-term stable operation and productivity.
Innovation Solution
A multiphase loop reactor design featuring inner and outer cylinders of different diameters forming a cylindrical annular gap, with spatially separated disperse phase inlets and a separating device to prevent mixing, allowing for countercurrent or cocurrent flow configurations and in-situ product separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a four-phase system with cocurrent flow is used in a multi-phase reactor, then all phases can be conducted simultaneously, but scalability is very limited and phase separation becomes very complex
Solution Approach 1:
The reactor is divided into two separate loop halves, each handling a specific phase separation task. The first loop separates the gaseous phase from the liquid phase, while the second loop separates the non-aqueous solvent phase from the aqueous phase. This segmentation allows each loop to be optimized for its specific separation function, reducing overall complexity while maintaining multi-phase capability.
Solution Approach 2:
The phase separation function is extracted from the main reaction zone and implemented as dedicated separation loops. The gaseous phase is extracted and separated in the first loop, while the non-aqueous solvent phase is extracted and separated in the second loop. This extraction of separation functions from the bulk reactor reduces complexity and enables scalability.
2Reliability
If nested cylinders are arranged to separate phases in a loop reactor, then phase separation is achieved, but about 20% of the active reactor volume becomes unavailable for mass transfer, severely limiting specific output
Solution Approach 1:
Instead of using nested cylinders that occupy radial space, the invention uses vertical dimensionality with separate loop halves. The first loop handles gaseous phase separation while the second loop handles non-aqueous solvent phase separation. This vertical arrangement in separate loops maximizes the use of reactor volume for mass transfer while achieving reliable phase separation.
3Reliability
If membrane processes are used for separation, then separation can be achieved, but fouling occurs and mass transport is slower, preventing stable long-term operation
Solution Approach 1:
The separation function is extracted from membrane-based systems and implemented through gravity-driven phase separation loops. The gaseous phase separates in the first loop and the non-aqueous solvent phase separates in the second loop, eliminating membrane fouling issues while maintaining separation capability and enabling stable long-term operation.
4Reliability
If phase separation occupies large space in the reactor, then separation is achieved, but the specific output of the reactor is severely limited
Solution Approach 1:
The reactor is segmented into two functional loop halves, each optimized for specific phase separations. This allows phase separation to occur in dedicated zones rather than occupying space throughout the reactor volume, improving volume efficiency while maintaining reliable separation of gaseous and non-aqueous solvent phases.
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
Enables efficient in-situ product separation and increased reactor productivity by preventing phase mixing and optimizing flow dynamics, allowing for continuous operation and reduced downstream processing.
Implementation Method 1
a first inlet for a first disperse phase for the inner cylinder and a second inlet for a second disperse phase for the cylinder ring gap are arranged in such a way that the first and the second disperse phases are spatially separated from one another and dispersed in the continuous phase
Implementation Method 2
A separating device is arranged opposite the inlets, which blocks interaction paths of the first and second disperse phases with one another
Data Source
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AI summary
The invention relates to a multi-phase loop reactor (1), comprising an internal cylinder (2) and an external cylinder (3) of different diameters, which are arranged such that the cylinders form a cylinder ring gap (4) between each other. The internal cylinder (3) or the cylinder ring gap (4) function as an upcomer, and the respective other one functions as a downcomer such that a continuous phase (100) can carry out a loop flow (103). According to the invention, a first inlet (5) for a first disperse phase (101) and a second inlet (6) for a second disperse phase (102) are arranged such that the first (101) and the second disperse phase (102) can be dispersed, spatially separated from one another, in the continuous phase (100). One of the first or second disperse phases (101, 102) drives the loop flow (103), and the other one of the first and second disperse phases (101, 102) generates a counter flow to the loop flow (103), and a separating device (7) is arranged in the opposite direction of the inlets (5, 6), which separating device prevents a mixing of the first and second disperse phases (101, 102). The invention further relates to a method for operating a multi-phase loop reactor (1).