Note: Descriptions are shown in the official language in which they were submitted.
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REACTOR WITH OPTIlVIIZED INTERNAL TRAY DESIGN
Cross-Reference to Related Applications
This application claims priority to U.S. Provisional Application
Serial No. 60/731,390, filed on 10/28/2005, the disclosure of which is
incorporated herein by reference in its entirety.
Field of the Invention
The present invention relates generally to a reactor for processing a
reaction medium having a viscosity that increases as the medium flows
through the reactor. In another aspect, the present invention concerns a
polymerization reactor having a plurality of vertically-spaced internal
trays over which a polymerization reaction medium flows while the
degree of polymerization of the reaction medium is increased. =
Background of the Invention
In certain chemical processing schemes, it is desirable for chemical
reactions to take place in a reaction medium flowing in one or more
relatively thin sheets. In such a processing scheme, the reaction
progresses over an extended period of time while the sheets of reaction
medium are exposed to the requisite reaction conditions. This type of
process is particularly advantageous where the chemical reaction
produces a gaseous reaction by-product, and it is desirable to rapidly and
completely disengage such by-product from the reaction medium. For
example, if the chemical reaction producing the gaseous by-product is
reversible, failure to adequately disengage the by-product could
counteract the desired reaction. When the reaction medium flows in one
or more relatively thin sheets, the gaseous reaction by-product can rapidly
escape the reaction medium. Further, when the reaction medium flows in
one or. more relatively thin sheets, the low hydrostatic pressure on the
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bottom portion of the reaction medium minimizes boiling suppression
that can be exhibited when reactions are executed using relatively deep
reaction mediums.
Although carrying out chemical reactions in relatively thin sheets
of a reaction medium has a number of advantages, this type of process
also presents a number of challenges. For example, because thin sheets of
reaction medium require large amounts of surface area on which to flow,
very large and/or numerous reactors may be required to produce
conunercial quantities of the reaction product. Further, in many processes
employing thin sheets of reaction medium, the viscosity of the reaction
medium changes as the reaction progresses. Thus, the viscosity of the
final product may be much greater or much less than the viscosity of the
initial reaction medium. This changing viscosity of the reaction medium
presents a number of design challenges because significant variations in
the flow rate and/or depth of the reaction medium can be undesirable.
One example of a common commercial process where it is
desirable to carry out a chemical reaction in one or more relatively thin
sheets of reaction medium is in the "finishing" stage of polyethylene
terephthalate (PET) production. During the PET finishing stage,
polycondensation causes the degree of polymerization of the reaction
medium to increase significantly and also produces ethylene glycol,
acetaldehyde, and water as reaction by-products. Typically, the degree of
polymerization of the reaction medium introduced into the fmishing
reactor/zone is 20-60 while the degree of polymerization of the reaction
medium/product exiting the finishing reaction is 80-200. This increase in
the degree of polymerization of the reaction medium during finishing
causes the viscosity of the reaction medium to increase significantly. In
addition, since the polycondensation reaction associated with PET
finishing is reversible, it is desirable to disengage the ethylene glycol
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reaction by-product from the reaction medium as quickly and completely
as possible.
Thus, there exists a need for a more efficient and economical
reactor that facilitates the processing of large quantities of a reaction
medium in relatively thin sheets for extended periods of time. Further,
there exists a need for a more efficient and effective PET finishing reactor
that facilitates the polycondensation of large quantities of reaction
medium flowing in relatively uniform, thin sheets through the finishing
reactor, while providing adequate residence time to achieve the requisite
degree of polymerization.
Summary of the Invention
In accordance with one embodiment of the present invention, there
is provided a reactor comprising a plurality of vertically-spaced uni-
directional sloped trays and a plurality of vertically-spaced bi-directional
sloped trays, where the slope of the uni-directional trays increases
downwardly.
In accordance with another embodiment of the present invention,
there is provided a reactor for processing a reaction medium. The reactor
comprises a plurality of vertically-spaced sloped trays. At least some of
the trays include an upwardly-extending weir over which at least a portion
of the reaction medium flows in order to pass to the next tray located
immediately therebelow.
