Analysis and optimization of cross-flow reactors with distributed reactant feed and product removal

A systematic and general model was proposed for the simulation of cross-flow reactors with product removal and reactant feed policies. Six types of cross-flow reactors were analyzed for reversible series-parallel reaction systems and their optimal feed distributions were determined by maximizing the desired product yield at the outlet of the reactor. The performances of reactors with different types of feed policies were compared at their optimal operating conditions. For irreversible reaction systems with lower order in distributed reactant for the desired reaction than those for undesired reactions, a higher yield and selectivity of the desired product could be achieved with the reactors with staged feed than with conventional co-feed reactors and a sufficiently high residence time was required by staged feed reactors to significantly improve the desired product yields and selectivities over those obtained by a co-feed reactor. However, for reversible reaction systems, the desired product yield always reached a maximum value, and then dropped down as the residence time increased. In addition to the kinetic order and residence time requirements, the rate constants of the reactions involved have to fall within certain ranges for the distributed feed reactor to obtain a higher maximum yield than one-stage co-feed reactors. Optimally distributed feed reactors always give higher maximum product yields than evenly distributed reactors with the same number of feed points. However, the improvement of yields is not as great as that between co-feed reactors and evenly distributed reactors. On the other hand, for reaction systems with higher order with respect to the distributed reactant in the desired reaction than the undesired reactions, co-feed reactors always give higher yield than staged feed reactors.     

多级串联等体积全混流反应器与平推流反应器等效性研究——以二级可逆反应为例

在多级串联全混流反应器中,在等温等容条件下给出了二级可逆反应第Ⅳ级反应器的出口浓度表达式.讨论了在相同操作条件下,达到平推流反应器的转化率所需要的等体积串联全混流反应器的级数Ⅳ;主要考察了正反应速率常数k1、平衡常数K、反应物初始浓度之比M、停留时间τ等因素对N的影响,得出了N与正反应速率常数k1、相平衡常数K以及停留...     

Production of structured triglycerides rich in n-3 polyunsaturated fatty acids by the acidolysis of cod liver oil and caprylic acid in a packed-bed reactor: equilibrium and kinetics

Structured triglycerides (ST) enriched in n-3 polyunsaturated fatty acids (PUFAs) (eicosapentaenoic acid, EPA, and docosahexaenoic acid, DHA) in position 2 of the triglyceride backbone were synthesised by acidolysis of cod liver oil (CLO) and caprylic acid (CA) catalysed by the 1,3-specific immobilised lipase Lipozyme IM. The reaction was carried out in three ways: (1) in a batch reactor (where the influence of temperature on the incorporation of CA into the CLO triglyceride was studied); (2) in an immobilised lipase packed-bed reactor (PBR) by recirculating the reaction mixture from the exit of the bed to the substrate reservoir (product recirculation) to determine the equilibrium composition; and (3) in a PBR without recirculation. A “lag” period of duration inversely proportional to the initial water amount of the lipase, was observed when new lipase was used. Apparently, during this “lag” period the hydro-enzymatic layer that surrounds the lipase surface reaches its water equilibrium content. A reaction scheme, where only the fatty acid in the positions 1 and 3 of the glycerol backbone were exchanged by CA, was proposed. The exchange equilibrium constants between CA and the native fatty acids of CLO were determined. The n-3 PUFAs (EPA and DHA) were the most resistant native fatty acids to exchange with exchange equilibrium constants of 1.32 and 0.28, respectively. Also, average reaction rates and kinetic constants of exchange of CA and native fatty acid of CLO were calculated. Low kinetic constants were observed for EPA, DHA and palmitic acid. For acidolysis reaction in the continuous mode PBR, the lipase amount/(flow rate × substrate concentration) ratio (m_L/q[TG]₀) could be considered as the intensive variable of the process for use in scale up of the PBR. A simple equation was proposed for the prediction of the fatty acid composition of the ST at the exit of the PBR as a function of the intensive variable m_L/q[TG]₀. At equilibrium, the ST produced had the following composition: CA 57%, EPA 5.1%, DHA 10.0% and palmitic acid 6.3% (only considering the major fatty acids). In addition, the proportion of EPA and DHA that esterified the position 2 of the ST was 13.5%, which represented 44% of the total fatty acids in the position 2 of the resultant ST.     

