Continuous Trifluoroethane Reactor with Rotary Cutting and Flow Deflector
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Solution Overview
Problem
Current production processes for 1,1,1-trifluoroethane (HFC-143a) suffer from low raw material utilization, high energy consumption, poor separation efficiency, frequent maintenance due to polymerization side reactions, and low product purity, primarily due to inadequate mixing and separation in traditional stirred reaction kettles.
Innovation Solution
A continuous reaction apparatus incorporating a submersible pump and flow deflector with offset flow-deflecting plates, a rotary cutting component, and a condensation disturbance component to enhance mixing, prevent polymerization, and integrate gas-liquid separation, suitable for high-pressure reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stirred reaction kettle is used, then the reaction can proceed under high pressure and temperature, but the mixing is inadequate leading to low raw material utilization and polymerization side reactions
Solution Approach 1:
The patent replaces static stirring with dynamic high-speed cutting and swirling flow. The rotary cutting component rotates at high speed to cut reactants into fine droplets, while the flow deflector creates intense swirling motion, transforming the static mixing process into a dynamic one that prevents polymerization and improves raw material utilization.
Solution Approach 2:
The patent segments the continuous fluid stream into fine droplets through the rotary cutting component. By cutting the reactant flow into micro-droplets, the surface area for reaction increases dramatically, improving mixing efficiency and preventing localized polymerization that occurs in traditional stirred kettles.
2Manufacturing precision
If regular stirred reaction kettle is used, then the system can maintain high pressure, but the separation efficiency is poor and energy consumption is high
Solution Approach 1:
The patent merges the reaction chamber with integrated gas-liquid separation functionality. The flow deflector and offset plates create a combined reaction-separation system where products are separated during the reaction process itself, eliminating the need for separate high-energy separation equipment and reducing overall energy consumption.
3Reliability
If traditional reaction process is used, then the reaction kettle can be maintained at high pressure, but polymerization side reactions occur frequently requiring frequent maintenance
Solution Approach 1:
The patent rushes through the reaction process by using high-speed cutting and intense mixing to complete the fluorination reactions quickly. By reducing the residence time of reactants in the high-pressure environment, the process skips over the time window where polymerization side reactions would normally occur, preventing equipment fouling and reducing maintenance needs.
4Productivity
If conventional mixing is used, then the reaction system is simple, but the mixing is inadequate leading to low reaction efficiency
Solution Approach 1:
The patent uses fluid dynamics and hydraulic principles to achieve mixing. The flow deflector and offset plates create hydrodynamic swirling flow patterns that intensify mixing without mechanical stirrers. The rotary cutting component uses hydraulic shear forces to cut droplets, replacing mechanical stirring with fluid-based mixing mechanisms.
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 apparatus significantly improves reaction efficiency, raw material utilization, product purity, and safety by preventing polymerization, reducing equipment size, and optimizing energy use, achieving over 98% utilization of vinylidene chloride and 98% purity of HFC-143a.
Implementation Method 1
a rotary cutting component arranged inside the reaction chamber body, used for cutting a fluid into micro/nanoscale fluid micro elements
Implementation Method 2
a submersible pump arranged at a bottom of the reaction chamber body
Implementation Method 3
a flow deflector comprising two sets of flow-deflecting plates, each set of said flow-deflecting plates comprising a plurality of flow-deflecting plates, the two sets of flow-deflecting plates being respectively fixed on two opposing sidewalls, and adjacent two flow-deflecting plates being in offset alignment
Implementation Method 4
a condensation disturbance component comprising a rotating shaft and a condenser surrounding the rotating shaft, the rotating shaft being used for throwing condensed liquid drops on the condenser into the rotary cutting component
Implementation Method 5
CH2═CCl2+HF→CH3CCl2F (HCFC-141b) Addition 1; CH3CCl2F+HF→CH3CClF2 (HCFC-142b)+HCl Substitution 2; CH3CClF2+HF→CH3CF3 (HCFC-143a)+HCl Substitution 3
Data Source
AI summary
A reaction apparatus used for a continuous reaction process for the preparation of trifluoroethane includes a housing, a rotary cutting component, a submersible pump and a flow deflector. The flow deflector includes two sets of flow-deflecting plates, each set of said flow-deflecting plates including a plurality of flow-deflecting plates. Two sets of flow-deflecting plates are fixed to each of the two opposing side walls, and the two adjacent flow-deflecting plates are in offset alignment. The submersible pump is arranged inside the reaction chamber body. A liquid inlet line can connect a directly to the submersible pump without requiring the arrangement of an additional pipeline.