In accordance with still another embodiment of the present
invention, there is provided a polymerization process comprising: (a)
introducing a reaction medium into a polymerization reactor comprising a
plurality of vertically-spaced sloped trays; (b) causing the reaction
medium to flow downwardly in the polymerization reactor over the
vertically-spaced trays, wherein the average thickness of the reaction
medium flowing on the vertically-spaced trays is maintained at about 2.5
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inches or more; and (c) withdrawing the reaction medium from the
polymerization reactor, wherein the degree of polymerization of the
reaction medium withdrawn from the polymerization reactor is at least
about 25 percent greater than the degree of polymerization of the reaction
medium introduced into the polymerization reactor.
In accordance with yet another embodiment of the present
invention, there is provided a process comprising: (a) introducing a
reaction medium into an upper section of a reactor comprising a plurality
of uni-directional sloped trays and a plurality of bi-directional sloped
trays; (b) causing the reaction medium to flow downwardly in the reactor
over the uni-directional and bi-directional trays; and (c) withdrawing the
reaction medium from a lower section of the reactor.
Brief Description of the Drawing Figures
FIG. 1 is a sectional front view of a reactor for processing a
reaction medium flowing downwardly therethrough, particularly
illustrating the reactor as including two tray boxes which each house a
plurality of vertically-spaced sloped internal trays over which the reaction
medium flows as it passes downwardly through the reactor.
FIG. 2a is a sectional top view of the reactor taken along line 2a-2a
in FIG. 1, particularly illustrating the length-wise direction of flow of the
reaction medium on the top uni-directional tray.
FIG. 2b is a sectional top view of the reactor taken along line 2b-
2b in FIG. 1, particularly illustrating the length-wise direction of flow of
the reaction medium on the uni-directional tray located just below the tray
shown in FIG. 2a.
FIG. 3a is a sectional top view of the reactor taken along line 3a-3a
in FIG. 1, particularly illustrating the width-wise direction of flow of the
reaction medium on a uni-directional tray located below the length-wise
trays illustrated in FIGS. 2a and 2b.
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FIG. 3b is a sectional top view of the reactor taken along line 3b-
3b in FIG. 1, particularly illustrating the width-wise direction of flow of
the reaction medium on the uni-directional tray located just below the tray
shown in FIG. 3a.
FIG. 4a is a sectional top view of the reactor of taken along line
4a-4a in FIG. 1, particularly illustrating the directional of flow of the
reaction medium on a downwardly-diverging bi-directional roof tray
located below the uni-directional trays.
FIG. 4b is a sectional top view of the reactor of taken along line
4b-4b in FIG. 1, particularly illustrating the direction of flow of the
reaction medium on a downwardly-converging bi-directional trough tray
located just below the roof tray shown in FIG. 4a.
FIG. 5a is an enlarged front view of the pair of length-wise uni-
directional trays circumscribed with phantom lines and labeled "5" in
~ FIG. 1.
FIG. 5b is a side view of the length-wise uni-directional trays
shown in FIG. 5a.
FIG. 6a is an enlarged front view of the pair of width-wise uni-
directional trays circumscribed with phantom lines and labeled "6" in
FIG. 1.
FIG. 6b is a side view of the width-wise uni-directional trays
shown in FIG. 6a.
FIG. 7a is an enlarged front view of the pair of bi-directional trays
circumscribed with phantom lines and labeled "7" in FIG. 1.
FIG. 7b is a side view of the bi-directional trays shown in FIG. 7a.
FIG. 8a is an enlarged front view of the transition assembly
circumscribed with phantom lines and labeled "8" in FIG. 1.
FIG. 8b is a top view of the transition assembly shown in FIG. 8a.
FIG. 9 is a sectional front view of a reactor constructed in
accordance with a first alternative embodiment of the present invention,
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particularly illustrating that the reactor has only a single tray box disposed
therein.
