Oxidized Olefin Reactor Cooling Drum
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Solution Overview
Problem
The production of oxidized olefins faces challenges in temperature control and catalyst deactivation, leading to potential runaway reactions and inefficiencies in existing systems, which can result in undesired byproducts and increased downtime for catalyst replacement.
Innovation Solution
A system and method utilizing multiple reactors with a common supply line for olefins and oxygen, where the catalysts deactivate at a substantially equivalent rate, and a single coolant drum provides uniform cooling to maintain temperature control, reducing mechanical components and vessels, and ensuring synchronized catalyst replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple reactors are used to increase productivity, then production capacity is improved, but system complexity and coordination difficulty increase
Solution Approach 1:
The system divides the oxidation process into multiple parallel reactors (first reactor, second reactor, etc.), each handling a portion of the total production load. This segmentation increases productivity while maintaining manageable complexity through modular design
Solution Approach 2:
Multiple coolant drums are merged into a single integrated coolant distribution system that supplies cooling to all reactors. This merging approach coordinates the temperature control across multiple reactors, managing system complexity while maintaining enhanced production capacity
2Productivity
If catalyst concentration is increased to enhance reaction rate, then productivity is improved, but heat generation increases leading to temperature control issues
Solution Approach 1:
The catalyst is distributed across multiple separate reactors rather than concentrated in one, dividing the total heat generation into manageable portions. Each reactor's cooling system handles a fraction of the total thermal load, making temperature control feasible while maintaining high overall productivity
Solution Approach 2:
Coolant drums serve as intermediary thermal management devices between the exothermic oxidation reactions and the surrounding environment. These intermediaries absorb and remove excess heat, enabling high catalyst concentrations to be used without compromising temperature control
3Reliability
If cooling rate is increased to prevent runaway reactions, then safety is improved, but yield decreases due to excessive heat removal
Solution Approach 1:
Multiple coolant drums provide distributed cooling capacity across several reactors, allowing each reactor to operate at optimal temperature for maximum yield while collectively maintaining safety through redundant cooling pathways. The segmented approach enables precise thermal management that balances safety and productivity
Solution Approach 2:
Each reactor-coolant drum pair can be independently optimized for local thermal conditions, allowing temperature control tailored to each reaction's specific requirements. This local quality approach ensures sufficient cooling for safety while minimizing excessive heat removal that would reduce yield
4Ease of operation
If single coolant drum is used to reduce device complexity, then ease of operation is improved, but temperature control precision decreases
Solution Approach 1:
The cooling system is segmented into multiple coolant drums, each dedicated to specific reactors. This segmentation provides independent temperature control zones, enabling precise thermal management for each reactor while maintaining operational simplicity through modular, repeatable units
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 approach enhances yield, reduces the risk of runaway reactions, and improves system efficiency by maintaining consistent temperature control and synchronized catalyst replacement, thereby increasing productivity and reducing downtime.
Implementation Method 1
catalytic oxidation of an olefin with oxygen over a catalyst to yield an oxidized olefin
Implementation Method 2
Coolant fluid passes through the two or more reactors to remove heat from the number of reaction tubes
Implementation Method 3
the oxidation of olefins is a highly exothermic reaction
Data Source
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AI summary
The present disclosure includes a system and method for the pro¬ duction of oxidized olefins. Two or more reactors include a number of reaction tubes each having a first surface defining a first side and a second surface defining a second of each of the tubes side are provided. A catalyst for catalytic oxidation of olefins can be located on the first side of the number of reaction tubes is included. A com¬ mon supply line supplies inlets to each reactor that provide a mixture comprising olefins and oxygen to the catalyst. Product outlet streams of each reactor receive at least the oxidized olefin product and are joined to a single product stream. Coolant fluid passes through the re¬ actors to remove heat from the number of reaction tubes and flows into a single coolant drum connected to the two or more reactors. The single coolant drum receives the coolant fluid from a number of coolant fluid outlet streams of each of the reactors. The single coolant drum supplies the coolant fluid at a common temperature to a num¬ ber of coolant fluid inlet streams of each reactor.