Polyethoxylation and polypropoxylation reactions: Kinetics,mass transfer and industrial reactor design

Ethoxylation and propoxylation reactions are performed in the industry to produce mainly non-ionic surfactants and ethylene oxide(EO)–propylene oxide(PO) copolymers.Both the reactions occur in gas–liquid reactors by feeding gaseous EO,PO or both into the reactor containing a solution of an alkaline catalyst(KOH or Na OH).Non-ionic surfactants are produced by using liquid starters like fatty alcohols,fatty acids or alkyl-phenols,while when the scope is to prepare EO–PO copolymers the starter can be a mono-or multi-functional alcohol of low molecular weight.Both reactions are strongly exothermic,and EO and PO,in some conditions,can give place to runaway and also to explosive side reactions.Therefore,the choice of a suitable reactor is a key factor for operating in safe conditions.A correct reactor design requires:(i) the knowledge of the kinetic laws governing the rates of the occurring reactions;(ii) the role of mass and heat transfer in affecting the reaction rate;(iii) the solubility of EO and PO in the reacting mixture with the non-ideality of the reacting solutions considered;(iv) the density of the reacting mixture.All these aspects have been studied by our research group for different starters of industrial interest,and the data collected by using semibatch well stirred laboratory reactors have been employed for the simulation of industrial reactors,in particular Gas–Liquid Spray Tower Loop Reactors.     

Theoretical analysis of reactant dosing concepts to perform parallel-series reactions

The possibility of enhancing selectivities and yields in networks of parallel and series reactions is investigated theoretically. Isothermal tubular reactors are considered where reactants can be introduced at the entrance and also over the wall. The latter way of dosing could be realised, e.g., in a membrane reactor where one or several reactants can be dosed through a porous reactor wall. Besides numerical solutions of the underlying mass balance equations of simplified reactor models, instructive analytical solutions were derived which are valid under certain constraints. Using these solutions an optimisation of the reactor performance could be performed. As objective function the molar fraction of a desired intermediate product at the reactor outlet was maximised. The impact of influencing via the dosing strategy applied the local composition (and thus the local reaction rates) and the component residence time distributions is elucidated.     

Oxidative dehydrogenation of n-butane on V/MgO catalysts. Influence of the type of contactor

A comparative study of the catalytic performance of a selective V-Mg-O catalyst in the oxidative dehydrogenation of n-butane is presented using three different types of reactor: (i) an adiabatic fixed-bed reactor; (ii) a fluidized-bed reactor; and (iii) an in situ redox fluidized-bed reactor. The results obtained indicate that the in situ redox fluidized-bed reactor outperforms the conventional fixed- and fluidized-bed reactors, especially at high n-butane conversions. Thus, a selectivity to C₄ olefins of 54% at n-butane conversions of 60% was achieved at 550°C using an in situ redox fluidized-bed reactor while selectivities to C₄-olefins lower than 43% were obtained on the other reactor types under the same reaction conditions (isoconversion and reaction temperature). This revised version was published online in July 2006 with corrections to the Cover Date.     

Homogeneous Tubular‐Flow Process for Monoolein Preparation

Esterification of fatty acids with glycerol is characterized by negligible solubility of the two liquid phases. The reactions to mono‐, di‐ and triglycerides taking place in the fatty acid phase, are limited by chemical equilibrium. The scope of this study is to investigate in a tubular reactor the conversion of a homogeneous mixture of oleic acid and glycerol in tert‐butanol. The liquid composition in this study was 1 mol of oleic acid, 6 mol of glycerol and 14 mol of tert‐butanol. Experiments were conducted in a tubular reactor at 35 atm over a temperature range of 200–240 °C and residence times of 0.7–17.6 h to determine the kinetics and the chemical equilibrium. The selectivity to monoolein was >95 mol %. A reversible second order reaction fits the data well.     