FIG. 10 is a sectional top view of the alternative reactor taken
along line 10-10 in FIG 9, particularly illustrating the manner in which
the single tray box is positioned in the reactor.
FIG. 11 is a sectional front view of a reactor constructed in
accordance with a second alternative embodiment of the present
invention, particularly illustrating that the reactor has three tray boxes
disposed therein.
FIG. 12 is a sectional top view of the alternative reactor taken
along line 12-12 in FIG 1, particularly illustrating the manner in which
the three tray boxes are positioned in the reactor.
FIG. 13 is a sectional top view of a reactor constructed in
accordance with a third alternative embodiment of the present invention,
particularly illustrating that the reactor has six tray boxes positioned side-
by-side in the reactor.
FIG. 14 is a side view of a series of uni-directional trays
constructed in accordance with an alternative embodiment of the present
invention, particularly illustrating that a gap can be formed at the back of
the uni-directional trays to allow a portion of the reaction medium to
overflow the back of one tray and fall to the next lower tray.
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Detailed Description of the Invention
Referring initially to FIG. 1, a reactor 20 is illustrated as
comprising a vessel shell 22, a distributor 24, and two tray boxes 26a,b.
Vessel shell 22 preferably has an elongated, generally cylindrical
configuration. The length-to-diameter (L:D) ratio of vessel shell 22 is
preferably at least about 1:1, more preferably in the range of from about
2:1 to about 30:1, and most preferably in the range of from 3:1 to 10:1.
During normal operation of reactor 20, vessel shell 22 is maintained in a
substantially vertical position.
Vessel shell 22 defines an upper inlet 28 and a lower outlet 30.
Distributor 24 and tray boxes 26a,b are vertically positioned between inlet
28 and outlet 30 so that reaction medium entering reactor 20 via inlet 28
can flow downwardly through distributor 24 and tray boxes 26a,b before
being discharged from reactor 20 via outlet 30.
When reactor 20 includes a plurality of tray boxes 26a,b,
distributor 24 is used to divide and distribute the flow of the incoming
reaction medium so that each tray box 26a,b receives and processes
substantially the same amount of the reaction medium. If reactor 20 were
to employ only one tray box, then the distributor would not divide the
flow of the reaction medium, but would still act to properly distribute the
reaction medium into the inlet of the tray box.
In the embodiment illustrated in FIGS. 1-8, reactor 20 includes two
substantially identical tray boxes 26a,b. The following section will
describe the configuration of only one tray box 26a with the
understanding that all the tray boxes 26a,b have substantially the same
configuration.
Referring to FIGS. I and 2a, tray box 26a includes a plurality of
upright sidewalls 27a,b,c,d which define a generally rectangular internal
space. Tray box 26a also includes a plurality of vertically-spaced sloped
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trays received in the internal space and rigidly coupled to sidewalls
27a,b,c,d. The internal space defined by sidewalls 27a,b,c,d is open at the
top and bottom so that the reaction medium can enter the top of tray box
26a, flow downwardly through the internal space over the sloped trays,
and exit the bottom of tray box 26a. Preferably, tray box 26a includes at
least about 10 trays, more preferably at least about 20 trays, and most
preferably in the range of from 30 to 100 trays. Of course, the preferred
total number of trays in the reactor 20 is simply the number of trays in
one tray box times the number of tray boxes in the reactor 20. The slope
of the trays generally increases downwardly in reactor 20 to
accommodate the increasing viscosity of the reaction medium as it flows
downwardly over the trays.
