Multistage reaction system with interstage sparger systems

A process for the alkylation of an aromatic substrate comprising:

• a. providing a multi-stage alkylation reaction zone within an elongated reactor having au upper catalyst bed extending transversely of said reactor and at least three subsequent catalyst beds extending transversely of said reactor and spaced from one another to provide an upper mixing zone between said first catalyst bed and the next subsequent catalyst bed, a second mixing zone between said second and third subsequent catalyst beds, and a third mixing zone between said third and fourth subsequent catalyst beds;
• b. supplying a feedstock containing an aromatic substrate and a C2-C4 alkylating agent to an inlet side of said reaction zone;
• c. operating said reaction zone at temperature and pressure conditions in which said aromatic substrate is in the gaseous phase to cause gas phase alkylation of said aromatic substrate as said aromatic substrate and said alkylating agent progressively traverse said catalyst beds;
• d. in the initial intermediate mixing zone between said first and second catalyst beds, supplying a quench fluid comprising a mixture of said aromatic substrate and said alkylating agent into the interior of said mixing zone through a plurality of flow paths in which one portion of said flow paths is directed upwardly within said mixing zone and another portion of said flow pas is directed downwardly within said mixing zone, wherein said quench fluid is supplied to said mixing zone through a plurality of dispersion channels extending transversely within said mixing zone and spaced laterally from one another wherein at least some of said dispersion channels dispense said quench fluid through said flow paths dirt upwardly and downwardly within said mixing zone;
• e. in at leapt one subsequent intermediate zone between adjacent catalyst beds, supplying a quench fluid comprising at least one of said aromatic substrate and said alkylating agent into the interior of sad mixing zone through a second plurality of flow paths in which one portion of said flow paths is directed upwardly within said mixing zone and another portion of said flow paths is directed downwardly wit said zone, wherein said quench fluid is supplied to said mixing zone through a plurality of dispersion channels extending transversely with said mixing zone and spaced laterally from one another wherein at least some of said dispersion channels dispense said quench fluid through said flow paths directed upwardly and downwardly within said mixing zone;
• and
• f. recovering alkylated product from a downstream outlet of said reaction zone.

A process for the alkylation of an aromatic substrate comprising:

• a. providing a multi-stage alkylation reaction zone within an elongated reactor having an upper catalyst bed extending transversely of said reactor and at least three subsequent catalyst beds extending transversely of said reactor and spaced from one another to provide an upper mixing zone between said first catalyst bed and the next subsequent catalyst bed, a second mixing zone between said second and third subsequent catalyst beds, and a third mixing zone between said third and fourth catalyst beds;
• b. in each of said mixing zones, providing a sparger system comprising a plurality of laterally-spaced dispersion channels extending transversely of said reactor and provided with linearly-spaced outlet orifices alternately directed downwardly and upwardly along the lengths of said dispersion channels;
• c. supplying a feedstock containing an aromatic substrate and a C2-C4 alkylating agent to an inlet side of said reaction zone;
• d. operating said reaction zone at temperature and pressure conditions in which said aromatic substrate is in the gaseous phase to cause gas phase alkylation of said aromatic substrate as said aromatic substrate and said alkylating agent progressively traverse said catalyst beds;
• e. in the initial intermediate mixing zone between said first and second catalyst beds, supplying a quench fluid comprising a mixture of said aromatic substrate and said alkylating agent to said sparger system to provide a plurality of alternating flow paths through said outlet orifices directed upwardly and downwardly within said mixing zone;
• f. in the next intermediate mixing zone between said second and third catalyst beds, supplying a quench fluid comprising a mixture of said aromatic substrate and said alkylating agent to said sparger system to provide a plurality of alternating flow paths through said outlet orifices directed upwardly and downwardly within said mixing zone;
• g. in the next intermediate mixing zone between said third and fourth catalyst beds, supplying a quench fluid comprising at least one of said aromatic substrate and said alkylating agent to said dispersion system to provide a plurality of alternating flow paths through said outlet orifices directed upwardly and downwardly within said mixing zone;
• and
• h. recovering alkylated product from a downstream outlet of said reaction zone.