Reactor Flow Regime Alteration for Higher Alcohol Yields
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Solution Overview
Problem
Mixed Alcohol Synthesis (MAS) processes face challenges with temperature control, high methanol yield, low higher alcohol production, and inflexibility in alcohol mix production due to unstable reactions and sensitivity to syngas composition ratios.
Innovation Solution
A method involving a reactor with a catalyst and syngas at controlled temperatures and pressures, using solvents like decane and supercritical fluids to stabilize reactions, improve heat and mass transfer, and recycle non-reactive components to enhance alcohol yields and flexibility in alcohol production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the reaction is operated at higher temperatures to increase productivity, then the reaction rate improves, but temperature run-away occurs leading to methanation and unacceptable levels of methane production
Solution Approach 1:
A liquid flow distributor is introduced as an intermediary component between the gas phase reactants and the catalyst. This distributor mediates the interaction by distributing liquid across the catalyst surface, which controls the reaction temperature and prevents runaway methanation while maintaining high productivity.
Solution Approach 2:
The invention changes the physical state parameters of the reaction system by introducing a liquid phase flow distributor. This alters the temperature and flow parameters locally at the catalyst surface, enabling operation at higher temperatures without runaway reactions.
2Stability of the object's composition
If the catalyst is diluted with inert material to stabilize the reaction, then temperature control improves, but the reactor size must be increased for commercial production
Solution Approach 1:
Instead of using inert dilution, a liquid flow distributor is introduced as an active intermediary that stabilizes temperature control through controlled liquid distribution. This allows the catalyst to be used at full concentration without requiring excessive reactor volume.
3Productivity
If the syngas H2:CO ratio is maintained precisely to optimize alcohol production, then higher alcohol yield improves, but the process becomes intolerant to syngas composition variations
Solution Approach 1:
The liquid flow distributor acts as a buffer intermediary that decouples the syngas composition from the catalyst surface conditions. By controlling liquid distribution, it moderates the reaction environment, making the process more tolerant of syngas ratio variations while maintaining high alcohol yields.
4Temperature
If reactor tubes are modified to improve heat transfer and stabilize reaction, then temperature control improves, but the modification cost increases and satisfactory performance is not achieved
Solution Approach 1:
Rather than modifying the reactor tubes themselves, the invention introduces a liquid flow distributor as an intermediary component. This achieves temperature stability through liquid distribution control without requiring complex or expensive tube modifications.
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 method stabilizes reactions, increases yields of higher alcohols, and allows for flexible production of specific alcohol cuts, accommodating varying syngas ratios, thereby overcoming the limitations of prior art.
Implementation Method 1
improves heat transfer and mass transfer
Implementation Method 2
improves heat transfer and mass transfer
Implementation Method 3
interacted the syngas and the catalyst in a wet mode so as to produce further reaction products
Implementation Method 4
the reintroduced non-reactive components comprise a supercritical fluid that is liquid at room conditions and supercritical in the reactor
Data Source
AI summary
Mixed alcohols are produced from syngas. The syngas is provided to a catalyst in a reactor at selected temperatures and pressures. Reactive products, including mixed alcohols, are removed from the reactor. Non-reactive components are removed from the mixed alcohols of their reaction products. At least part of the non-reactive components are reintroduced in the reactor along with syngas. The non-reactive components are a solvent or a supercritical fluid. The nonreactive components can be reintroduced into the reactor with reactive components such as methanol or CO2.