Referring again to FIG. 1, it is preferred for tray box 26a to include
trays with different configurations and/or orientations to optimize flow of
the reaction medium therethrough. Preferably, tray box 26a includes a
plurality of uni-directional trays 32 and a plurality of bi-directional trays
34. As used herein, the term "uni-directional tray" means a tray that
slopes in only one direction so that fluid flowing in the tray box at the
elevation of that tray flows only in one direction. As used herein, the
term "bi-directional tray" means a tray that slopes in two directions so
that fluid flowing in the tray box at the elevation of that tray flows in two
directions. In a preferred embodiment of the present invention, at least a
portion of the uni-directional trays 32 are located above at least a portion
of the bi-directional trays 34. Most preferably, all of the uni-directional
trays 32 are located above all of the bi-directional trays 34. Preferably,
tray box 26a includes at least about 5 uni-directional trays, more
preferably at least about 10 uni-directional trays, and most preferably in
the range of from 15 to 50 uni-directional trays. Preferably, tray box 26a
includes at least about 5 bi-directional trays, more preferably at least
about 10 bi-directional trays, and most preferably in the range of from 15
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to 50 bi-directional trays. Preferably, at least about 10 percent of all of
the trays in tray box 26a are uni-directional trays, more preferably at least
about 20 percent are uni-directional trays, and most preferably in the
range of from 30 percent to 80 percent are uni-directional trays.
Preferably, at least about 10 percent of all the trays in tray box 26a are bi-
directional trays, more preferably at least about 20 percent are bi-
directional trays.
As illustrated in FIG. 1, tray box 26a preferably includes an upper
set 36 and a lower set 38 of uni-directional trays 32. Upper set 36 of uni-
directional trays 32 preferably includes a plurality of length-wise sloped
trays 40. Lower set 38 of uni-directional trays 32 preferably includes a
plurality of width-wise sloped trays 42. As shown by the arrows in FIGS.
2 and 3, it is preferred for each uni-directional tray 32 to be elongated -
with length-wise sloped trays 40 (FIG. 2) being sloped in the direction of
tray elongation, while width-wise sloped trays 42 (FIG. 3) are sloped
perpendicular to the direction of tray elongation. As illustrated in FIGS. 2
and 3, the directions of slope of length-wise sloped trays 40 and width-
wise sloped trays 42 are substantially perpendicular to one another.
As illustrated in FIGS. 1, 2, and 5, vertically adjacent length-wise
sloped trays 40a,b are sloped in generally opposite directions so that the
reaction medium is forced to flow back and forth over length-wise sloped
trays 40 as it progresses downwardly in reactor 20. As illustrated in
FIGS. 2 and 5, each length-wise sloped tray 40 includes a substantially
flat, substantially rectangular main member 44 and a weir 46. In the
embodiment illustrated in FIGS. 1-6, three sides of main member 44 are
preferably coupled to and sealed along three of the four sidewalls 27 of
the tray box 26a, while a gap 47 (FIG. 2a,b and 5b) is formed between the
fourth side of main member 44 and the remaining sidewall 27 of tray box
26a. Gap 47 provides a passageway though which the reaction medium
can fall downwardly onto the next lower length-wise sloped tray 40.
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Main member 44 is sloped downwardly so that the reaction medium can
flow by gravity towards weir 46. The downward slope of main member
44 is preferably in the range of from about 0.5 to about 10 degrees from
horizontal, most preferably in the range of from 1 to 4 degrees from
horizontal.
Referring again to FIGS. 2 and 5, main member 44 presents a
generally flat, upwardly-facing upper surface. Main member 44
preferably has substantially no openings therein so that all liquid flowing
on tray 40 must pass over/through weir 46 in order to leave tray 40. Weir
46 extends upwardly from the upper surface of main member 44
proximate the lowest elevation of main member 44. Preferably, weir 46
is spaced less than about 6 inches from the terminal edge of main member
44, more preferably less than about 3 inches, and most preferably less
than 2 inches. Preferably, weir 46 extends all the way along the width of
length-wise sloped tray 40, from sidewall 27a to sidewall 27c. Weir 46
helps maintain a substantially uniform sheet of reaction medium on tray
40. Preferably, weir 46 has a height of at least about 2.5 inches. More
preferably, the height of weir 46 is in the range of from 3 to 12 inches.
As illustrated in FIG. 5a, a plurality of relatively small weir openings 48
are preferably formed near the bottom of weir 46, adjacent main member
44. Weir openings 48 permit a relatively small quantity of reaction
medium to flow therethrough during normal operation of reactor 20.