Assessment of micro-structured fixed-bed reactors for highly exothermic gas-phase reactions

The application of micro-structured fixed-bed reactors for highly exothermic partial oxidation reactions and their comparison to established multi-tubular fixed-bed reactors was investigated by numerical simulation. As examples, the partial oxidations of butane to maleic anhydride and of o-xylene to phthalic anhydride were chosen. The simulation results revealed that the reactor productivity, i.e. the amount of product per unit of reactor volume, achievable in micro-structured fixed-bed reactors is between 2.5 and 7 times higher than in conventional multi-tubular fixed-bed reactors without the danger of excessive pressure drop. For the partial oxidation of butane to maleic anhydride this can be explained by the increased reactor efficiency caused by lower efficiency losses through heat and mass transfer limitations. In addition, maleic anhydride selectivities and yields are higher in micro-structured fixed-bed reactors. In the case of o-xylene oxidation to phthalic anhydride the main advantage is that egg-shell catalysts in the conventional fixed-bed reactor can be replaced by bulk catalysts in the micro-structured fixed-bed reactor. For this reaction, product selectivities are very similar for all reactor configurations. Thus the catalyst inventory and reactor productivity are strongly increased. This study underlines, that micro-structured fixed-bed reactors exhibit the potential to intensify large scale industrial processes significantly.     

多孔膜反应器中丙烷催化脱氢制丙烯的模拟研究

针对丙烷高效脱氢制丙烯的多孔膜反应器构建了无量纲数学模型并进行了模拟研究,考察了催化剂活性、透氢膜性能、操作条件对多孔膜反应器中丙烷脱氢的转化率、丙烯收率、氢气收率和纯度的影响。结果表明,移走产物氢气可以有效提升膜反应器的性能,其性能的提升程度由不同温压条件下催化剂和透氢膜性能共同决定。高活性催化剂是丙烷高效转化的基础,催化剂活性越高,膜反应器内的产氢速率越快;其次,膜的选择性和渗透通量越高,氢气的移除效率越高,可在最大程度上打破热力学平衡的限制,使反应向生成丙烯的方向移动。当多孔透氢膜的氢气渗透率在10^-7~10^-6 mol·m^-2·s^-1·Pa^-1,H₂/C₃H₈选择性达到100时,其丙烷转化率可以与Pd膜反应器内的转化率相当,但分离的氢气纯度低于Pd膜反应器。与传统的固定床反应器相比,膜反应器由于促进了化学平衡的移动,可以在较低的反应温度下获得相当高的丙烷转化率,且丙烷转化率随着反应压力的增加呈现出一个最大值。该模拟研究可为实际生产过程中膜反应器用于PDH反应的高效强化提供有益的技术指导。     

Production of p‐toluenesulfonic acid by sulfonating toluene with gaseous sulfur trioxide

Toluene was sulfonated by gaseous sulfur trioxide to prepare p‐toluenesulfonic acid. The effects of reaction temperature and toluene conversion on the isomer selectivities and the dynamic viscosity of the reaction mixture in a well‐stirred tubular glass reactor of 4 cm diameter and 16 cm height were investigated. Lower selectivity to the m‐isomer was obtained at lower reaction temperature and lower conversion of toluene, whereas the selectivity to the p‐isomer seemed to be less affected by these parameters. With the increase in toluene conversion a sharp increase in viscosity of the reaction mixture was observed, which was attributed to the saturation of the toluenesulfonic acids dissolved in toluene. A pilot‐scale stainless steel jet loop reactor (JLR) of 0.3 m diameter and 4 m height with an external cooler was constructed and used for the continuous sulfonation of toluene. It was found that the JLR was very effective for the fast removal of the large amount of reaction heat, and selectivities to the p‐isomer around 85% and to the m‐isomer below 1.2% were obtained. © 2001 Society of Chemical Industry     

Preliminary design and simulation of a microstructured reactor for production of synthesis gas by steam methane reforming

The present study considers the potentials of the well-known production of syngas by steam methane reforming (SMR), by operation within microstructured reactors. The model of a microchannel reactor is developed, including very fast kinetic reaction rates on the coated catalytic walls of the reactor module. By varying the characteristic dimensions of the channels, and considering technical constraints on the design and operating conditions, the results demonstrate that the SMR reactor can be drastically miniaturized while maintaining its productivity without any additional pressure drop. Furthermore, by reducing the channel characteristic dimensions, it is possible to suppress heat and mass-transfer limitations enabling SMR reactor operation at thermodynamic equilibrium. A fast method for preliminary design of microstructured heat-exchanger reactors is developed, that enables to identify the optimal channels number and heat power needed to reach process specifications.     

