反(fan)應(ying)(ying)(ying)過程的基本(ben)特征決定(ding)(ding)了適宜的反(fan)應(ying)(ying)(ying)器(qi)(qi)形式。例(li)如氣固相(xiang)反(fan)應(ying)(ying)(ying)過程大(da)致是用固定(ding)(ding)床(chuang)反(fan)應(ying)(ying)(ying)器(qi)(qi)、流化(hua)床(chuang)反(fan)應(ying)(ying)(ying)器(qi)(qi)或移動(dong)床(chuang)反(fan)應(ying)(ying)(ying)器(qi)(qi)。但(dan)是適宜的選型則需考慮反(fan)應(ying)(ying)(ying)的熱效應(ying)(ying)(ying)、對反(fan)應(ying)(ying)(ying)轉化(hua)率和(he)選擇率的要(yao)求、催化(hua)劑物理化(hua)學性態和(he)失活等(deng)多種因素。
不銹鋼反(fan)應(ying)(ying)器(qi)的(de)(de)(de)操(cao)作方(fang)式(shi)和加料(liao)方(fang)式(shi)也需考慮。例如，對(dui)于(yu)有串聯或平(ping)行副(fu)反(fan)應(ying)(ying)的(de)(de)(de)過程，分段進料(liao)可(ke)能優于(yu)一次進料(liao)。溫(wen)度(du)序(xu)列(lie)也是反(fan)應(ying)(ying)器(qi)選型(xing)的(de)(de)(de)一個重(zhong)要因素。例如，對(dui)于(yu)放熱(re)的(de)(de)(de)可(ke)逆(ni)反(fan)應(ying)(ying)，應(ying)(ying)采用先高后低的(de)(de)(de)溫(wen)度(du)序(xu)列(lie)，多級、級間(jian)換熱(re)式(shi)反(fan)應(ying)(ying)器(qi)可(ke)使反(fan)應(ying)(ying)器(qi)的(de)(de)(de)溫(wen)度(du)序(xu)列(lie)趨于(yu)合理。
下面主(zhu)要介紹釜式(shi)反(fan)應器(qi)、管式(shi)反(fan)應器(qi)、塔式(shi)反(fan)應器(qi)、固定床(chuang)反(fan)應器(qi)、流化(hua)床(chuang)反(fan)應器(qi)。
①. 釜式反應器
釜(fu)(fu)式(shi)反應(ying)(ying)(ying)器(qi)也稱槽式(shi)、鍋式(shi)反應(ying)(ying)(ying)器(qi)，它是各類反應(ying)(ying)(ying)器(qi)中(zhong)結(jie)構較(jiao)(jiao)為(wei)簡(jian)單(dan)且應(ying)(ying)(ying)用(yong)(yong)(yong)較(jiao)(jiao)廣(guang)的一種(zhong)。主要應(ying)(ying)(ying)用(yong)(yong)(yong)于液-液均(jun)相反應(ying)(ying)(ying)過(guo)(guo)程，在(zai)(zai)氣-液、液-液非均(jun)相反應(ying)(ying)(ying)過(guo)(guo)程中(zhong)也有應(ying)(ying)(ying)用(yong)(yong)(yong)。在(zai)(zai)化工生產(chan)中(zhong)，既適用(yong)(yong)(yong)于間(jian)歇操作(zuo)(zuo)過(guo)(guo)程，又可單(dan)釜(fu)(fu)或(huo)多釜(fu)(fu)串聯用(yong)(yong)(yong)于連(lian)續操作(zuo)(zuo)過(guo)(guo)程，但在(zai)(zai)間(jian)歇生產(chan)過(guo)(guo)程中(zhong)應(ying)(ying)(ying)用(yong)(yong)(yong)最多。釜(fu)(fu)式(shi)反應(ying)(ying)(ying)器(qi)具有適用(yong)(yong)(yong)的溫度(du)和(he)壓力(li)范圍寬、適應(ying)(ying)(ying)性(xing)強、操作(zuo)(zuo)彈性(xing)大、連(lian)續操作(zuo)(zuo)時(shi)(shi)溫度(du)濃(nong)度(du)容易控制、產(chan)品質量均(jun)一等特點(dian)。但用(yong)(yong)(yong)在(zai)(zai)較(jiao)(jiao)高轉化率工藝要求(qiu)時(shi)(shi)，需要較(jiao)(jiao)大容積。通常在(zai)(zai)操作(zuo)(zuo)條(tiao)件比較(jiao)(jiao)緩和(he)的情況(kuang)下使用(yong)(yong)(yong)，如(ru)常壓、溫度(du)較(jiao)(jiao)低且低于物料(liao)沸點(dian)時(shi)(shi)，應(ying)(ying)(ying)用(yong)(yong)(yong)此類反應(ying)(ying)(ying)器(qi)最為(wei)普遍。