During shutdown of reactor 20, weir openings 48 allow substantially all
of the reaction medium to be drained off of trays 40, so that a pool of the
reaction medium does not remain trapped behind weir 46 when reactor 20
is shut down.
As illustrated in FIGS. 1, 3, and 6, vertically adjacent width-wise
sloped trays 42a,b are sloped in generally opposite directions so that a
reaction medium is forced to flow back and forth over width-wise sloped
trays 42 as it progresses downwardly in reactor 20. As illustrated in
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FIGS. 3 and 6, each width-wise sloped tray 42 includes a substantially
flat, substantially rectangular main member 50 and a weir 52. Three sides
of main member 44 are coupled to and sealed along three of the four
sidewalls 27 of tray box 26a, while a gap 53 (FIGs. 3a,b and 6a) is formed
between the fourth side of main member 50 and the remaining sidewall
27 of tray box 26a. Gap 53 provides a passageway though which the
reaction medium can fall downwardly onto the next lower width-wise
sloped tray 42. Main member 50 is sloped so that the reaction medium
can flow by gravity downwardly towards weir 52. The downward slope
of width-wise sloped trays 42 increases downwardly in reactor 20.
Preferably, the uppermost one of the width-wise sloped trays 42 has a
downward slope in the range of from about 0.5 to about 10 degrees from
horizontal, most preferably in the range of from 1 to 4 degrees from
horizontal. Preferably, the lowermost one of the width-wise sloped trays
42 has a downward slope in the range of from about 2 to about 20 degrees
from horizontal, most preferably in the range of from 4 to 10 degrees
from horizontal. Preferably, the downward slope of the lowermost one of
the width-wise sloped trays 42 is at least about 1 degree greater than the
downward slope of the uppermost one of the width-wise sloped trays 42,
more preferably at least about 2 degrees greater than the downward slope
of the uppermost one of the width-wise sloped trays 42, and most
preferably in the range of from 4 to 10 degrees greater than the downward
slope of the uppermost one of the width-wise sloped trays 42.
Referring again to FIGS. 3 and 6, main member 50 preferably has
substantially no openings therein so that all liquid flowing on tray 42
must pass over/through weir 52 in order to leave tray 42. Main member
50 presents a generally upwardly-facing upper surface. Weir 52 extends
upwardly from the upper surface of main member 50 proximate the
lowest elevation of main member 50. Preferably, weir 52 is spaced from
the terminal edge of main member 50 by a distance of less than about 6
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inches, more preferably less than about 3 inches, and most preferably less
than 1 inch. Preferably, weir 52 extends all the way between sidewall 27b
and sidewall 27d. Weir 52 helps maintain a substantially uniform sheet
of reaction medium on tray 42. Preferably, weir 52 has a height of at least
about 2.5 inches. More preferably, the height of weir 52 is in the range
of from 3 to 12 inches. As illustrated in FIG. 6b, a plurality of relatively
small weir openings 54 are preferably formed near the bottom of weir 52,
adjacent main member 50. Weir openings 54 permit a relatively small
quantity of reaction medium to flow therethrough during normal
operation of reactor 20. During shutdown of reactor 20, weir openings 54
allow substantially all of the reaction medium to be drained off of trays
42, so that a pool of the reaction medium does not remain trapped behind
weir 52 when reactor 20 is shut down.
In one embodiment of the present invention, at least 5 of the uni-
directional trays 32 are equipped with a weir, more preferably at least 10
of the uni-directional trays 32 are equipped with a weir. Preferably, at
least 10 percent of all the uni-directional trays 32 in tray box 26a are
equipped with a weir, more preferably at least 33 percent of the uni-
directional trays 32 are equipped with a weir, and most preferably at least
66 percent of the uni-directional trays 32 are equipped with a weir.