微孔无机膜反应器研究

主要介绍了无机膜在化学反应中的应用－－膜反应器研究，对膜反应器的特点、类型、应用、影响因素以及与其它反应器的比较进行了评述，并对其应用前景进行了展望。     

Trickle bed reactor diluted with fine particles and coiled tubular flow-type reactor for kinetic measurements without external effects

Gas and liquid velocities in laboratory scale trickle bed reactors are one or two orders of magnitude lower than those in commercial reactors. Then, the kinetic data may include the external effects. This shortcoming of laboratory scale trickle bed reactor can be resolved by diluting the catalyst bed with fine inert particles. The catalyst bed dilution increases dynamic liquid holdup, pressure drop, gas–liquid mass transfer coefficient. Hydrogenation of 2-phenylpropene on Pd/Al₂O₃ was performed with the trickle bed reactor diluted with fine inert particles and the coiled tubular flow-type reactor to compare the kinetics with that of the basket type batch reactor. The trickle bed reactor diluted with fine inert particles is suitable to obtain the reaction rate without external effects even if the liquid velocity is low. The coiled tubular flow-type reactor should be used at high gas velocities.     

Strategies for lipase‐catalyzed production and the purification of structured phospholipids

This work provides different strategies for the enzymatic modification of the fatty acid composition in soybean phosphatidylcholine (PC) and the subsequent purification. Enzymatic transesterification reactions with caprylic acid as acyl donor were carried out in continuous enzyme bed reactors with a commercial immobilized lipase (Lipozyme RM IM) as catalyst. Operative stability of the immobilized lipase was examined under solvent and solvent‐free conditions. The long reaction time required to have a high incorporation, combined with rapid deactivation of the enzyme, makes the solvent‐free transesterification reaction unfavorable. Performing the reaction in the presence of solvent (hexane) makes it possible to have high incorporation into PC and deactivation of the lipase is less pronounced as compared to solvent‐free operations. For solvent‐free operation, it is suggested to recycle the reaction mixture through the packed bed reactor, as this would increase incorporation of the desired fatty acids, due to increased contact time between substrate and enzyme in the column. Removal of free fatty acids from the reaction mixture can be done by ultrafiltration; however, parameters need to be selected with care in order to have a feasible process. No changes are observed in the phospholipid (PL) distribution during ultrafiltration, and other techniques as column chromatography may be required if high purity of individual PL species is desired. LC/MS analysis of transesterified PC revealed the presence of 8:0/8:0‐PC, showing that acyl migration takes place during the acidolysis reaction.     

Selective hydrogenation of sunflower seed oil in a three-phase catalytic membrane reactor

Continuous hydrogenation of sunflower seed oil has been carried out in a novel three-phase catalytic membrane hydrogenation reactor. The membrane reactor consisted of a membrane impregnated with Pd as the active catalyst, which provided a catalytic interface between the gas phase (H₂) and the oil. Hydrogenations were carried out at different pressures, temperatures, and selectivities, and the formation of trans isomers was monitored during the hydrogenation runs. For the three-phase catalytic membrane reactor, interfacial transport resistances and intraparticle diffusion limitations did not influence the hydrogenation reaction. Hydrogenation runs under kinetically controlled conditions showed that oleic and elaidic acid were not hydrogenated in the presence of linoleic acid. Initial formation of stearic acid was caused by direct conversion of linoleic acid into stearic acid by a shunt reaction. Furthermore, high selectivities led to high trans levels, which is in accordance with the many published data on hydrogenation of vegetable oils in slurry reactors. Finally, the catalytic membrane showed severe catalyst deactivation. Only partial recovery of the catalyst activity was possible.     

Synthesis of MTBE in zeolite membrane reactors

A zeolite membrane was employed to selectively remove water from the reaction atmosphere during the gas-phase synthesis of methyl-tert-butyl ether (MTBE) from tert-butanol and methanol. This reaction was carried out over a bed of Amberlyst™ 15 catalyst packed on the inside of a zeolite tubular membrane. The results obtained with different hydrophilic membranes (mordenite or NaA zeolite) are presented. Prior to reaction, the zeolite membranes were characterized by measuring their performance in the separation of the equilibrium mixture containing water, methanol, tert-butanol, MTBE and isobutene. The results obtained with zeolite membrane reactors (ZMR) were compared with those of a fixed bed reactor (FBR) under the same operating conditions. MTBE yields obtained with the ZMR at 334 K reached 67.6%, under conditions where the equilibrium value without product removal (FBR) would be 60.9%.     

