Gas/Liquid Oligomerization Reactor with Transverse Internals
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Solution Overview
Problem
Existing gas/liquid reactors in ethylene oligomerization processes face challenges with ethylene breakthrough, leading to significant losses and reduced productivity due to inefficient gas dissolution in the liquid phase.
Innovation Solution
A gas/liquid reactor design featuring at least two transverse internals positioned within the reaction chamber to slow down the ascent of gaseous ethylene, thereby increasing its residence time in the liquid phase and enhancing dissolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gaseous ethylene flows rapidly through the liquid phase in a conventional gas/liquid reactor, then the reactor operates with simple structure and short residence time, but ethylene breakthrough occurs leading to loss of ethylene and reduced productivity
Solution Approach 1:
The reaction chamber is divided into multiple sections by transverse internals (baffles or plates) positioned at different heights. These internals segment the gas flow path, forcing gaseous ethylene to pass through multiple liquid-phase zones rather than rising directly to the gas headspace. This segmentation increases the effective contact time and surface area for dissolution, reducing ethylene breakthrough while maintaining reactor productivity.
Solution Approach 2:
The transverse internals introduce a horizontal dimension to the gas flow path that was previously purely vertical. By forcing the gas to move laterally across the liquid phase multiple times as it passes through the internals, the gas follows a tortuous path that increases residence time and dissolution efficiency without significantly increasing reactor height.
2Volume of stationary object
If the liquid phase height is reduced to decrease reactor volume, then device complexity and cost are reduced, but residence time decreases leading to increased ethylene breakthrough
Solution Approach 1:
The transverse internals divide the liquid phase into multiple shorter zones vertically. Although the total liquid height is reduced, the segmentation creates multiple liquid-gas contact interfaces that collectively provide sufficient residence time for ethylene dissolution. The gas must traverse each segmented zone sequentially, accumulating total contact time equivalent to or greater than in taller reactors.
Solution Approach 2:
By introducing horizontal flow paths through the transverse internals, the reactor compensates for reduced vertical height. The gas travels laterally across the liquid phase multiple times, effectively increasing the path length and residence time within a compact vertical footprint, thus maintaining dissolution efficiency while reducing overall reactor volume.
3Productivity
If transverse internals are added to slow down gas ascent and increase residence time, then ethylene breakthrough is limited and conversion improves, but device complexity increases
Solution Approach 1:
The transverse internals are simple segmented structures (baffles or plates) that can be easily manufactured and installed. Each internal is a basic component that segments the flow path, and multiple such simples components together achieve the complex function of reducing breakthrough without requiring a single complex device.
Solution Approach 2:
The internals allow independent optimization of geometric parameters such as opening area ratio (20-80% of cross-sectional area), hydraulic diameter (21-500 mm), and vertical positioning. These parameter adjustments enable tuning of gas flow resistance and liquid-gas contact efficiency to achieve optimal conversion while managing structural complexity.
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 reactor effectively limits ethylene breakthrough, improving conversion rates and maintaining high selectivity for desired linear α-olefins, while also increasing productivity and reducing costs.
Implementation Method 1
gaseous ethylene not dissolved in the said liquid... the passage of gaseous ethylene from the liquid lower part of the reaction chamber to the gas headspace... improve its conversion... improve the dissolution of the gaseous ethylene
Data Source
AI summary
The present invention relates to the field of gas/liquid reactors making possible the oligomerization of ethylene to give linear olefins by homogeneous catalysis with a reaction chamber comprising transverse internals capable of slowing down the ascent of the gaseous ethylene in the said reactor.