The weir can help provide more residence time in the inventive
reactor than in conventional designs, while requiring equivalent or less
reactor volume, trays, and/or metal surfaces. Further, the weirs can help
provide a thicker sheet of reaction medium on the trays than conventional
PET finisher designs. Also, it should be noted that the embodiments
described herein advantageously provide thinner sheets of reaction
medium falling downwardly from tray to tray and thicker sheets of
reaction medium on the trays.
As illustrated in FIGS. 1, 4, and 7, bi-directional trays 34 are
coupled to and extend between sidewalls 27b,d of box tray 26a. Bi-
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directional trays 34 include alternating roof trays 34a and trough trays
34b. As perhaps best illustrated in FIGS. 4a and 7a, each bi-directional
roof tray 34a includes an upright divider member 56 and a pair of
downwardly sloping roof members 58,60 extending in generally opposite
directions from the bottom of divider member 56. Roof members 58,60
diverge from one another as they extend downwardly and outwardly from
divider member 56. A first gap 62 is formed between the terminal edge
of roof member 58 and sidewall 27a. A second gap 64 is formed between
the terminal edge of roof member 60 and sidewall 27c. The reaction
medium flows downwardly through gaps 62,64 in order to reach the next
lower bi-directional trough tray 34b.
Referring now to FIGS. 4b and 7a, each bi-directional trough tray
34b includes a pair of downwardly sloping trough members 66,68
coupled to and extending inwardly from sidewalls 27a,c of tray box 26a.
Trough members 66,68 converge towards one another as they extend
downwardly and inwardly from sidewalls 27a,c. A gap 70 is formed
between the lower terminal edges of trough members 66,68. Gap 70 is
sufficiently large to allow the separate sheets of reaction medium flowing
on trough members 66,68 to remain separate as they fall through gap 70
to the next lower roof tray 34a. The separate portions of the reaction
medium that flow on trough members 66,68 fall downwardly through gap
70 on opposite sides of the dividing member 56 of the next lower roof
tray 34a.
In a preferred embodiment of the present invention, the slope of
the bi-directional trays 34 increase downwardly in reactor 20. Preferably,
the uppermost one of the bi-directional trays 34 has a downward slope in
the range of from about 0.5 to about 10 degrees from horizontal, most
preferably in the range of from 1 to 4 degrees from horizontal.
Preferably, the lowermost one of the bi-directional trays 42 has a
downward slope in the range of from about 5 to about 40 degrees from
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horizontal, most preferably in the range of from 10 to 25 degrees from
horizontal. Preferably, the downward slope of the lowermost one of the
bi-directional trays 34 is at least about 2 degrees greater than the
downward slope of the uppermost one of the bi-directional trays 34, more
preferably at least about 4 degrees greater than the downward slope of the
uppermost one of the bi-directional trays 34, and most preferably in the
range of from 6 to 20 degrees greater than the downward slope of the
uppermost one of the bi-directional trays 34.
Referring now to FIGS. 1 and 8, a transition member 72 is
employed to transition the flow of the reaction medium from single sheet
flow on uni-directional trays 32 to double sheet flow on bi-directional
trays 34. Transition member 74 is coupled to and extends between
sidewalls 27b,d of tray box 26a. Transition member 74 includes an upper
distribution bin 76 and a lower distribution tray 78. Distribution bin 76 is
operable to receive the reaction medium from the lower most uni-
directional tray 32 and split the reaction medium into two substantially
equal portions. The two equal portions of reaction medium are
discharged from the bottom of distribution bin 76 onto separate diverging
sections 80a,b of distribution tray 78. In the same manner, subsequent
splits in the flow exiting from downstream bi-directional trays is possible
using similar distribution boxes. In this manner, multiple bi-directional
pathways can be created if required by viscosity, flowrate, and liquid
depth targets.
