Process for high shear gas-liquid reactions

• US 7,538,237 B2
• Filed: 05/28/2004
• Issued: 05/26/2009
• Est. Priority Date: 07/02/1999
• Status: Expired due to Term

• Current Assignee: The 323 Trust
• Original Assignee: Kreido Laboratories (Namliong SkyCosmos, Inc.)
• Inventors: Cihonski, John L., Gulliver, Eric A., Holl, Richard A.
• Primary Examiner(s): Carr; Deborah D
• Application Number:
  US10/857,295
• Publication Number:
  US 20050033069A1
• Time in Patent Office: 1,824 Days
• Field of Search: None
• US Class Current: 554/141
• CPC Class Codes: B01F 27/116 Stirrers shaped as cylinders, balls or rollers
• CPC Class Codes: B01F 27/272 with means for moving the materials to be mixed axially between the surfaces of the rotor and the stator, e.g. the stator rotor system formed by conical or cylindrical surfaces
• CPC Class Codes: B01F 27/74 with rotary cylinders
• CPC Class Codes: B01F 33/05 Mixers using radiation, e.g. magnetic fields or microwaves to mix the material B01F23/2133, B01F23/238, B01F23/55, B01F33/3031, B01F33/3032 take precedence
• CPC Class Codes: B01F 33/83613 by grinding or milling
• CPC Class Codes: B01F 33/8362 with chemical reactions
• CPC Class Codes: B01F 35/4122 at the side walls of the receptacle
• CPC Class Codes: B01F 35/512 characterised by surface properties, e.g. coated or rough
• CPC Class Codes: B01F 35/54 Closely surrounding the rotating element
• CPC Class Codes: B01F 35/90 Heating or cooling systems
• CPC Class Codes: B01J 19/082 Gamma-radiation only
• CPC Class Codes: B01J 19/10 employing sonic or ultrasonic vibrations
• CPC Class Codes: B01J 19/122 Incoherent waves gamma-radiation B01J19/082
• CPC Class Codes: B01J 19/125 X-rays
• CPC Class Codes: B01J 19/126 Microwaves
• CPC Class Codes: B01J 19/127 Sunlight; Visible light
• CPC Class Codes: B01J 19/18 Stationary reactors having moving elements inside B01J19/08, B01J19/26 take precedence
• CPC Class Codes: B01J 19/1887 forming a thin film
• CPC Class Codes: B01J 2208/00 Processes carried out in the presence of solid particles; Reactors therefor
• CPC Class Codes: B01J 2219/00094 Jackets
• CPC Class Codes: B01J 2219/00141 : Microwaves
• CPC Class Codes: B01J 2219/00146 : Infrared radiation
• CPC Class Codes: B01J 2219/00164 : controlling the flow
• CPC Class Codes: B01J 2219/00166 : controlling the residence time inside the reactor vessel
• CPC Class Codes: B01J 2219/00168 : controlling the viscosity
• CPC Class Codes: B01J 2219/0888 : Liquid-liquid
• CPC Class Codes: B01J 2219/1227 : Reactors comprising tubes with open ends
• CPC Class Codes: B01J 2219/182 : horizontal
• CPC Class Codes: B01J 2219/1943 : cylindrical
• CPC Class Codes: B22F 2998/00 : Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B29B 7/385 : fluid mixers
• CPC Class Codes: B29B 7/401 : having a casing closely surrounding the rotor, e.g. with a plunger for feeding the material B29B7/407, B29B7/42 take precedence
• CPC Class Codes: B29B 7/603 : in measured doses, e.g. proportioning of several materials
• CPC Class Codes: B29B 7/826 : Apparatus therefor
• CPC Class Codes: B29B 7/90 : Fillers or reinforcements , e.g. fibres
• CPC Class Codes: B29C 48/03 : characterised by the shape of the extruded material at extrusion
• CPC Class Codes: B29C 48/38 : using two or more serially arranged screws in the same barrel
• CPC Class Codes: B29K 2021/00 : Use of unspecified rubbers as moulding material
• CPC Class Codes: B29K 2105/16 : Fillers
• CPC Class Codes: B29K 2503/04 : Inorganic materials
• CPC Class Codes: C02F 1/30 : by irradiation
• CPC Class Codes: C02F 1/302 : with microwaves
• CPC Class Codes: C02F 1/32 : with ultraviolet light
• CPC Class Codes: C02F 1/36 : ultrasonic vibrations
• CPC Class Codes: C08K 3/01 : characterized by their specific function
• CPC Class Codes: C22C 32/0094 : with organic materials as the main non-metallic constituent, e.g. resin
• CPC Class Codes: F28D 11/02 : the movement being rotary, e.g. performed by a drum or roller F28D11/08 takes precedence

