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US 7,922,981 B2Granted
Dispersion-intensified, coalescence-intensified chemical reactor and method
AssigneeAnilitics Process Chemistry & Engineering, Inc.
InventorEdward G. Hauptmann
Life of this patent
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Abstract
Apparatus for intensifying heterogeneous chemical reactions is described. For the case of liquid-liquid reactions, with drops of a reactant distributed throughout the second continuous reactant, the physical phenomena of drop dispersion (break up) and drop coalescence are identified as the main physical steps affecting reaction rates. A basic flow cell structure is described in which the respective actions of dispersion and coalescence can be greatly intensified through the creation of enhanced body forces and shear flow zones. The basic cell structure can be arranged into pipe flow reactors to suit any production or process requirements. The basic cell structure is equally applicable to gas-liquid reactions with drops of one reactant being conveyed by a moving gas stream.
Claims25
An apparatus to allow chemical reactions between reactants comprising:
- a vessel through which the reactants flow co-currently;
- a baffle structure within the vessel to define a plurality of flow cells, each flow cell having an interior and at least one inlet to allow flow to pass into the cell interior as a jet to define a dispersion zone for the reactants, and an obstruction spaced from the at least one inlet to redirect the flow and form a coalescence zone for the reactants adjacent the obstruction, and at least one outlet to allow flow to exit the flow cell;
- a vessel inlet for introducing at least one reactant into the vessel having multiple openings to introduce the at least one reactant into other reactants already flowing through the vessel, the openings being positioned to introduce the at least one reactant into multiple flow cells.
A method for promoting chemical reactions between reactants comprising:
- delivering the reactants through a vessel in a mixed co-current flow including a first reactant distributed as drops throughout a second reactant;
- and
- controlling the flow through the vessel to create a flow path that alternates between dispersing the drops and coalescing the drops to increase the reaction rate by directing the flow through at least one flow cell in the vessel, the flow cell having at least one inlet to allow flow to pass through the inlet as a jet to define a dispersion zone for the drops. and an obstruction spaced from the at least one inlet to redirect the flow and form a coalescence zone for the drops within an interior of the flow cell adjacent the obstruction, and at least one outlet adjacent the obstruction to allow flow to exit the flow cell, wherein the at least one flow cell is arranged in an array of a plurality of flow cells within the vessel positioned to intercept and control flow through the vessel.
An apparatus to allow chemical reactions between reactants comprising:
- a vessel through which the reactants flow co-currently, the vessel comprising a hollow body having a longitudinal axis;
- a baffle structure within the vessel to define at least one flow cell having an interior and at least one inlet to allow flow to pass into the cell interior as a jet to define a dispersion zone for the reactants, and an obstruction spaced from the at least one inlet to redirect the flow and form a coalescence zone for the reactants adjacent the obstruction, and at least one outlet to allow flow to exit the flow cell,
- wherein the baffle structure is formed from a plurality of elements arranged within the body to define an array of interconnected flow cells that communicate with each other by virtue of the outlet of one flow cell being the inlet of one or more other flow cells, and the plurality of elements includes members of generally T-shaped cross-section, the members being arranged through the hollow body in a repeating pattern to define the array of interconnected flow cells.
An apparatus to allow chemical reactions between reactants comprising:
- a vessel through which the reactants flow co-currently, the vessel comprising a hollow body having a longitudinal axis;
- a baffle structure within the vessel to define at least one flow cell having an interior and at least one inlet to allow flow to pass into the cell interior as a jet to define a dispersion zone for the reactants, and an obstruction spaced from the at least one inlet to redirect the flow and form a coalescence zone for the reactants adjacent the obstruction, and at least one outlet to allow flow to exit the flow cell,
- wherein the baffle structure is formed from a plurality of elements arranged within the body to define an array of interconnected flow cells that communicate with each other by virtue of the outlet of one flow cell being the inlet of one or more other flow cells, and the plurality of elements includes a central core element of cylindrical configuration aligned along the longitudinal axis of the hollow body having a plurality of spaced first annular elements extending radially outwardly from the core element and a plurality of spaced second annular elements extending radially inwardly from the hollow body, the first and second annular elements co-operating to define a plurality of interconnected flow cells of annular configuration within an annular space about the central core element.
An apparatus to allow chemical reactions between reactants comprising:
- a vessel through which the reactants flow co-currently, the vessel comprising a hollow body having a longitudinal axis;
- a baffle structure within the vessel to define at least one flow cell having an interior and at least one inlet to allow flow to pass into the cell interior as a jet to define a dispersion zone for the reactants, and an obstruction spaced from the at least one inlet to redirect the flow and form a coalescence zone for the reactants adjacent the obstruction, and at least one outlet to allow flow to exit the flow cell,
- wherein the baffle structure is formed from a plurality of elements arranged within the body to define an array of interconnected flow cells that communicate with each other by virtue of the outlet of one flow cell being the inlet of one or more other flow cells, and the plurality of elements includes:
- a ring cell element comprising an annular cylindrical member having an opening therethrough of a first diameter and an annular disc member having a central opening of a second diameter less than the first diameter positioned against an end of the annular cylindrical member;
- a plurality of the ring cell elements of different first diameters being arranged through the hollow body centered about the longitudinal axis in a repeating pattern to define an array interconnected annular flow cells.
2 more elements
An apparatus to allow chemical reactions between reactants comprising:
- a vessel through which the reactants flow co-currently, the vessel comprising a hollow body having a longitudinal axis;
- a baffle structure within the vessel to define at least one flow cell having an interior and at least one inlet to allow flow to pass into the cell interior as a jet to define a dispersion zone for the reactants, and an obstruction spaced from the at least one inlet to redirect the flow and form a coalescence zone for the reactants adjacent the obstruction, and at least one outlet to allow flow to exit the flow cell,
- wherein the baffle structure is formed from a plurality of internal baffles extending transversely to the longitudinal axis to restrict axial flow and direct flow radially within the body with an array of flow cells extending between adjacent baffles, the flow cells having inlets and outlets oriented to permit radial flow through the cells;
- and
- wherein the internal baffles comprise alternating disc plates and annular plates spaced along the longitudinal axis of the hollow body to define a series of interrupted central channels for flow extending between pairs of disc plates and a series of interrupted annular perimeter channels for flow extending between pairs of annular plates, the interrupted channels communicating through arrays of flow cells extending between adjacent overlapping plate surfaces in an annular configuration, whereby flow through the hollow body is directed longitudinally along a central channel, radially outwardly through one of the arrays of flow cells, longitudinally along an annular perimeter channel, and radially inwardly through another of the arrays of flow cells.
2 more elements
Dependencies are inferred from the claim text.