High Interfacial Area Multiphase Reactor (RM-1069)

The present invention is concerned with improvements in contacting distinct, physical phases such as gases and liquids.

There are many commercially important operations in which it is necessary to physically mix plural distinct phases such as gases and liquids. Indeed, reactions between a gas and a liquid are common in the chemical industry. In such processes, it is important to maximize the interfacial area between the distinct phases so as to optimize the rate of reaction, the yield, or the like.

It is an object of the present invention to provide improvements in contacting of plural, distinct phases so as to enhance or improve the chemical processes being conducted.

Another object of the present invention is to provide improvements in absorption and reaction of olefins, either gases or liquids, by sulfuric acid in the hydration of olefins to produce alcohols.

In its simplest sense, the present invention provides a method for improving the contacting of plural, distinct fluid phases contained in a vertically disposed vessel by axially injecting a stream of the dispersed distinct fluid phases together into the fluid phases contained in the vessel. Importantly, the injected stream is injected with sufficient fluid movement to force the fluid contained in the vessel to circulate downwardly through substantially the central region of the vessel and upwardly in an annular region between the central region and the outer vessel wall.

FIG. 1 is a schematic illustration of the present invention.

FIG. 2 is a schematic illustration of an alternate aspect of the present invention.

The present invention will be described by referring specifically to the dispersion of a gas like propylene or butene in a liquid like sulfuric acid. However, it should be readily appreciated that the principles and concepts described herein are equally applicable to other processes in which contacting of distinct phases is desired.

Turning now to FIG. 1, there is shown a generally cylindrical, vertically disposed vessel 10 having sidewalls 11 and top and bottom walls 12 and 14, respectively. Vessel 10 is also provided with a conduit 4 for removal of liquids for recycle via lines 5 and 6. A conduit 2 is provided for introduction of liquids recycled via lines 5 and 6. Vessel 10 is also equipped with a conduit 3 for removal of liquid product for delivery, for example, to a liquid product store (not shown). Line 8 is provided connecting a gaseous olefin source (not shown) with recycle line 6. Thus, a gaseous olefin and sulfuric acid may be fed together via conduit 2 into the vessel 10.

Conduit 2 contains disk and donut baffles, 18 and 19, respectively, for turning and mixing the gaseous olefin and liquid sulfuric acid as it passes through conduit 2. The mixture of gas and liquid then passes into a pipe 21 centrally positioned in a cylindrical mixing vessel 22. As can be seen, pipe 21 has a plurality of holes 23 for further mixing of the gas and liquid. The fluid then exits the mixing vessel 22 and flows into a nozzle 24 which opens below the level of liquid in the vessel 10.

The nozzle 24 is designed to direct the flow of dispersed gas and liquid phases downwardly substantially in the central region of the vessel. Thus, the flow of dispersed phases ejected from the nozzle will flow outwardly as well as downwardly as shown by the dotted lines. The angle at which the dispersed phases are ejected from nozzle 24 will depend upon a number of factors such as the ratio of the length to diameter of the vessel. In general, however, the angle of ejection of dispersed fluid phases from nozzle 24 will be such that the fluid at its maximum length of downward travel will flow outwardly for a distance between 0.4 to 0.7 times the diameter of vessel 10. The diameter of the nozzle is sufficient to transfer enough momentum from fluid ejected from the nozzle to fluid in its flow path to move from about 3 to about 20 times the amount of fluid ejected. This can be achieved by sizing the nozzle diameter to be from about 1/12 to about 1/20 the length of the vessel.

Located within vessel 10 is a baffle 17 for directing the flow of dispersed fluid radially outwardly. This baffle is positioned substantially normal to the downward flow of fluid ejected from nozzle 24 and placed near the bottom of the vessel. Indeed, it is preferred that the baffle have a diameter of from about 0.4 to about 0.7 times the diameter of the vessel and that it be located at a distance from the vessel bottom that is about 0.2 to about 0.5 times the diameter of the vessel.

In operation then a mixture of the olefin and sulfuric acid is churned and mixed by the baffles in the conduit 2 and fed through holes 23 of pipe 21 causing extremely small bubbles to be formed. The gas and liquid mixture then is emitted as a jet of fluid from nozzle 24 and is injected into the fluid contained in the vessel. The jet of fluid exiting the nozzle exchanges its momentum with the fluid in the central region 15 of the vessel especially the fluid directly in its conical flow path, and causes the fluid in this region to move in substantially a downwardly direction but also in an outwardly direction. This movement in turn causes the entire contents of the vessel to move. This fluid moves upwardly in the annular region between the side walls 11 and the central region 15. As shown, baffle 17 deflects the jet energy of the fluids flowing downwardly, and deflects them radially outwardly preventing the energy from leaving through the recycle exit conduit 4.

In operation, recycle flows are adjusted to give five turnovers of fluid within the vessel or an axial liquid velocity within the vessel which is at least three times, for example, from three to five times, the buoyant rise velocity of the largest bubble in the vessel. This results in an extremely high vapor holdup of small bubbles formed by the holes 23 of pipe 21 and the nozzle 24. Furthermore, by maintaining a high recirculation rate within the vessel, bubble coalescence is reduced with the concomitant result that the high interfacial areas that are generated by the holes 23 in mixer 22 are maintained.

Turning now to FIG. 2, an alternate but particularly preferred embodiment of the present invention is shown. In this embodiment, ring sparger pipes 26 and 27 are located at the lower end of the annular region of vessel 10. Preferably the spargers are located in the annular region sufficiently above baffle 17 so as not to interfere with the downward flow of fluid from central region 15. In operation, a portion of the gaseous olefin is sparged through the annular ring sparger 26 to aid in setting up and maintaining the flow of fluids circulating in vessel 10. Similarly, a portion of the liquid acid is sparged through ring spargers 27 from line 29. Indeed, it is particularly preferred that the openings in the gas spargers be substantially orthogonal to the openings in the liquid sparger as is described in greater detail in copending application Ser. No. 210,550 filed Jun. 21, 1988 now abandoned, which is incorporated herein by reference.

When the ring sparger is used, from about five to about fifty percent of the total amount of gas fed to the vessel, and preferably about ten percent of the gas fed to the vessel is fed in the annular region through the annular sparger 26 providing a buoyancy driving force in the outer annular region that stabilizes the recirculating flow. Typically the volumetric ratio of gas to liquid is in the range of from about 4:1 to about 1:2.

While in the preceding discussion specific mention was made with respect to using a gas and a liquid, in other applications, such as processes involving two distinct liquid phases or two liquid and one gaseous phase, it is preferred to circulate the recycle fluid through a separator drum, particularly where a phase volume ratio enhancement or control is desired over and beyond that available by proportioning the two liquid feeds to the reactor. This technique is described in copending application Ser. No. 235,572 filed Aug. 24, 1988, now abandoned and is incorporated herein by reference.