Distribution bin 76 includes a pair of sloping sidewalls 82a,b
which converge downwardly towards one another. A divider line 84 is
defined at the location where sidewalls 82a,b join one another. A
plurality of first openings 86a are defined in sidewall 82a proximate
divider line 84. A plurality of second openings 86b are defined in
sidewall 82b proximate divider line 84. Preferably, transition member 78
includes a total of at least about 10 openings 86a,b. As best illustrated in
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FIG 8b, first and second openings 86a,b are located on opposite sides of
divider line 84. Preferably, the cumulative open area defined by first
openings 86a is substantially equal to the cumulative open area defined by
second openings 86b, so that equal amounts of reaction medium
automatically flow through first and second openings 86a,b. First
openings 86a are aligned over first section 80a of distribution tray 78,
while second openings 86b are aligned over second section 80b of
distribution tray 78.
As shown in FIGS. 8a,b, the terminal edges of first and second
sloping sections 80a,b, of distribution tray 78 are spaced from sidewalls
27a,c so that gaps 88a,b are formed therebetween. The two substantially
equal portions of reaction medium discharged from distribution bin 76
flow on downwardly-sloping diverging sections 80a,b of distribution tray
78 toward gaps 88a,b. The separate portions of the reaction medium then
fall off of distribution tray 78, through gaps 88a,b, and onto the
uppermost converging bi-directional tray 34b. As mentioned above, the
two substantially equal portions of the reaction medium are then kept
separate as they flow downwardly over bi-directional trays 34.
Referring now to FIGS. 9 and 10, a first alternative reactor design
is illustrated. Alternative reactor 100 includes only a single tray box 102.
This design has the advantage of not needing to split the feed equally
among multiple tray boxes. Thus, the construction of distributor 104 is
simplified. Also, the total number of trays, distribution of different types
of trays, number or weirs, location of weirs, and slope trays in reactor 100
are different than that of reactor 20 (FIGS 1-8). These differences
illustrate that it may be desirable to vary the design of the reactor to meet
the particular requirements of the process within which it is implemented.
However, all designs disclosed herein are within the ambit of the present
invention.
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Referring now to FIGS. 11 and 12, a second alternative reactor
design is illustrated. Alternative reactor 200 includes three tray boxes
202a,b,c.
Referring now to FIG. 13, a third alternative reactor design is
illustrated. Alternative reactor 300 includes six tray boxes 302. This
design has the advantage of using more space within the reaction vessel,
so the size of the reaction vessel can be reduced.
Referring now to FIG. 14, an alternative uni-directional tray design
is illustrated. The uni-directional trays 400 illustrated in FIG. 14 are
similar to those illustrated in FIGS. 5 and 6, but are configured to provide
a gap 402 between the back 404 of each uni-directional tray 400 and the
nearest sidewall 406 of the tray box. It should be understood that
sidewall 406 need not be a wall of the tray box with the trays 400 are
associated; rather, sidewall 406 can be the wall of another tray box or the
wall of the reactor vessel. As illustrated in FIG. 14, this gap 402 between
the back 404 of each tray 400 and the nearest sidewall 406 allows a
portion of the processed reaction medium 408 to overflow the back 404 of
the tray 400 and fall downwardly to the next lower tray 400. In order to
provide a sufficiently large opening for passage of the overflowing
reaction medium 408, it is preferred for the gap 402 between the back 404
of the trays 400 and the nearest sidewall 406 to have an average width of
at least about 1 inch, more preferably in the range of from about 1.5 to
about 12 inches, and most preferably in the range of from 2 to 8 inches.
In the embodiment illustrated in FIG. 14, it is preferred for the
back 404 of each uni-directional tray 400 to include a rounded lower edge
410 that permits the overflowing reaction medium 408 to "cling" to the
upper tray 400 until it is positioned over at least a portion of the next
lowest tray 400. Once positioned over the next lowest tray 400, the
reaction medium 408 falls from the upper tray 400 to the lower tray 400,
where it is recombined with the portion of the reaction medium 408 that
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flowed over the terminal edge 412 of the upper tray 400 and onto the
lower tray 400. In order to allow the overflowing reaction medium to
cling to the upper tray 400 until positioned over the lower tray 400, it is
preferred for the rounded lower edge 410 of the uni-directional trays 400
to have a minimum radius of curvature of at least 1 inch, more preferably
in the range of from about 1.5 to about 12 inches, and most preferably in
the range of from 2 to 8 inches.