Abstract

A process for performing a chemical reaction between a plurality of chemical reactants in the presence of a catalyst, with at least a first reactant in a liquid phase and at least a second reactant in a gas phase, the first and second reactants mixing at least by interdiffusion. The process comprises supplying the reactants to a passage defined by a first surface and a second surface and optionally moving at least one of the first surface and second surface relative to each other. The reactants their mixture or reaction products form respective boundary layers against the first and second surfaces and the radial spacing between the first surface and second surface is equal to or less than the back-to-back radial thicknesses of the boundary layers.

Claims

1. A process for performing a chemical reaction between a first reactant and a second reactant in the presence of a catalyst, the first reactant being in a liquid phase and the second reactant being in a gas phase, the process comprising:

supplying the first reactant and the second reactant to a passage defined by a first surface and a second surface, the first reactant supplied to the passage by a first reactant flow and the second reactant supplied to the passage by a second reactant flow, wherein the first reactant mixes with the second reactant at least by interdiffusion, the first reactant, the second reactant and any mixture and reaction products thereof, forming respective boundary layers against the first and second surfaces, each boundary layer having a radial thickness;

providing a radial spacing between the first surface and second surface that is one of (1) a radial spacing not greater than the back-to-back combined radial thicknesses of the boundary layers and (2) a radial spacing greater than the back-to-back combined radial thicknesses with a third layer between the two boundary layers, wherein the third layer is too thin to support at least one of (1) turbulent convection and (2) uneven channeling; and

reacting the first reactant with the second reactant in the passage.

2. The process of claim 1, further comprising moving at least one of the first surface and second surface relative to each other.

3. The process of claim 2, wherein the radial spacing between the first surface and the second surface in the passage ranges from a first radial spacing to a second radial spacing, the first radial spacing greater than the second radial spacing.

4. The process of claim 1, wherein the chemical reaction is p-xylene oxidation, the first reactant being p-xylene in a solution with a suitable solvent, the second reactant being oxygen.

5. The process of claim 4, wherein the solvent is water.

6. The process of claim 1, wherein the chemical reaction is hydrogenation of unsaturated fatty acids, the first reactant being an oil comprising an unsaturated fatty acid and the second reactant being hydrogen.

7. A process for performing a chemical reaction between a plurality of chemical reactants in the presence of a catalyst, at least a first reactant being in a liquid phase and at least a second reactant being in a gas phase, the process comprising:

supplying the first reactant and the second reactant to a passage defined by a first surface and a second surface, the first reactant supplied to the passage by a first reactant flow and the second reactant supplied to the passage by a second reactant flow, wherein the first reactant mixes with the second reactant at least by interdiffusion, the first reactant, the second reactant and any mixture and reaction products thereof, forming respective boundary layers against the first and second surfaces, each boundary layer having a radial thickness;

providing a radial spacing between the first surface and second surface that is one of (1) a radial spacing not greater than the back-to-back combined radial thicknesses of the boundary layers and (2) a radial spacing greater than the back-to-back combined radial thicknesses with a third layer between the two boundary layers, wherein the third layer is too thin to support at least one of (1) turbulent convection and (2) uneven channeling; and

reacting the first reactant with the second reactant in the passage.

8. The process of claim 7, further comprising moving at least one of the first surface and second surface relative to each other.

9. The process of claim 8, wherein the radial spacing between the first surface and the second surfaces in the passage ranges from a first radial spacing to a second radial spacing, the first radial spacing greater than the second radial spacing.

10. The process of claim 7, wherein the chemical reaction is p-xylene oxidation, the first reactant being p-xylene in a solution with a suitable solvent, the second reactant being oxygen.

