Vertical-Horizontal Bubble Reactor for Ethylbenzene Oxidation
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Solution Overview
Problem
The existing horizontal bubble column reactors used for oxidizing ethylbenzene to ethylbenzene hydroperoxide suffer from insufficient gas-liquid contact, leading to low productivity and selectivity due to inadequate mixing and long initiation times, resulting in a low single pass conversion of ethylbenzene in industrial processes.
Innovation Solution
A combination of a vertical bubble reactor and a horizontal bubble reactor is used, where the vertical reactor includes a flow guide cylinder and a first gas distributor to enhance liquid back-mixing and reduce initiation time, and the horizontal reactor is divided into compartments with a liquid phase channel and a second gas distributor to promote continuous reaction and avoid liquid flow dead zones, optimizing the oxidation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a horizontal bubble column reactor is used for ethylbenzene oxidation, then the reactor structure is simple and easy to operate, but the gas-liquid contact is insufficient leading to low productivity
Solution Approach 1:
The horizontal bubble column reactor is divided into multiple reaction zones by internal baffles, creating segmented flow paths that enhance gas-liquid contact efficiency while maintaining the simple horizontal reactor structure
Solution Approach 2:
The patent introduces a vertical dimension to the horizontal reactor by adding internal baffles and flow distributors that create three-dimensional flow patterns, improving gas-liquid contact without changing the overall horizontal reactor configuration
2Manufacturing precision
If a horizontal bubble column reactor is used, then the liquid flows horizontally with low back-mixing which improves reaction selectivity, but the initiation time is long and reaction rate is low
Solution Approach 1:
The patent introduces preliminary mixing zones and flow distributors at the inlet regions to pre-mix the gas and liquid phases before they enter the main reaction zones, reducing the initiation time while maintaining the low back-mixing characteristics needed for high selectivity in the subsequent reaction zones
3Manufacturing precision
If the single pass conversion of ethylbenzene is kept low to maintain selectivity, then side reactions are minimized, but the equipment capacity is reduced
Solution Approach 1:
The reactor is divided into multiple reaction zones with different residence times and mixing intensities, allowing the first zones to operate at higher conversion for productivity while subsequent zones maintain conditions optimized for selectivity, effectively decoupling the trade-off between single pass conversion and product selectivity
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 configuration increases the concentration of free radicals, reduces by-product production, and improves the selectivity of ethylbenzene hydroperoxide by controlling its concentration at the initiation stage, resulting in enhanced reaction efficiency and productivity.
Implementation Method 1
vertical bubble reactor and a horizontal bubble reactor
Implementation Method 2
insufficient gas-liquid contact
Implementation Method 3
the oxidation process of an organic substance generally follows the mechanism of free radicals
Implementation Method 4
oxidizing ethylbenzene with air to produce ethylbenzene hydroperoxide
Data Source
AI summary
Disclosed are a device and method for oxidizing an organic substance, particularly a method for preparing ethylbenzene hydroperoxide by reacting ethylbenzene with an oxygen-containing gas. The device comprises a vertical bubbling reactor (1) and a horizontal bubbling reactor (11) connected to a reaction product outlet of the vertical bubbling reactor (1), wherein the horizontal bubbling reactor (11) is internally provided with a plurality of reaction compartments (21) which are arranged along the axial direction thereof, and a liquid phase channel (22) is provided between adjacent reaction compartments (21).