α-Olefin Oligomer Reactor Mist Capture via Condensate Droplets
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Solution Overview
Problem
The existing methods for producing α-olefin oligomers face challenges with heat exchanger fouling due to reaction solution mist entrainment, leading to reduced heat-exchange efficiency and increased ventilation resistance, which disrupts continuous operation.
Innovation Solution
Dispersing a foulant-free condensate liquid or reaction solvent as droplets within the reactor's gas phase to capture the reaction solution mist, preventing its entrainment and subsequent fouling of the heat exchanger, achieved through a circulatory feed system and droplet dispersion using an atomizer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If gas is withdrawn from the reactor and cooled/condensed by a heat exchanger to remove heat of polymerization, then heat removal efficiency is improved, but reaction solution mist entrainment occurs causing heat exchanger fouling
Solution Approach 1:
A liquid substantially free of foulant is introduced as an intermediary substance into the gas phase part of the reactor. This liquid acts as a mediator that captures reaction solution mist through absorption or adhesion, preventing the mist from reaching and fouling the heat exchanger while allowing continuous heat removal operation
2Reliability
If gas linear velocity is controlled to prevent mist entrainment, then heat exchanger fouling is reduced, but heat removal efficiency decreases
Solution Approach 1:
The liquid substantially free of foulant serves as a intermediary that enables the system to maintain higher gas linear velocities for effective heat removal while preventing mist entrainment damage. The liquid captures mist particles that would otherwise be carried by the high-velocity gas flow to the heat exchanger
3Productivity
If continuous operation is maintained without cleaning the heat exchanger, then productivity is improved, but fouling accumulates reducing heat exchange efficiency
Solution Approach 1:
The liquid substantially free of foulant is introduced into the reactor as a preliminary protective measure against fouling. This liquid continuously captures reaction solution mist before it can reach the heat exchanger, preventing fouling accumulation and enabling prolonged continuous operation without cleaning interruptions
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 prevents heat exchanger fouling, ensuring long-term stable operation by effectively capturing reaction solution mist and reducing the frequency of heat exchanger cleaning.
Implementation Method 1
part of gas of the gas phase inside a reactor is withdrawn from the reactor and cooled/condensed by a heat exchanger
Implementation Method 2
cooled/condensed by a heat exchanger (condenser) and the condensate liquid and uncondensed gas are circulated to the reactor
Implementation Method 3
the condensate liquid and uncondensed gas are circulated to the reactor
Implementation Method 4
said circulatory feed liquid is dispersed as droplets in the gas phase part inside said reactor
Implementation Method 5
liquid substantially free of a foulant is dispersed as droplets in the gas phase part inside a reactor, the reaction solution mist can be captured by the droplet
Data Source
AI summary
The present invention relates to a production method of an α-olefin oligomer for producing an α-olefin by performing an oligomerization reaction of an α-olefin in a reaction solvent in the presence of a catalyst in a reactor, which is a production method of an α-olefin oligomer, comprising circulating and feeding, to the reactor, a condensate liquid obtained by introducing part of gas of the gas phase part inside the reactor into a heat exchanger and cooling the gas, wherein the condensate liquid circulated and fed to the reactor is dispersed in the gas phase part inside the reactor; and a production apparatus of an α-olefin oligomer.