Integrated apparatus and process for high recovery of acetylene from the reaction of calcium carbide with water

An apparatus for the production of acetylene and hydrated lime by the reaction of water with calcium carbide particles comprising;

• a primary reactor constructed for upward flow of water and with an upward water velocity control flow restrictor disposed to direct the upward flow of water in the primary reactor, the restrictor constructed and sized to allow impurities denser than hydrated lime produced by reaction of water and calcium carbide particles in the primary reactor to settle into a holding zone, and to entrain and carry upwards calcium carbide particles of less than a predetermined size and hydrated lime up and over an overflow at a periphery of the primary reactor,
• water inlet for introducing water into the primary reactor for upward flow through the velocity control restrictor,
• makeup water inlet for introducing makeup water into the primary reactor,
• feeder for introducing calcium carbide into the top of the primary reactor,
• secondary reactor concentrically disposed around the primary reactor such that water with calcium carbide particles and hydrated lime from primary reactor flowing over the overflow flow directly into the secondary reactor, the secondary reactor constructed and dimensioned to provide essentially plug-flow reaction of water with calcium carbide particles and to allow the hydrated lime produced in the primary and secondary reactors to settle into a dense zone at the bottom of the secondary reactor,
• acetylene output for withdrawing acetylene produced in the primary and secondary reactors, hydrated lime output for withdrawing hydrated lime that has settled in the dense zone from the dense zone of the secondary reactor,
• secondary water output for withdrawing water from the secondary reactor from a region in the secondary reactor not in the dense zone,
• recycle conduit directing from the secondary water output to the water inlet of primary reactor.