Variable-Diameter Oligomerization Reactor for Ethylene Dissolution
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Solution Overview
Problem
Existing gas/liquid reactors for ethylene oligomerization face inefficiencies due to significant ethylene loss through the headspace, leading to reduced productivity and selectivity, particularly when managing high amounts of undissolved ethylene.
Innovation Solution
A reactor design with consecutive zones of decreasing diameter from the bottom to the top, increasing the height of the liquid phase without changing the volume, enhances ethylene dissolution and limits the 'piercing' phenomenon by extending the residence time of ethylene in the liquid phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the reactor volume is increased to improve ethylene dissolution, then the productivity improves, but the device complexity and cost increase
Solution Approach 1:
The patent transitions from a conventional horizontal reactor configuration to a vertical reactor configuration. This dimensional change allows the liquid phase to occupy a greater height within the same reactor footprint, increasing the liquid-gas contact area and improving ethylene dissolution without requiring a larger reactor volume. The vertical arrangement maximizes the use of vertical space to enhance mass transfer efficiency.
Solution Approach 2:
The patent introduces a vortex flow regime in specific zones of the reactor to enhance local mass transfer. By creating rotational flow patterns, the liquid-gas interface is intensified, increasing the contact area and transfer rate of ethylene from the gas phase to the liquid phase. This localized enhancement of flow characteristics improves dissolution efficiency without requiring a larger reactor volume.
2Productivity
If the liquid phase height is increased to improve ethylene dissolution, then the productivity improves, but the reactor volume increases
Solution Approach 1:
The patent adopts a vertical reactor configuration that prioritizes height utilization over horizontal expansion. By arranging the reactor vertically and optimizing the liquid phase height within the vertical dimension, the design increases the residence time and contact area for ethylene dissolution without proportionally increasing the overall reactor volume. This dimensional strategy allows higher liquid phase height while maintaining compact reactor footprint.
3Productivity
If the reactor is purged to remove gaseous compounds, then the selectivity improves, but ethylene loss increases
Solution Approach 1:
The patent enhances ethylene dissolution in the liquid phase before significant piercing can occur. By optimizing the liquid-gas contact conditions and increasing the dissolution rate through vortex flow and vertical configuration, ethylene is transferred to the liquid phase in advance, reducing the amount of undissolved gas that would otherwise pierce through to the headspace and require purging.
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 improves ethylene conversion and selectivity to desired linear alpha-olefins by increasing the height of the liquid phase, thereby reducing ethylene loss and maintaining high saturation levels.
Implementation Method 1
improve the dissolution of gaseous ethylene and therefore limiting the piercing phenomenon for a given volume of liquid phase
Data Source
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AI summary
The invention relates to a gas/liquid oligomerization reactor having successive zones with variable diameters. The invention also relates to a process for the oligomerization of ethylene using a gas/liquid oligomerization reactor having successive zones with variable diameters.