Falling film sulfonation reactor

Mist separator 2 Falling-film sulfonation reactor 3 Gas separator 4 Finishing reactor 5 Hydrolyser 6 Blender 7 Storage tank... 

Fig. 2. High speed photos of organic film—high velocity air dynamics in falling film sulfonation process (a) and (b) are vertical flat plate organic—air dynamics where (a) shows BAB—air at top, (b) BAB sulfonic acid—air at bottom of reactor (c) simulated AUied-type concentric reactor inner cylindrical...

A detailed description of typical sulfonation systems - is omitted from the production descriptions contained in this chapter. However, all MES processes share the common use of a falling-film sulfonation system for the initial reaction of ME with air/SOj. The processes differ in the treatment of MESA after the sulfonation reactor. The sulfonation systems shown in Figure 11.1 are generic for... 

Summary of Characteristics of Falling Film Continuous SOj Sulfonation Processes. Both concentric and multitubular reactor systems suppHed by competing manufacturers have surprisingly similar operating characteristics organic feedstock loading of ca 0.4 kg/(h-mm) (circumference) for LAB, and ca 0.3 kg/(h-mm) for alcohol ethoxylates an SO concentration of 3.3—5.0 vol % SO for LAB sulfonation, and 2—3% SO ... 

With a reaction enthalpy of A RH = -170 kJ/g mol the sulfonation with S03 is strongly exothermic. As the color of the acid is dependent not only on the residence time but also to a considerable extent on the reaction temperature, it is necessary to have an effective thermal dissipation. This applies to all of the reactors listed in Table 13. The falling film reactors, of which there are various designs, have the advantage that a very short residence time can be realized [152]. 

As a rule, sulfonation takes place continually in a cascade or a falling film reactor (Table 14) at about 50-70°C. The S03 is steadily diluted to a concentration of 5-10 vol % with air or an inert gas. The LAB conversion reaches a value between 92% and 98% [156,157]. Mixing of the already formed alkyl-benzenes with fresh S03 leads to undesired highly sulfonated byproducts. In order to prevent these side reactions, all processes operate concurrently. 

The process is shown schematically in Fig. 1. During the first stage of the process, a-olefins are sulfonated with diluted S03 gas in a falling film reactor. The optimum molar ratio of S03/olefin varies from 1.0 to 1.2. As the sulfonation reaction is very rapid and exothermic, the reaction temperature can rise to... 

In summary, mild sulfonation of detergent range 10 in a falling film reactor followed by direct neutralization and hydrolysis leads to an IOS system rich in sodium p-hydroxysulfonates and having low concentrations of residual sul-tones, inorganic sulfate, and free oil. 

Sulfur melting, burning, and S03 production Multitube falling film reactor (MTFFR) sulfonation Neutralization... 

Neutralization of organic acid within 1 min after sulfonation reactor. A separate aging step is not needed under commercial reactor conditions Short residence time falling film reactor required to avoid thermal breakdown of R0S03H... 

Sulfonation of the common feedstocks proceeds with a highly exothermic instantaneous initial reaction, followed by a fast but not instant step that is also highly exothermic. The second reaction does not always proceed to completion (e.g., LAB, FAME) in the lower zone of a short residence time falling film reactor (FFR). For these organic feedstocks aging under well-defined conditions of temperature and reaction time is required. 

The detergent industry requires process equipment having high operation flexibility, low energy demand, low operation cost, consistent production yield, and, of course, ecological optimization with respect to effluents and air pollution control. To comply with these requirements, the continuous S03/gas sulfonation and double-step neutralization are the basic principles applied in multitube falling film reactor and Neutrex neutralization (Fig. 5). 

The gaseous S03 stream (previously diluted with dry air to a concentration ranging from 7% to 2.5% volume) is then fed to the sulfonation/sulfation section which is based on a multitube falling film reactor having a number of tubes proportional to the plant production capacity (Figs. 8 and 9). The S03 gas is fed to the upper part of the reactor and distributed equally to each reaction tube. 

Multitubular falling film continuous SO3 sulfonation units, 23 547 Multi tubular reactors, 23 544 Multiunit pilot plants, 19 459 Multiuse facility design, 11 47 Multiuse operation, for fermentation, 11 47 Multivariable control, 20 701... 

Batch processes are currently used for the manufacture of small volume specialty sulfonates based on H2S04, oleum, CISO3H, sulfite, or SO3 reagents. Production of large volume sulfonates or alcohol sulfates generally utilize continuous S03 falling-film processes based on multitubular or concentric designed reactor systems. 

An example of a reaction performed in a falling-film reactor is the sulfonation of dodecyl benzene. 

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