Variable-Diameter Oligomerization Reactor for Ethylene Breakthrough

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Solution Overview

Problem

Existing gas/liquid reactors for ethylene oligomerization suffer from significant ethylene breakthrough, leading to loss and reduced productivity and selectivity due to inefficient dissolution of gaseous ethylene in the liquid phase.

Innovation Solution

A reactor design with successive zones of decreasing diameter from bottom to top, increasing the height of the liquid phase without altering the reactor volume, enhances ethylene dissolution and limits breakthrough.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the height of the liquid phase is increased to improve ethylene dissolution, then the dissolution efficiency improves, but the reactor volume increases

Engineering Contradiction:

Improveethylene dissolution efficiencyVSAvoidreactor volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The reactor is divided into multiple zones with different diameters along the vertical axis. The lower zone has a larger diameter to accommodate the liquid phase, while the upper zone has a smaller diameter. This segmentation allows the liquid phase height to be increased for better dissolution without proportionally increasing the total reactor volume, as the upper portion occupies less volume.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different zones of the reactor are designed with different diameters to optimize local functions. The lower zone with larger diameter provides sufficient volume for liquid phase accommodation and dissolution processes, while the upper zone with smaller diameter reduces overall volume while maintaining the benefits of increased liquid height.

Inventive Principle:

Principle #3Local quality

2Productivity

If the residence time of gaseous ethylene in the liquid phase is increased to improve conversion, then the conversion efficiency improves, but the reactor height increases

Engineering Contradiction:

Improveethylene conversionVSAvoidreactor height

Core Design Contradiction:

ProductivityVSLength of stationary object

Solution Approach 1:

The reactor is segmented into zones with varying diameters, allowing the liquid phase to occupy a greater proportion of the reactor volume. This increases the residence time of gaseous ethylene in the liquid phase for improved conversion, while the tapered upper section prevents a proportional increase in overall reactor height.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of increasing residence time solely by increasing reactor height, the invention utilizes the radial dimension by varying the diameter along the vertical axis. This creates a three-dimensional optimization where the liquid phase volume is maximized relative to the overall reactor volume, extending residence time without linearly increasing height.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If the purging of the gaseous headspace is increased to remove breakthrough ethylene, then the selectivity improves, but the ethylene loss increases

Engineering Contradiction:

Improveprocess selectivityVSAvoidethylene loss

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The invention converts the harmful breakthrough phenomenon into a beneficial process by designing the reactor to accommodate and dissolve the breakthrough ethylene in the liquid phase. The increased liquid phase volume and residence time allow breakthrough ethylene to be absorbed and utilized rather than purged, transforming waste into productive material.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

Instead of discarding breakthrough ethylene through purging, the reactor design recovers it by providing sufficient liquid phase volume and residence time for dissolution. The breakthrough ethylene that would normally be lost is instead captured and converted in the liquid phase, improving both selectivity and reducing loss.

Inventive Principle:

Principle #34Discarding and recovering

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 by increasing the residence time of gaseous ethylene in the liquid phase, achieving high ethylene saturation and reducing ethylene loss.

Implementation Method 1

improve its conversion in said process, while retaining good selectivity for desired linear alpha-olefins by limiting the phenomena of breakthrough by means of a gas/liquid reactor having successive zones of decreasing diameter from the bottom to the top of the reactor

Methodology Applied

Scientific EffectDissolution: Absorption (physical)

Implementation Method 2

The passage of gaseous ethylene from the liquid lower part of the reaction chamber to the gaseous headspace is a phenomenon referred to as breakthrough

Methodology Applied

Scientific EffectMass transfer: Diffusion

Data Source

PatentUS12544733B2Gas/liquid oligomerization reactor having successive zones with variable diameters

Publication Date: 2026.02.10 IFP ENERGIES NOUVELLES

AI summary

The present invention relates to a gas/liquid oligomerization reactor with successive zones of variable diameter. The invention also relates to a process for the oligomerization of ethylene using a gas/liquid oligomerization reactor with successive zones of variable diameter.