Exothermic process with porous means to control reaction rate and exothermic heat

A process for forming a reaction product fluid by reaction of one or more first reactants and one or more second reactants, which process comprises:

• (a) feeding into a first reactor zone having mixing elements therein said one or more first reactants at a first pressure;
• (b) feeding one or more of said second reactants at a second pressure higher than said first pressure into a second reactor zone which is separated from said first reactor zone by a porous wall which is capable of being penetrated by said second reactant at multiple sites to produce in said first reactor zone a resulting mixture having components selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof;
• and
• (c) maintaining the pressure within said second reaction zone higher than the pressure in said first reactor zone at corresponding locations along the length of said porous wall, to thereby inhibit any flow of the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted second reactant and combinations thereof through said porous wall from said first reactor zone to said second reactor zone;
• wherein said one or more second reactants pass once through said porous wall to contact said one or more first reactants in said first reactor zone and form said reaction product fluid comprising a liquid, a gas or combinations thereof in said first reactor zone, and the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof exit only from said first reactor zone, wherein said product flow from said reactor is first passed through a heat exchanger before said portion of said product flow is recycled back and blended with said one or more first reactants being fed into said first reactor zone,
• wherein said porous wall through which said one or more second reactants passes into said first reactor zone has a viscosity normalized permeability ranging from about 10.sup.-6 to about 5.times.10.sup.-2 cm.sup.3 cp/cm.sup.2 sec psi.

A process for forming a reaction product fluid by reaction of one or more first reactants and one or more second reactants, which process comprises:

• (a) feeding into a first reactor zone having mixing elements therein said one or more first reactants at a first pressure;
• (b) feeding one or more of said second reactants at a second pressure higher than said first pressure into a second reactor zone which is separated from said first reactor zone by a porous wall which is capable of being penetrated by said second reactant at multiple sites to produce in said first reactor zone a resulting mixture having components selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof;
• and
• (c) maintaining the pressure within said second reaction zone higher than the pressure in said first reactor zone at corresponding locations along the length of said porous wall, to thereby inhibit any flow of the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted second reactant and combinations thereof through said porous wall from said first reactor zone to said second reactor zone;
• wherein said one or more second reactants pass once through said porous wall to contact said one or more first reactants in said first reactor zone and form said reaction product fluid comprising a liquid, a gas or combinations thereof in said first reactor zone, and the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof exit only from said first reactor zone,
• wherein a portion of the product flow from said reactor is recycled back and blended with said one or more second reactants being fed into said second reactor zone, and,
• wherein said product flow from said reactor is first passed through a heat exchanger before said portion of said product flow is recycled back and blended with said one or more second reactants being fed into said second reactor zone,
• wherein said porous wall through which said one or more second reactants passes into said first reactor zone has a viscosity normalized permeability ranging from about 10.sup.-6 to about 5.times.10.sup.-2 cm.sup.3 cp/cm.sup.2 sec psi.

A process for forming a reaction product fluid by reaction of one or more first reactants and one or more second reactants, which process comprises:

• (a) feeding into a first reactor zone having mixing elements therein one or more first reactants at a first pressure;
• (b) feeding one or more second reactants at a second pressure higher than said first pressure into a second reactor zone separated from said first reactor zone by a porous wall which is capable of being penetrated by said one or more second reactants at multiple sites to produce in said first reactor zone a resulting mixture having components selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof;
• and
• (c) maintaining the pressure within said second reaction zone higher than the pressure in said first reaction zone at corresponding locations of said porous wall, to thereby inhibit any flow of the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted second reactant and combinations thereof through said porous wall from said first reactor zone to said second reactor zone;
• wherein said one or more second reactants pass through said porous wall to contact said one or more first reactants in said first reactor zone and form said reaction product fluid comprising a liquid, a gas or combinations thereof in said first reactor zone, and the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof exit only from said first reactor zone, and the temperature of the reaction is between about 0.degree. and 400.degree. C.,
• wherein said porous wall through which said one or more second reactants passes into said first reactor zone has a viscosity normalized permeability ranging from about 10.sup.-6 to about 5.times.10.sup.-2 cm.sup.3 cp/cm.sup.2 sec psi.

An exothermic process for forming a reaction product fluid by reaction of one or more first liquid reactants with one or more second liquid reactants, which process comprises:

• (a) feeding one or more first liquid reactants at a first pressure through a first reactor zone having mixing elements therein;
• (b) feeding one or more second liquid reactants at a second pressure higher than said first pressure into a second reactor zone which is separated from said first reactor zone by a porous wall which is capable of being penetrated at multiple sites to produce in said first reactor zone a resulting mixture having components selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof;
• and
• (c) maintaining the pressure within said second reaction zone higher than the pressure in said first reaction zone at corresponding locations of said porous wall, to thereby inhibit any flow of the components of said first reactor zone one which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted second reactant and combinations thereof through said porous wall from said first reactor zone to said second reactor zone;
• wherein said one or more second liquid reactants pass once through said porous wall to contact said one or more first liquid reactants in said first reactor zone and form said reaction product fluid only in said first reactor zone, and the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof exit only from said first reactor zone,
• wherein said porous wall through which said one or more second reactants passes into said first reactor zone has a viscosity normalized permeability ranging from about 10.sup.-6 to about 5.times.10.sup.-2 cm.sup.3 cp/cm.sup.2 sec psi.