11. The process of claim 10, wherein the solvent is water.

12. The process of claim 7, wherein the chemical reaction is hydrogenation of unsaturated fatty acids, the first reactant being an oil comprising an unsaturated fatty acid and the second reactant being hydrogen.

13. A process for performing a chemical reaction between a first reactant and a second reactant in the presence of a catalyst, the first reactant being in a liquid phase and the second reactant being in a gas phase, the process comprising:

introducing the first reactant and the second reactant into an apparatus comprising a first surface and a second surface able to move relative to each other, the first surface and second surface defining a passage, the first reactant reacting with the second reactant in the passage, the first reactant, the second reactant and any mixture and reaction product thereof forming respective boundary layers against the first and second surfaces, each boundary layer having a radial thickness;

providing a radial spacing between the first surface and second surface that is one of (1) a radial spacing not greater less than the back-to-back combined radial thicknesses of the boundary layers and (2) a radial spacing greater than the back-to-back combined radial thicknesses with a third layer between the two boundary layers, wherein the third layer is too thin to support at least one of (1) turbulent convection and (2) uneven channeling; and

moving at least one of the first surface and the second surface relative to the other.

14. The process of claim 13, wherein the radial spacing between the first surface and the second surfaces in the passage ranges from a first radial spacing to a second radial spacing, the first radial spacing greater than the second radial spacing.

15. The process of claim 13, wherein the catalyst is introduced into the apparatus in a solid phase.

16. The process of claim 13, further comprising bringing at least one of the first reactant and the second reactant to a predetermined temperature, before introducing the first reactant and the second reactant into the apparatus.

17. The process of claim 16, wherein bringing at least one of the first reactant and second reactant to a predetermined temperature is performed by passing at least one of the first reactant and second reactant through a pre-heater device connected to the apparatus.

18. The process of claim 13, wherein the apparatus has a head end and a body, a first inlet located on the head end and a second inlet located on the body, the first reactant introduced in the apparatus through the first inlet, the second reactant introduced in the apparatus through the second inlet.

19. The process of claim 14, wherein the apparatus has a head end and a body, a first inlet located on the head end and a second inlet located on the body, the second inlet connected to a portion of the passage having the second radial spacing.

20. The process of claim 13, wherein introducing the first reactant and the second reactant is performed contemporaneously with moving at least one of the first surface and the second surface.

21. The process of claim 13, wherein the chemical reaction is p-xylene oxidation, the first reactant being p-xylene in a solution with a suitable solvent, the second reactant being oxygen.

22. The process of claim 21, wherein the solvent is water.

23. The process of claim 13, wherein the chemical reaction is hydrogenation of unsaturated fatty acids, the first reactant being an oil comprising an unsaturated fatty acid and the second reactant being hydrogen.

24. A process for performing a chemical reaction between a plurality of chemical reactants in presence of a catalyst, at least one reactant being in a liquid state and at least one reactant being in a gas state, the process comprising:

introducing the first reactant and the second reactant into an apparatus comprising a first surface and a second surface with at least one of said surfaces able to move relative to the other, the first surface and second surface defining a passage, the first reactant reacting with the second reactant in the passage, the first reactant, the second reactant and any mixture and reaction product thereof forming respective boundary layers against the first and second surfaces, each boundary layer having a radial thickness;

providing a radial spacing between the first surface and second surface that is one of (1) a radial spacing not greater than the back-to-back combined radial thickness of the boundary layers and (2) a radial spacing greater than the back-to-back combined radial thicknesses with a third layer between the two boundary layers, wherein the third layer is too thin to support at least one of (1) turbulent convection and (2) uneven channeling; and

moving at least one of the first surface and the second surface relative to the other.

25. The process of claim 24, wherein the radial spacing between the first surface and the second surface ranges from a first radial spacing to a second radial spacing, the first radial spacing being greater than the second radial spacing.

26. The process of claim 24, further comprising bringing at least one the reactants to a predetermined temperature, before introducing the first reactant and the second reactant into the apparatus.

27. The process of claim 24, wherein the chemical reaction is formation of hydrogen peroxyde, the reactants comprising oxygen and hydrogen gases, a glycerine solution and a solution one DI H20.