Shell and Tube Heat Exchanger for Cyclopentadiene Dimerization

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Solution Overview

Problem

Conventional methods for producing dicyclopentadiene via cyclopentadiene dimerization face challenges such as high energy consumption, low conversion rates, and the risk of runaway reactions due to inefficient heat management and mixing in tubular reactors.

Innovation Solution

A method utilizing four serial shell and tube heat exchangers with fins, providing a large heat exchange area and controlled temperature profiles to manage exothermic heat effectively, preventing runaway reactions and enhancing conversion rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a tubular reactor is used to provide long residence time for high conversion rate, then the conversion rate is improved, but the energy consumption increases and runaway reaction risk increases due to high reaction temperature

Engineering Contradiction:

Improveconversion rateVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The single tubular reactor is divided into multiple sections with different heating conditions. The reaction system comprises a first reaction zone with first heating conditions and a second reaction zone with second heating conditions, allowing different parts of the reaction process to occur under optimized conditions for conversion and energy efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heating conditions (temperature profile) are changed along the length of the reactor. The first heating condition in the first reaction zone is different from the second heating condition in the second reaction zone, enabling optimization of both conversion rate and energy consumption by adjusting temperature parameters at different stages

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high reaction temperature is used to achieve high conversion rate, then the conversion rate is improved, but the heat release increases causing runaway reaction

Engineering Contradiction:

Improveconversion rateVSAvoidrunaway reaction risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The reaction zone is segmented into multiple sections with different temperature profiles. This allows the exothermic reaction to be managed in controlled stages, preventing sudden heat accumulation that would lead to runaway reactions while maintaining high conversion rate

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system uses multiple temperature sensors positioned at different locations to monitor the reaction process and provides feedback for controlling the heating conditions. This feedback mechanism ensures that temperature remains within safe limits while maintaining high conversion rate

Inventive Principle:

Principle #23Feedback

3Ease of operation

If stirred-tank reactor with impeller is used for mixing, then the mixing is improved, but the energy consumption increases and hot spots are formed limiting conversion rate

Engineering Contradiction:

Improvemixing efficiencyVSAvoidenergy consumption

Core Design Contradiction:

Ease of operationVSUse of energy by moving object

Solution Approach 1:

The mechanical mixing system (impeller) is replaced with a field-based approach using heating conditions that promote uniform distribution of reactants and products through thermal fields, eliminating the need for high-energy mechanical stirring while maintaining mixing effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 significantly improves the conversion rate of cyclopentadiene to dicyclopentadiene while preventing runaway reactions, leading to more efficient and cost-effective production.

Implementation Method 1

four serial shell and tube heat exchangers that provide large heat exchange area and a large volumetric ratio of heat exchange medium to reaction mixture

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

The first tubes comprise fins... flowing a heat transfer medium through a first shell of the first shell and tube heat exchanger

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 3

the cyclopentadiene dimerization is highly exothermic... the temperature control mechanism, and the configuration of the shell and tube heat exchangers are capable of effectively mitigating the temperature rises caused by large exothermic heat released by the dimerization reaction

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Data Source

PatentEP3894378B1Dimerization of cyclopentadiene using shell & tube heat exchanger

Publication Date: 2022.11.30 SABIC GLOBAL TECHNOLOGIES BV

Figure 1
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Figure 3A~3B

AI summary

Systems and methods for producing dicyclopentadiene via thermal dimerization of cyclopentadiene. The feed stream comprising cyclopentadiene is flowed through four shell and tube heat exchangers in series. Each of the shell and tube heat exchangers comprise a shell and one or more tubes disposed in the shell. The feed stream is flowed in the tubes while the heat transfer medium is flowed in the shell to absorb the exothermic heat released by the dimerization of cyclopentadiene in the tubes. In this way, the temperature in the tubes is controlled at a level where the conversion rate of cyclopentadiene is above 99% and the occurrence of runaway reaction is substantially prevented.