An exothermic process for forming a reaction product fluid by reaction of one or more liquid first reactants with one or more second reactants, at least one of which is gaseous, which comprises:

• (a) feeding said one or more liquid first reactants at a first pressure through a first reactor zone having mixing elements therein;
• (b) feeding said one or more second reactant, at least one of which is gaseous at ambient conditions, at a second pressure higher than said first pressure into a second reactor zone which is separated from said first reactor zone by a porous wall which is capable of being penetrated by said one or more second reactants at multiple sites to produce in said first reactor zone a resulting mixture having components selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof and
• (c) maintaining the pressure within said second reaction zone higher than the pressure in said first reaction zone at corresponding locations of said porous wall, to thereby inhibit any flow back of the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted second reactant and combinations thereof through said porous wall from said first reactor zone to said second reactor zone;
• wherein said one or more second reactants pass once through said porous wall to contact said one or more liquid first reactants in said first reactor zone and form said reaction product fluid only in said first reactor zone, and the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof exit only from said first reactor zone,
• wherein said porous wall through which said one or more second reactants passes into said first reactor zone has a viscosity normalized permeability ranging from about 10.sup.-6 to about 5.times.10.sup.-2 cm.sup.3 cp/cm.sup.2 sec psi.

An exothermic process for forming a reaction product fluid by reaction of one or more first reactants and one or more second reactants which comprises:

• (a) feeding a first reactant at a first pressure through a first reactor zone containing mixing elements having at least one dimension which is equal to from about 1/2 to about 1/100 of the largest dimension of said first reactor zone wherein said one dimension and said largest dimension are measured in the dimension which is perpendicular to the flow of said first reactant through said first reactor zone;
• (b) feeding a second reactant at a second pressure higher than said first pressure into a second reactor zone separated from said first reactor zone by a porous wall having multiple openings capable of being penetrated by said second reactant at multiple sites to produce in said first reactor zone a resulting mixture having components selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof;
• and
• (c) maintaining the pressure within said second reaction zone higher than the pressure in said first reaction zone at corresponding locations of said porous wall, to thereby inhibit any flow of the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted second reactant and combinations thereof through said porous wall from said first reactor zone to said second reactor zone;
• whereby said second reactant passes through said porous wall to contact said first reactant in said first reactor zone and form said reaction product only in said first reactor zone, and the components of said first reactor zone one which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof exits only from said first reactor zone,
• wherein said porous wall through which said one or more second reactants passes into said first reactor zone has a viscosity normalized permeability ranging from about 10.sup.-6 to about 5.times.10.sup.-2 cm.sup.3 cp/cm.sup.2 sec psi.

A process for forming a reaction product fluid by reaction of a first liquid reactant with a second liquid reactant, which process comprises:

• (a) feeding a first liquid reactant at a first pressure into a first reactor zone containing particles having at least one dimension which is equal to from about 1/2 to about 1/100 of the largest dimension of said first reactor zone wherein said one dimension and said largest dimension are measured perpendicular to the flow of said liquid reactant through said first reactor zone;
• (b) feeding a second liquid reactant at a second pressure higher than said first pressure into a second reactor zone separated from said first reactor zone by a porous wall capable of being penetrated by said second liquid reactant at multiple sites to produce in said first reactor zone a resulting mixture having components selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof;
• and
• (c) maintaining the pressure within said second reaction zone higher than the pressure in said first reaction zone at corresponding locations of said porous wall, to thereby inhibit any flow through said porous wall from said first reactor zone to said second reactor zone, of the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted second reactant and combinations thereof;
• whereby said second liquid reactant passes through said porous wall to contact said first liquid reactant in said first reactor zone and form said reaction product fluid comprising a liquid, a gas, or combinations thereof only in said first reactor zone, and the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof exit only from said first reactor zone,
• wherein said porous wall through which said one or more second reactants passes into said first reactor zone has a viscosity normalized permeability ranging from about 10.sup.-6 to about 5.times.10.sup.-2 cm.sup.3 cp/cm.sup.2 sec psi.

A process for forming a product by reaction of one or more first reactants and one or more second reactants which comprises:

• (a) feeding into a first reactor zone having mixing elements therein said one or more first reactants at a first pressure;
• (b) feeding one or more of said second reactants at a second pressure higher than said first pressure into a second reactor zone separated from said first reactor zone by a porous wall which is capable of being penetrated by said second reactant at multiple sites to produce in said first reactor zone a resulting mixture having components selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof;
• and
• (c) maintaining the pressure within said second reaction zone at all locations of said porous wall higher than the pressure in said first reaction zone at corresponding locations of said porous wall, to thereby inhibit any flow of the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted second reactant and combinations thereof through said porous wall from said first reaction zone to said second reaction zone;
• wherein said one or more second reactants will pass through said porous wall to contact said one or more first reactants in said first reactor zone and form said product only in said first reactor zone, and the components of said first reactor zone which are selected from the group consisting of said reaction product fluid, unreacted said first reactant, unreacted said second reactant and combinations thereof exit only from said first reactor zone wherein the flow of the first reactant is pulsed flowed at a rate which changes the flow rate from about a maximum flow rate in one direction to zero flow and then to about 20% of the maximum rate in the reverse direction and thereafter returns to the maximum flow rate in the original direction,
• wherein said porous wall through which said one or more second reactants passes into said first reactor zone has a viscosity normalized permeability ranging from about 10.sup.-6 to about 5.times.10.sup.-2 cm.sup.3 cp/cm.sup.2 sec psi.