Slurry Reactor

Slurry reactor
Contents:
 Introduction to Slurry Reactors
 Types & Construction
 Operation and Working
 Start up and Shut down
 Trouble shooting
 Advantages & disadvantages
 Applications
 Incident
Introduction to Slurry Reactors
Slurry reactors are three-phase reactors, meaning they can be used to react
solids, liquids, and gases simultaneously. They usually consist of a catalyst (solid)
suspended in a liquid, through which a gas is bubbled. They can operate in either
semi-batch or continuous mode.
The slurry phase Fischer-Tropsch reactor pictured below is used in a gas-to-liquid

(GTL) process plant to convert natural gas into GTL diesel.
Slurry reactors are three phase reactors (solid/liquid/gas). Pictured below is a

slurry reactor used in the production of polyethylene products.
Types of slurry reactor:
There are following types of slurry reactor;
 Bubble Column Reactor

 Fischer Tropsch Reactor
 Slurry Batch Reactor
Bubble Column Reactor:

A bubble column reactor is an apparatus used to generate and control gas-liquid
chemical reactions. It consists of a vertically-arranged cylindrical column filled
with liquid, at the bottom of which gas is inserted.
Principle:
The introduction of gas takes place at the bottom of the column and causes a
turbulent stream to enable an optimum gas exchange. Numerous forms of
construction exist. The mixing is done by the gas sparging and it requires less
energy than mechanical stirring. The liquid can be in parallel flow or counter-
current.
Bubble column reactors are characterized by a high liquid content and a

moderate phase boundary surface. The bubble column is particularly useful in
reactions where the gas-liquid reaction is slow in relation to the absorption rate.
This is the case for gas-liquid reactions with a Hatta number Ha <0.3.
Bubble column reactors are used in various types of chemical reactions like wet
oxidation, or as algae bioreactor. Since the computerized design of bubble
columns is restricted to a few partial processes, experience in the choice of a
particular type column still plays an important role.
Fischer Tropsch Reactor:
The Fischer–Tropsch process is a collection of chemical reactions that converts a
mixture of carbon monoxide and hydrogen into liquid hydrocarbons. It was first
developed by Franz Fischer and Hans Tropsch at the Kaiser-Wilhelm-Institut für
Kohlenforschung in Mülheim an der Ruhr, Germany, in 1925. The process, a key
component of gas to liquids technology, produces a synthetic lubrication oil and
synthetic fuel, typically from coal, natural gas, or biomass.[1] The Fischer–Tropsch
process has received intermittent attention as a source of low-sulfur diesel fuel
and to address the supply or cost of petroleum-derived hydrocarbons. A Fischer–
Tropsch-type process has also been suggested to have produced a few of the
building blocks of DNA and RNA within asteroids
Principle:
Generally, the Fischer–Tropsch process is operated in the temperature range of
150–300 °C (302–572 °F). Higher temperatures lead to faster reactions and higher
conversion rates but also tend to favor methane production. For this reason, the
temperature is usually maintained at the low to middle part of the range.
Increasing the pressure leads to higher conversion rates and also favors formation
of long-chained alkanes, both of which are desirable. Typical pressures range from
one to several tens of atmospheres. Even higher pressures would be favorable,
but the benefits may not justify the additional costs of high-pressure equipment,
and higher pressures can lead to catalyst deactivation via coke formation.
Reaction mechanism:
The Fischer–Tropsch process involves a series of chemical reactions that produce
a variety of hydrocarbons, ideally having the formula (CnH2n+2). The more useful
reactions produce alkanes as follows:
(2n + 1) H2 + n CO → CnH2n+2 + n H2O
where n is typically 10–20. The formation of methane (n = 1) is unwanted. Most of

the alkanes produced tend to be straight-chain, suitable as diesel fuel. In addition
to alkane formation, competing reactions give small amounts of alkenes, as well
as alcohols and other oxygenated hydrocarbons
Several reactions are necessary:

 Associative adsorption of CO
 Splitting of the C–O bond
 Dissociative adsorption of 2 H2
 Transfer of 2 H to the oxygen to yield H2O
 Desorption of H2O
 Transfer of 2 H to the carbon to yield CH2
Slurry Batch Reactor:
The diagram below shows the synthesis of methanol in a slurry batch reactor.
Syngas enters at the bottom of the reactor into heated mineral oil. The gas then
reacts with the assistance of suspended catalyst to form the methanol product.
Unreacted gas and methanol vapor exit though the top of the reactor. Once out
of the reactor, the methanol is condensed to a liquid.
Whole process of Slurry Batch Reactor shown in fig..

rotor
H2 from reservoir
(consumption measured)
P to heat source
pressure
vessel
shaft heater
liquid
product
withdrawal reactants + H 2
suspended products
catalyst
particles H2
Construction of slurry reactor:
Sparger:
Used to introduce air in reactor.
Install at the bottom, consist of tube and holes for escape air and gases.
Cooling Coils:
Water is circulated through
these coils to lower the temperature
inside the reaction vessel.
Probes:
Heat transfer probes
Mass Transfer Probes
Bubble size measurement probe
Temperature probe
Hydro-cloning Section:
Hydro-cloning section is attached separate to the vessel.
A Hydro-clone is a static device that applies centrifugal force to a liquid
mixture so as to promote the separation of heavy and light components.
Operation and Working:
The diagram below shows the synthesis of methanol in a slurry batch reactor.
Syngas enters at the bottom of the reactor into heated mineral oil. The gas then
reacts with the assistance of suspended catalyst to form the methanol product.
Unreacted gas and methanol vapor exit though the top of the reactor. Once out
of the reactor, the methanol is condensed to a liquid.
ADVANTAGES DISADVANTAGES
 Good temperature control.  Reactor may plug up.
 Good heat recovery.  Uncertainties in design process.
 Constant overall catalytic activity  Finding suitable liquids may be
maintained easily by addition of
difficult.
small amount of catalyst.
 Useful for catalysts that can't be  Higher ratio of liquid to catalyst
pelletized. than in other reactors.
 Large heat capacity of reactor acts
as a safety feature against
explosions.
Applications:
Stack gas scrubbing with lime or magnesia.
Waste water treatment.
Ethylene oxychlorination.
Oxidation of toluene to benzoic acid.
Ethylene oxidation to acetaldehyde.
Olefin polymerization using catalyst suspension.
Fatty oil hydrogenation with catalytic suspension.

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What are the different types of slurry reactors discussed?

How does a bubble column reactor work?

Slurry reactor

 Types & Construction

 Operation and Working

 Start up and Shut down

 Advantages & disadvantages

The slurry phase Fischer-Tropsch reactor pictured below is used in a gas-to-liquid

Slurry reactors are three phase reactors (solid/liquid/gas). Pictured below is a

 Bubble Column Reactor

Bubble Column Reactor:

Bubble column reactors are characterized by a high liquid content and a

(2n + 1) H2 + n CO → CnH2n+2 + n H2O

where n is typically 10–20. The formation of methane (n = 1) is unwanted. Most of

Several reactions are necessary:

Whole process of Slurry Batch Reactor shown in fig..

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