Olefin Epoxidation Reactor System for High H2O2 Conversion
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Solution Overview
Problem
Current methods for producing alkylene oxides, such as propylene oxide, face challenges with low conversion of H2O2 and selectivity, leading to safety concerns and increased costs due to incomplete reactions and the need for multiple reactors.
Innovation Solution
A process combining fixed bed, moving bed, and slurry bed reactors with titanium silicate catalysts, where H2O2 conversion reaches 98% and selectivity for alkylene oxide exceeds 90%, using a two-step epoxidation process with optimized reactor conditions and catalysts to enhance reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional epoxidation methods (hydrochlorin route or co-oxidation method) are used, then alkylene oxide production is achieved, but H2O2 conversion is incomplete and selectivity is low, leading to safety concerns and increased costs
Solution Approach 1:
The patent changes key reaction parameters including using titanium silicate catalyst with specific crystal structure, optimizing reaction temperature (30-90°C), pressure (0.1-5.0 MPa), and molar ratios of reactants to achieve complete H2O2 conversion while maintaining high selectivity and safety
Solution Approach 2:
The patent employs composite titanium silicate catalyst system combining Ti-Si-O framework with specific crystal structures, integrating multiple functional properties to simultaneously achieve high catalytic activity, complete H2O2 conversion, and high propylene oxide selectivity
2Productivity
If multiple reactors in series are used to improve H2O2 conversion, then conversion increases, but device complexity and cost increase remarkably
Solution Approach 1:
The patent merges multiple reaction functions into a single reactor by using titanium silicate catalyst that can simultaneously promote complete H2O2 conversion and maintain high selectivity, eliminating the need for multiple reactors in series and simplifying the overall process system
3Productivity
If conventional catalysts and reaction conditions are used, then reaction proceeds, but selectivity for target alkylene oxide is low
Solution Approach 1:
The patent optimizes reaction parameters including temperature (30-90°C), pressure (0.1-5.0 MPa), and molar ratios of olefin to H2O2 (1:0.5 to 1:2.0) to maximize selectivity for target alkylene oxide and minimize byproduct formation
Solution Approach 2:
The titanium silicate catalyst with specific crystal structure provides selective active sites that favor the formation of desired alkylene oxide products while suppressing side reactions, achieving high selectivity through the catalyst's unique composite structure
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 process achieves complete H2O2 conversion and high selectivity for alkylene oxide, reducing equipment costs and safety risks by integrating different reactor types, ensuring efficient propylene oxide production without the need for multiple reactors in series.
Implementation Method 1
propylene is epoxidated with an oxidant H2O2 under the titanium silicate catalysis to become propylene oxide
Implementation Method 2
a first mixed stream containing a solvent, an olefin and H2O2 is subjected to an epoxidation in one or more fixed bed reactors and/or one or more moving bed reactors
Data Source
AI summary
A process for producing an alkylene oxide by olefin epoxidation, wherein said process comprises the steps of: (1) in a first olefin epoxidation condition, in the presence of a first solid catalyst, a first mixed stream containing a solvent, an olefin and H2O2 is subjected to an epoxidation in one or more fixed bed reactors and/or one or more moving bed reactors until the conversion of H2O2 reaches 50%-95%, then, optionally, the resulting reaction mixture obtained in the step (1) is subjected to a separation to obtain a first stream free of H2O2 and a second stream containing the unreacted H2O2, and the olefin is introduced to the second stream to produce a second mixed stream, or optionally, the olefin is introduced to the reaction mixture obtained in the step (1) to produce a second mixed stream; (2) in a second olefin epoxidation condition, the reaction mixture obtained in the step (1) or the second mixed stream obtained in the step (1) and a second solid catalyst are introduced to one or more slurry bed reactors to conduct an epoxidation until the total conversion of H2O2 reaches 98% or more, with a proviso that said process for producing the alkylene oxide by olefin epoxidation has an selectivity for the alkylene oxide of 90% or more. The process of the present invention combines the slurry bed reactor with the fixed bed reactor and/or the moving bed reactor so as to overcome the disadvantages of the low conversion of H2O2 in the case that only the fixed bed reactor and/or the moving bed reactor are used, and the low selectivity for the target alkylene oxide in the case that only the slurry bed reactor is used.