Reactor in commercial

Factors re.sponsible for the occurrence of scale-up effects can be either material factors or size/shape factors. In addition, differences in the mode of operation (batch or semibatch reactor in the laboratory and continuous reactor on the full scale), or the type of equipment (e.g. stirred-tank reactor in the laboratory and packed- or plate- column reactor in commercial unit) can be causes of unexpected scale-up effects. A simple misuse of available tools and information also can lead to wrong effects. 

Reactor design Since electrochemically promoted reactor is a chemical reactor, the design of reactors will be the main factor effecting the use of electrochemically promoted reactors in commercial scale [43]. Recently designed bipolar monolithic electrochemically promoted reactors seem to provide an attractive solution for practical applications [35,44]. 

The time-scale for the development of a nuclear reactor is long natural development and prototype operation of the reactor system known to be feasible takes 5-7 years the length of time that must elapse before a promising idea can become a nuclear reactor in commercial operation overseas is probably well over... 

The feature that is most usefiil in distinguishing commercial methanol processes from one another is the type of reactor used. The four basic types in use ate shown in Figure 7. There are a variety of proprietary reactor designs commercially available from Hcensors, all of which are either one of these four types or a combination of two among them (17—22). 

Spent fuel can be stored or disposed of intact, in a once-through mode of operation, practiced by the U.S. commercial nuclear power industry. Alternatively, spent fuel can be reprocessed, ie, treated to separate the uranium, plutonium, and fission products, for re-use of the fuels (see Nuclear REACTORS, CHEMICAL reprocessing). In the United States reprocessing is carried out only for fuel from naval reactors. In the nuclear programs of some other countries, especially France and Japan, reprocessing is routine. 

Herm/es/Djnamit JS obe/Process. On a worldwide basis, the Hercules Inc./Dynamit Nobel AG process is the dorninant technology for the production of dimethyl terephthalate the chemistry was patented in the 1950s (67—69). Modifications in commercial practice have occurred over the years, with several variations being practiced commercially (70—72). The reaction to dimethyl terephthalate involves four steps, which alternate between liquid-phase oxidation and liquid-phase esterification. Two reactors are used. Eirst, -xylene is oxidized with air to -toluic acid in the oxidation reactor, and the contents are then sent to the second reactor for esterification with methanol to methyl -toluate. The toluate is isolated by distillation and returned to the first reactor where it is further oxidized to monomethyl terephthalate, which is then esterified in the second reactor to dimethyl terephthalate. 

The demand for uranium ia the commercial sector is primarily determined by the consumption and inventory requirements of nuclear power reactors. In March 1997, there were 433 nuclear power plants operating worldwide with a combined capacity of about 345 GWe (net gigawatts electric)... 

Catalysts intended for different appHcations may require their own unique types of reactor and operating conditions, but the key to designing a successful system is to use the same feedstock composition that is expected in the ultimate commercial installation and to impose so far as is possible the same operating conditions as will be used commercially (35). This usually means a reactor design involving a tubular or smaH-bed reactor of one type or another that can simulate either commercial multitubular reactors or commercial-size catalyst beds, including radial flow reactors. 

In commercial practice, chlorination may be carried out either in batches or continuously. Glass-lined or nickel reactors may be used. Because certain metallic impurities such as iron catalyze ring chlorination and self-condensation, their presence must be avoided. The cmde product is purged of dissolved... 

Epichlorohydrin Elastomers without AGE. Polymerization on a commercial scale is done as either a solution or slurry process at 40—130°C in an aromatic, ahphatic, or ether solvent. Typical solvents are toluene, benzene, heptane, and diethyl ether. Trialkylaluniinum-water and triaLkylaluminum—water—acetylacetone catalysts are employed. A cationic, coordination mechanism is proposed for chain propagation. The product is isolated by steam coagulation. Polymerization is done as a continuous process in which the solvent, catalyst, and monomer are fed to a back-mixed reactor. Pinal product composition of ECH—EO is determined by careful control of the unreacted, or background, monomer in the reactor. In the manufacture of copolymers, the relative reactivity ratios must be considered. The reactivity ratio of EO to ECH has been estimated to be approximately 7 (35—37). 

As an example the use of ceramic membranes for ethane dehydrogenation has been discussed (91). The constmction of a commercial reactor, however, is difficult, and a sweep gas is requited to shift the product composition away from equiUbrium values. The achievable conversion also depends on the permeabihty of the membrane. Figure 7 shows the equiUbrium conversion and the conversion that can be obtained from a membrane reactor by selectively removing 80% of the hydrogen produced. Another way to use membranes is only for separation and not for reaction. In this method, a conventional, multiple, fixed-bed catalytic reactor is used for the dehydrogenation. After each bed, the hydrogen is partially separated using membranes to shift the equihbrium. Since separation is independent of reaction, reaction temperature can be optimized for superior performance. Both concepts have been proven in bench-scale units, but are yet to be demonstrated in commercial reactors. 

In the design of reactors for fluids in the presence of granular catalysts, account must be taken of heat transfer, pressure drop and contacting of the phases, and, in many cases, of provision for periodic or continuous regeneration of deteriorated catalyst. Several different lands of vessel configurations for continuous processing are in commercial use. Some reaciors with sohd catalysts are represented in Figs. 23-18 and 23-24. 

Figure 2.2.1 shows the simplified sketch of the reactor used for the microactivity test. As can be seen, a fluid-bed catalyst is tested in a fixed bed reactor in the laboratory to predict its performance in a commercial fluid bed reactor. This can be done only because enormous empirical experience exists that has accumulated throughout several decades in several hundreds of reactors both in production and in laboratories. The standard states ... 

Mass velocities are still much smaller than in production reactors, and Reynolds numbers based on particle diameter are frequently much less than 100. Consequently flow is not similar to that in commercial reactors, and heat and mass transfer are much poorer. 

Peclet number independent of Reynolds number also means that turbulent diffusion or dispersion is directly proportional to the fluid velocity. In general, reactors that are simple in construction, (tubular reactors and adiabatic reactors) approach their ideal condition much better in commercial size then on laboratory scale. On small scale and corresponding low flows, they are handicapped by significant temperature and concentration gradients that are not even well defined. In contrast, recycle reactors and CSTRs come much closer to their ideal state in laboratory sizes than in large equipment. The energy requirement for recycle reaci ors grows with the square of the volume. This limits increases in size or applicable recycle ratios. 

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