Scale-up of a packed bubble column reactor: From semi-batch to continuous mode in an industrial plant

Abstract

<span style="font-size:11.0pt;line-height:115%; font-family:" calibri","sans-serif";mso-fareast-font-family:"dejavu="" sans";="" mso-bidi-font-family:arial;mso-ansi-language:en-us;mso-fareast-language:en-us;="" mso-bidi-language:ar-sa"="">A simplified approach to the model development and scale-up of a packed bubble column reactor from pilot semi-batch mode to continuous commercial operation has been presented. This is illustrated by choosing the reaction of ethynylation of formaldehyde to 1,4-butynediol for which correct reaction mechanism is difficult to postulate in the compelling safety limitations. The apparent reaction kinetics has been determined ·from the semi-batch pilot data for previous catalyst charges. The true kinetics has been predicted taking into account the gas-liquid, liquid-solid mass transfer and axial dispersion effects and has been expressed as a function of catalyst loading, temperature and 'age' of the catalyst. The actual conversion from the commercial reactor system was found to match the model prediction reasonably well.</span>