Reactor Cavity for High-Pressure Gas-Liquid Reaction Volume Control
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Solution Overview
Problem
In continuously operating reactors, varying feed rates of starting materials and product demands lead to unpredictable average residence times, causing unwanted side reactions and decompositions, particularly in high-pressure gas-liquid reactions, where a simple and cost-effective method to reversibly reduce reactor volume is needed.
Innovation Solution
A reactor design with a cylindrical shell divided into a backmixed zone, a zone of limited backmixing, and a cavity, where the third internal element forms a gas collection cavity that reduces the reaction volume by preventing liquid occupation, allowing adjustable gas volume and shortening the residence time without requiring pressure-resistant construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the reactor volume is reduced to decrease residence time and prevent unwanted reactions, then the reaction volume is reduced, but the reactor cannot adapt to varying feed rates and product demands
Solution Approach 1:
The reactor incorporates a movable bottom for the gas collection cavity that can be adjusted vertically to change the cavity volume dynamically. This allows the liquid reaction volume to be adapted in real-time according to varying feed rates and product demands, while maintaining control over residence time to prevent unwanted side reactions and decompositions
2Volume of stationary object
If displacement bodies with inner cavities are introduced to reduce reaction volume, then the reaction volume is reduced, but the displacement bodies must be pressure-resistant toward reaction pressure which increases complexity and cost
Solution Approach 1:
Instead of introducing complex pressure-resistant displacement bodies into the reactor, the invention extracts the gas collection function into a separate movable bottom structure. This allows the use of simple, non-pressure-resistant materials for the cavity construction while still achieving volume reduction, thereby decreasing device complexity and cost
3Object-generated harmful factors
If the reaction volume is reduced to prevent unwanted subsequent reactions and decompositions, then the residence time is shortened, but the reactor loses flexibility in handling varying generation rates of starting materials
Solution Approach 1:
The movable bottom enables dynamic adjustment of the gas collection cavity volume, allowing the reactor to adapt its liquid reaction volume to match varying starting material generation rates. This maintains optimal residence time to prevent unwanted reactions while providing the flexibility needed for varying production demands
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 optimizes reactor space utilization, reduces average residence time, and minimizes unwanted reactions by allowing flexible volume adjustment, enhancing the efficiency of high-pressure gas-liquid reactions.
Implementation Method 1
a third internal element which in the interior extends in the longitudinal direction of the reactor, is open at the bottom and is preferably delimited at the top by the first cylindrical internal element, wherein the third internal element forms the cavity in which gas bubbles collect and do not escape upwards
Implementation Method 2
a gas and a liquid are introduced into a backmixed zone of a reactor and in the backmixed zone the gas is dispersed in the liquid by stirring and/or injection of gas and/or a liquid jet
Data Source
AI summary
A process for performing a continuous gas/liquid biphasic high-pressure reaction, wherein a gas and a liquid are introduced into a backmixed zone of a reactor and in the backmixed zone the gas is dispersed in the liquid by stirring, injection of gas and/or a liquid jet, a reaction mixture consecutively traverses the backmixed zone and a zone of limited backmixing, and a liquid reaction product is withdrawn at a reaction product outlet of the zone of limited backmixing, wherein the reactor comprises: an interior formed by a cylindrical vertically oriented elongate shell, a bottom and a cap, wherein the interior is divided by means of internals into the backmixed zone, the zone of limited backmixing and a cavity, a first cylindrical internal element which in the interior extends in the longitudinal direction of the reactor and which delimits the zone of limited backmixing from the backmixed zone, backmixing-preventing second internal elements in the form of random packings, structured packings or liquid-permeable trays arranged in the zone of limited backmixing and a third internal element which in the interior extends in the longitudinal direction of the reactor and is open at the bottom, wherein the third internal element forms the cavity in which gas bubbles collect and do not escape upwards, thus preventing the volume of the cavity from being occupied by liquid and reducing the reaction volume. The reaction volume of the reactor used in the process can be reversibly reduced in simple fashion. The invention further relates to a process for adapting the reaction volume of a reactor suitable for performing a gas/liquid biphasic high-pressure reaction having an outlet for a liquid reaction product in which an internal element is arranged so as to form a cavity open at the bottom in which gas bubbles collect and do not escape upwards, thus preventing the volume of the cavity from being occupied by liquid and reducing the reaction volume.