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Résultats exploitables
The prime objective was to develop, through a total Process Intensification (PI) approach, validated design tools and guidelines for aiding the design and operation of intensified chemical reactor-heat exchangers (HEX reactors) for the energy-efficient, clean processing of two-phase, liquid-liquid (L/L) fast non-isothermal reactions.
A liquid-liquid chemical reaction scheme has been developed to assess heat and mass transfer rates within HEX reactors. This chemical probe has been used to characterise the performance of commercial designs of compact heat exchangers and mixers as chemical reactors. Selected industrial liquid-liquid reactions have been studied and their sensitivity to various parameters including heat and mass transfer rates assessed.
Mathematical models, both generic and specific, have been developed, allowing simulation of the results from exothermic liquid-liquid reactions, and providing information on the interrelationships between chemistry, physical properties, and heat and mass transport. Experimental studies to provide visualisation of 2 phase flows, give droplet size distributions and quantification of heat transfer within HEX reactors have been completed.
Guidelines for the selection and design of intensified liquid-liquid chemical reactor-heat exchangers have been produced. A first paper design for a multi-channel heat exchanger reactor, incorporating direct injection of reagents into the zones of optimum mass and heat transfer has been produced, with the unit being manufactured and trials performed.
Excellent results from the operation of two industrial chemical reactions in HEX reactors have been obtained. Reaction times have been dramatically reduced, the safety of the processing operation increased, and in one case by-product levels reduced by 99%. Evidence for significant potential energy savings has been produced.
The economic and environmental benefits resulting from this project include:
-Reduction in the amounts of by-products from industrial processes.
-Reduction in energy usage for the separation and disposal of waste products.
-Lower CO2, NOx and SOx emissions.
-Recovery of high grade heat available from HEX reactors.
-Lower plant capital and operating costs for smaller, safer, continuous operation.
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