生物柴油新反应器及其应用

生物柴油是石化柴油的重要补充.用传统的搅拌釜和管式反应器制备生物柴油,存在反应速率慢、转化率低的问题.从提高反应速率和转化率两方面综述了生物柴油新反应器的研究进展.提高反应速率的反应器包括:微波反应器、空化反应器、旋转床反应器、振荡流反应器、高剪切反应器、静态反应器、微反应器和液液膜反应器.提高转化率的反应器包括:反应/分离器、反应蒸馏反应器和膜反应器.比较了它们的优势和缺陷.提出联合使用几种技术,将强化传质与分离技术进行有效整合,使反应器小型化并缩短工艺流程,以建立适应未来的生产效率高的便携式生物柴油厂.     

Glycerol ethers synthesis from glycerol etherification with tert-butyl alcohol in reactive distillation

This paper presents a study of glycerol etherification with tert-butyl alcohol catalyzed by Amberlyst 15 in reactive distillation (RD). A thermodynamic analysis is firstly investigated by applying three group contribution methods, to determine the equilibrium composition by minimization of the Gibbs free energy and to compare the predicted values against measured data. Next, the kinetic model parameters are regressed by matching measured data from an autoclave reactor. The activity based Langmuir-Hinshelwood model is found to give the best representation of the reaction rate data. The regressed kinetic rate expressions are also compared against independently measured data in fixed bed reactors reported in the literature and found to give a good match. Finally, using the developed models, it is shown by simulation as well as verification by experiments, that the suitable RD configuration for the production of glycerol ethers in RD is the one consisting of 6 rectifying stages and 6 reaction stages without stripping stage.     

Production of specific-structured triacylglycerols by lipase-catalyzed interesterification in a laboratory-scale continuous reactor

A laboratory-scale continuous reactor was constructed for production of specific structured triacylglycerols containing essential fatty acids and medium-chain fatty acids (MCFA) in the sn-2 and sn-1,3 positions, respectively. Different parameters in the lipase-catalyzed interesterification were elucidated. The reaction time was the most critical factor. Longer reaction time resulted in higher yield, but was accompanied by increased acyl migration. The concentration of the desired triacylglycerol (TAG) in the interesterification product increased significantly with reaction time, even though there was only a slight increase in the incorporation of MCFA. Increased reactor temperature and content of MCFA in the initial reaction substrate improved the incorporation of MCFA and the yield of the desired TAG in the products. Little increase of acyl migration was observed. Increasing the water content from 0.03 to 0.11% (w/w substrate) in the reaction substrate had almost no effect on either the incorporation or the migration of MCFA, or on the resulting composition of TAG products and their free fatty acid content. Therefore, we conclude that the water in the original reaction substrate is sufficient to maintain the enzyme activity in this continuous reactor. Since the substrates were contacted with a large amount of lipase, the reaction time was shorter compared with a batch reactor, resulting in reduced acyl migration. Consequently, the purity of the specific structured TAG produced was improved. Interesterification of various vegetable oils and caprylic acid also demonstrated that the incorporation was affected by the reaction media. Reaction conditions for lipase-catalyzed synthesis of specific structured TAG should be optimized according to the oil in use. Presented in part at Food Science Conference, Copenhagen, Denmark, January 30–31, 1997.     

A novel ultrasonic reactor for continuous production of biodiesel from waste acid oil

FAME was produced by a two-step in-situ transesterification of acid oil (AO) with methanol in a novel continuous flow ultrasonic reactor system composed of four ultrasonic reactors with different frequency. The hydrodynamic behavior of the reactor was investigated by a step response technique, and the effect of ultrasonic frequency on mono-alkyl esters of long chain fatty acids (FAMEs) formation was also investigated. The production process includes an in-situ sulfuric acid-catalyzed esterification of AO with methanol in the first two ultrasonic reactors successively followed by an in-situ base-catalyzed transesterification in the other two ultrasonic reactors. The AO initial free fatty acids (FFA) content about 17.5 w% was cut down to less than 1 w% by sulfuric acid-catalyzed esterification. FAME yields in excess of 97.0% identified by gas chromatography/mass spectrometry (GC/MS) were obtained by the two-step in-situ reaction. The maximum and minimum volumetric productivity could reach 13.76 L·h^?1 and 10.24 L·h^?1 respectively.