Loop-Venturi Reactor Heat Exchange and Circulation Design
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Solution Overview
Problem
Existing chemical reactors face challenges in efficiently managing heat dissipation and maintaining high space-time yields during exothermic reactions, leading to local overheating, side reactions, and reduced catalyst lifespan due to inadequate heat transfer and circulation flow designs.
Innovation Solution
A vertically extended reactor with internally located heat exchanger tubes surrounded by a cooling medium, where the reaction medium flows through the heat exchanger tubes, and a propulsion jet nozzle system creates an internal circulation flow to enhance heat transfer and mixing, minimizing temperature gradients and mechanical stress on the catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If heat exchanger tubes are arranged inside the reactor with cooling medium surrounding them, then heat dissipation performance is improved, but device complexity increases
Solution Approach 1:
The patent combines the heat exchanger tubes directly inside the reactor vessel, merging the reaction chamber and heat exchange functions into a single integrated structure. This eliminates the need for separate external heat exchangers and complex piping systems, thereby improving heat dissipation performance while avoiding excessive device complexity.
Solution Approach 2:
The reactor design makes the reactor vessel serve multiple functions: it acts as both the reaction chamber and the heat exchange system. The cooling medium flows through the reactor while the reaction mixture passes through the heat exchanger tubes, allowing simultaneous heat dissipation and reaction in the same space.
2Loss of energy
If circulation volume ratio is increased to improve heat removal, then heat dissipation is improved, but mechanical stress on catalyst increases
Solution Approach 1:
The patent creates different flow regimes in different regions of the reactor. The propulsion jet nozzle generates intense local circulation in specific zones to enhance heat removal, while other regions maintain gentler flow conditions that are less stressful to the catalyst. This localized approach allows effective heat management without uniformly high mechanical stress throughout the reactor.
Solution Approach 2:
The circulation flow is dynamically controlled through the propulsion jet nozzle system, which can adjust circulation intensity based on reaction conditions. This dynamic flow management allows optimization of heat removal efficiency while adapting to protect the catalyst from excessive mechanical stress during different operational phases.
3Productivity
If propulsion jet nozzle creates strong circulation flow to enhance mixing, then mass transfer is improved, but energy consumption increases
Solution Approach 1:
The propulsion jet nozzle utilizes the reaction mixture itself as the working fluid to drive the circulation flow. The system leverages the kinetic energy and pressure of the reacting fluids to create the circulation pattern, rather than requiring separate external pumps or motors. This self-service approach enhances mixing and mass transfer while minimizing additional energy consumption.
Solution Approach 2:
The patent employs hydraulic principles through the propulsion jet nozzle, which uses fluid pressure and velocity to generate circulation flow. The nozzle converts the hydraulic energy of the reaction mixture into kinetic energy that drives the circulation, providing an energy-efficient mechanism for enhancing mixing and mass transfer compared to mechanical stirring systems.
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 design effectively dissipates large amounts of heat, maintains isothermal conditions, and increases space-time yields while extending catalyst lifespan by optimizing heat transfer and circulation flow, reducing the formation of by-products and improving reaction efficiency.
Implementation Method 1
the cooling medium surrounds the tubes of the heat exchanger of the device according to the invention, whereas the conversion takes place in the tubes
Implementation Method 2
the cooling medium enters the inner tubes via a feed chamber arranged outside of the reactor chamber flows in and flows out via the space between the inner and outer tubes
Implementation Method 3
a propulsion jet nozzle (9) directed downwards for the introduction of the reaction medium, which is arranged vertically in the gas space of the reactor (1) and whose outlet is above the at least one mixing chamber (8) and which forms a jet pump with the mixing chamber (8)
Implementation Method 4
at least one means arranged below the heat exchanger (2) and below the mixing chamber (8) for deflecting the reaction medium flowing down through the mixing chamber (8) in such a way that the reaction medium flows back up through the heat exchanger (2)
Data Source
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AI summary
The invention relates to a device of the loop-Venturi reactor type for the continuous reaction of liquids with gases, in particular for hydrogenation, oxidation or acetylation, e.g. for the production of diaminotoluene by the hydrogenation of dinitrotoluol. The invention also relates to a method for the continuous reaction of liquid reactants with gaseous reactants in the device. The coolant surrounds the tubes of the heat exchanger of the device according to the invention, whereas the reaction takes place in the tubes.