Reactor decomposition

Figure 11.8 Comparison of co-current and counter-current porous membrane reactors decomposition of ammonia with a high hydrogen/nitrogen separation factor (= 50 627 C[ColUns etal., 1993)...

The problems of monomer recovery, reaction medium viscosity, and control of reaction heat are effectively dealt with by the process design of Montedison Fibre (53). This process produces polymer of exceptionally high density, so although the polymer is stiU swollen with monomer, the medium viscosity remains low because the amount of monomer absorbed in the porous areas of the polymer particles is greatly reduced. The process is carried out in a CSTR with a residence time, such that the product k jd x. Q is greater than or equal to 1. is the initiator decomposition rate constant. This condition controls the autocatalytic nature of the reaction because the catalyst and residence time combination assures that the catalyst is almost totally expended in the reactor. 

The following conditions are stipulated the catalyst decomposition rate constant must be one hour or greater the residence time of the continuous reactor must be sufficient to decompose the catalyst to at least 50% of the feed level the catalyst concentration must be greater than or equal to 0.002 x Q, where the residence time, is expressed in hours. An upper limit on the rate of radical formation was also noted that is, when the rate of radical formation is greater than the addition rate of the primary radicals to the monomers, initiation efficiency is reduced by the recombination of primary radicals. 

The same reactants are used for manufacture as for sodium fluoride. An excess of acid is required to crystallize the bifluoride. The crystals are dewatered, dried, sized, and packaged. Cooling of the reaction is necessary to avoid over-heating and decomposition. Reactors and auxiUary equipment are the same as for sodium fluoride. 

The thermal catalytic route proposed involves heating the fresh reactant feed plus recycle up to 790°C and feeding this material into a M0S2 catalyst fixed-bed reactor operating at 0.1 MPa (1 atm). The route yields a production of H2 almost 50% higher than the decomposition of H2S route. 

Both zirconium hydride and zirconium metal powders compact to fairly high densities at conventional pressures. During sintering the zirconium hydride decomposes and at the temperature of decomposition, zirconium particles start to bond. Sintered zirconium is ductile and can be worked without difficulty. Pure zirconium is seldom used in reactor engineering, but the powder is used in conjunction with uranium powder to form uranium—zirconium aUoys by soHd-state diffusion. These aUoys are important in reactor design because they change less under irradiation and are more resistant to corrosion. 

The BWR water chemistry parameters are given in Table 4 (19). Originally, no additives were made to feedwater—condensate or the primary water. The radiolytic decomposition of the fluid produced varying concentrations of O2 in the reactor vessel, ranging from about 200 ppb O2 in the reactor recirculation water to about 20 ppm O2 in the steam. Stoichiometric amounts of hydrogen were also produced, ie, 2 mL for each mL of O2. Feedwater O2 was about 30 ppb, hence the radiolytic decomposition of the water was a primary factor in determining the behavior of materials in the primary system and feedwater systems. 

Ethylbenzene Hydroperoxide Process. Figure 4 shows the process flow sheet for production of propylene oxide and styrene via the use of ethylbenzene hydroperoxide (EBHP). Liquid-phase oxidation of ethylbenzene with air or oxygen occurs at 206—275 kPa (30—40 psia) and 140—150°C, and 2—2.5 h are required for a 10—15% conversion to the hydroperoxide. Recycle of an inert gas, such as nitrogen, is used to control reactor temperature. Impurities ia the ethylbenzene, such as water, are controlled to minimize decomposition of the hydroperoxide product and are sometimes added to enhance product formation. Selectivity to by-products include 8—10% acetophenone, 5—7% 1-phenylethanol, and <1% organic acids. EBHP is concentrated to 30—35% by distillation. The overhead ethylbenzene is recycled back to the oxidation reactor (170—172). 

Pyrolysis. Benzene undergoes thermal dehydrocondensation at high temperatures to produce small amounts of biphenyls and terphenyls (see Biphenyl AND terphenyls). Before the 1970s most commercial biphenyl was produced from benzene pyrolysis. In a typical procedure benzene vapors are passed through a reactor, usually at temperatures above 650°C. The decomposition of benzene iato carbon and hydrogen is a competing reaction at temperatures of about 750°C. Biphenyls are also formed when benzene and ethylene are heated to 130—160°C ia the presence of alkaH metals on activated AI2O3 (33). 

Chlorine free radicals used for the substitutioa reactioa are obtaiaed by either thermal, photochemical, or chemical means. The thermal method requites temperatures of at least 250°C to iaitiate decomposition of the diatomic chlorine molecules iato chlorine radicals. The large reaction exotherm demands close temperature control by cooling or dilution, although adiabatic reactors with an appropriate diluent are commonly used ia iadustrial processes. Thermal chlorination is iaexpeasive and less sensitive to inhibition than the photochemical process. Mercury arc lamps are the usual source of ultraviolet light for photochemical processes furnishing wavelengths from 300—500 nm. 

Removal of metal chlorides from the bottoms of the Hquid-phase ethylene chlorination process has been studied (43). A detailed summary of production methods, emissions, emission controls, costs, and impacts of the control measures has been made (44). Residues from this process can also be recovered by evaporation, decomposition at high temperatures, and distillation (45). A review of the by-products produced in the different manufacturing processes has also been performed (46). Several processes have been developed to limit ethylene losses in the inerts purge from an oxychlorination reactor (47,48). 

Oxychlorination of Ethylene or Dichloroethane. Ethylene or dichloroethane can be chlorinated to a mixture of tetrachoroethylene and trichloroethylene in the presence of oxygen and catalysts. The reaction is carried out in a fluidized-bed reactor at 425°C and 138—207 kPa (20—30 psi). The most common catalysts ate mixtures of potassium and cupric chlorides. Conversion to chlotocatbons ranges from 85—90%, with 10—15% lost as carbon monoxide and carbon dioxide (24). Temperature control is critical. Below 425°C, tetrachloroethane becomes the dominant product, 57.3 wt % of cmde product at 330°C (30). Above 480°C, excessive burning and decomposition reactions occur. Product ratios can be controlled but less readily than in the chlorination process. Reaction vessels must be constmcted of corrosion-resistant alloys. 

Traditionally, sodium dichromate dihydrate is mixed with 66° Bh (specific gravity = 1.84) sulfuric acid in a heavy-walled cast-iron or steel reactor. The mixture is heated externally, and the reactor is provided with a sweep agitator. Water is driven off and the hydrous bisulfate melts at about 160°C. As the temperature is slowly increased, the molten bisulfate provides an excellent heat-transfer medium for melting the chromic acid at 197°C without appreciable decomposition. As soon as the chromic acid melts, the agitator is stopped and the mixture separates into a heavy layer of molten chromic acid and a light layer of molten bisulfate. The chromic acid is tapped and flaked on water cooled roUs to produce the customary commercial form. The bisulfate contains dissolved CrO and soluble and insoluble chromic sulfates. Environmental considerations dictate purification and return of the bisulfate to the treating operation. 

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