It should also be noted that the embodiment illustrated in FIG. 14
employs uni-directional trays 400 without weirs. Thus, the terminal
edges 412 of the trays 400 illustrated in FIG. 14 are defined by an edge of
the substantially flat main member 414 of the trays 400, rather than by the
upper edge of a weir. However, it is contemplated that the back-overflow
design illustrated in FIG. 14 is also suitable for use with trays having
weirs.
The reactors illustrated in FIGS. 1-14 can be employed in a variety
of different processes. These reactors are particularly useful in processes
where it is advantageous for chemical reactions to take place in relatively
thin sheets of a reaction medium. Further, these reactors are designed to
accommodate the situation where the viscosity of the reaction medium
increases during processing. In a preferred embodiment of the present
invention, the dynamic viscosity (measured in poise) of the reaction
medium exiting the reactor is at least about 50 percent greater than the
dynamic viscosity of the reaction medium entering the reactor, more
preferably at least about 250 percent greater than the dynamic viscosity of
the reaction medium entering the reactor, and most preferably at least
1,000 percent greater than the dynamic viscosity of the reaction medium
entering the reactor. Preferably, the reactor(s) described above are
polymerization reactors employed to process a reaction medium
undergoing polymerization.
CA 02625449 2008-04-11
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In a particularly preferred process, the reactor is employed in a
process for producing polyethylene terephthalate (PET). In such a
process, the reaction medium entering the reactor preferably has a degree
of polymerization (DP) in the range of from about 20 to about 75, more
preferably in the range of from about 35 to about 60, and most preferably
in the range of from 40 to 55. As used herein, "degree of polymerization"
or "DP" means number-average degree of polymerization, which is
defined as the number-average polymer molecular weight divided by the
repeat unit molecular weight. As the reaction medium flows downwardly
through the reactor, the DP of the reaction medium increases due to
polycondensation. Preferably, the DP of the reaction medium exiting the
reactor is at least about 25 percent greater than the DP of the reaction
medium entering the reactor, more preferably in the range of from about
50 to about 500 percent greater than the DP of the reaction medium
entering the reactor, and most preferably in the range of from 80 to 400
percent greater than the DP of the reaction medium entering the reactor.
Preferably, the reaction medium exiting the reactor has a DP in the range
of from about 75 to about 200, more preferably in the range of from about
90 to about 180, and most preferably in the range of from 105 to 165.
In a preferred embodiment of the present invention, the reaction
conditions in the reactor are maintained at a temperature in the range of
from about 250 to about 325 C and a pressure in the range of from about
0.1 to about 4 torr, more preferably at a temperature in the range of from
about 270 to about 310 C and a pressure in the range of from about 0.2 to
about 2 torr, and most preferably at a temperature in the range of from
275 to 295 C and a pressure in the range of from 0.3 to about 1.5 torr.
The mean residence time of the reaction medium in the reactor is
preferably in the range of from about 0.25 to about 5 hours, most
preferably in the range of from 0.5 to 2.5 hours.
CA 02625449 2008-04-11
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The reactor configuration described above with reference to FIGS.
1-14 is preferably operable to maintain an average depth of the reaction
medium on the trays of at least about 2.5 inches, most preferably in the
range of from 3 to 12 inches.
The inventors note that for all numerical ranges provided herein,
the upper and lower ends of the ranges can be independent of one another.
For example, a numerical range of 10 to 100 means greater than 10 and/or
less than 100. Thus, a range of 10 to 100 provides support for a claim
limitation of greater than 10 (without the upper bound), a claim limitation
of less than 100 (without the lower bound), as well as the full 10 to 100
range (with both upper and lower bounds).
The invention has been described in detail with particular reference
to preferred embodiments thereof, but will be understood that variations
and modification can be effected within the spirit and scope of the
invention.
