Gas-liquid reactions are very common in Chemical Process Industry and contribute to more than 30% of all the chemical commercial reactions. There are several commercially important reactions where the gas phase is pure/explosive/toxic.
In all these cases the gas phase is expensive and complete utilization of the solute gas is desired. The key feature of these reactors is the efficiency at which gas-liquid mixing occurs. For this purpose, it is important that the un-reacted gas from the gas space is drawn back into liquid. This difficult task has been achieved in the recently developed novel reactor design (which is patented). It uses the self induction principle for impellers. Energy efficient impeller designs have been developed for gas induction and gas dispersion. It is also efficient for gas-liquid-solid three phase reactions. The solid phase may be a catalyst or undergo a chemical reaction.
The solids concentration may vary from 0.005% v/v (in the case of noble metal catalyst) or 25% v/v (when solids undergo chemical reaction). It is a proven design and a large number of reactors are in successful commercial operation with a size range from 500 to 20,000 Liters.
Over Ninety Reactors are in successful commercial operation. Following are some details:
|No||Application||Range of reactor volume||Product category|
|1.||Saturation of double bonds. For example, In this case paraffin’s are formed from olefins or saturated fatty acids or saturated oils from the corresponding unsaturated acids and oils.||5 m3 - 20 m3||Fatty acids, hydrogenation (or hardening) of natural oils.|
|2.||Nit rile to amine. In this case C º N group is converted in to –CH2NH2.||0.1 m3 - 8 m3||Soap intermediates, Specialty chemicals|
|3.||Saturation of aromatic ring. The ring of substituted aromatic compounds are saturated.||0.5 m3 - 4.0 m3||Substituted anthraquinones, specialty chemicals, perfumery chemicals, cyclohexyl amine|
|4.||Hydrogenation of aromatic nitro-compounds such m-dinitrobenzene, o-nitroaniline, p-nitroaniline, o-dinitrobenzene, p-dinitrobenzene’s, nitrotoluenes, nitroxylenes, nitro chlorobenzenes, nitroanisoles, nitro cumenes, etc.||2 m3 - 12 m3||Dye, pharmaceutical and agro-chemical intermediates.|
|5.||Reductive amination and reductive alkylation.||1 m3 - 5 m3||Surface active agents, Pharmaceutical intermediates.|
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