②. 管(guan)式反應器
管(guan)(guan)式(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器主要用(yong)(yong)(yong)于氣相(xiang)(xiang)、液相(xiang)(xiang)、氣-液相(xiang)(xiang)連(lian)續(xu)(xu)(xu)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)過程，由單根(gen)（直管(guan)(guan)或(huo)(huo)盤管(guan)(guan)）連(lian)續(xu)(xu)(xu)或(huo)(huo)多(duo)根(gen)平行排列的(de)(de)管(guan)(guan)子組成，一般設有(you)套管(guan)(guan)或(huo)(huo)殼管(guan)(guan)式(shi)換熱裝置。操作(zuo)時，物料(liao)自一端連(lian)續(xu)(xu)(xu)加入，在管(guan)(guan)中連(lian)續(xu)(xu)(xu)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)，從另一端連(lian)續(xu)(xu)(xu)流出，便達(da)到了要求的(de)(de)轉(zhuan)化(hua)率。由于管(guan)(guan)式(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器能承受較高的(de)(de)壓力，故用(yong)(yong)(yong)于加壓反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)尤為合(he)適，例如油(you)脂(zhi)或(huo)(huo)脂(zhi)肪酸加氫生(sheng)產高碳醇、裂解(jie)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)用(yong)(yong)(yong)的(de)(de)管(guan)(guan)式(shi)爐便是(shi)管(guan)(guan)式(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器。此(ci)種反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器具有(you)容積小、比表面大(da)、返混(hun)少、反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)混(hun)合(he)物連(lian)續(xu)(xu)(xu)性變化(hua)、易于控(kong)制(zhi)等優點。但若反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)速度較慢時，則有(you)所(suo)需管(guan)(guan)子長(chang)(chang)、壓降較大(da)等不足(zu)。隨著化(hua)工生(sheng)產越(yue)來(lai)越(yue)趨于大(da)型化(hua)、連(lian)續(xu)(xu)(xu)化(hua)、自動(dong)化(hua)，連(lian)續(xu)(xu)(xu)操作(zuo)的(de)(de)管(guan)(guan)式(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器在生(sheng)產中使用(yong)(yong)(yong)越(yue)來(lai)越(yue)多(duo)，某些傳統上一直使用(yong)(yong)(yong)間歇攪拌釜(fu)(fu)的(de)(de)高分子聚合(he)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)，目前也開始改用(yong)(yong)(yong)連(lian)續(xu)(xu)(xu)操作(zuo)的(de)(de)管(guan)(guan)式(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器。管(guan)(guan)式(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器的(de)(de)長(chang)(chang)徑比較大(da)，與釜(fu)(fu)式(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器相(xiang)(xiang)比在結構上差異較大(da)，有(you)直管(guan)(guan)式(shi)、盤管(guan)(guan)式(shi)、多(duo)管(guan)(guan)式(shi)等。
③. 塔(ta)式反應器
塔(ta)式(shi)(shi)(shi)反(fan)(fan)應(ying)(ying)(ying)器(qi)的(de)長徑比介于釜式(shi)(shi)(shi)和管式(shi)(shi)(shi)之(zhi)間(jian)。主要用于氣(qi)-液反(fan)(fan)應(ying)(ying)(ying)，常用的(de)有(you)(you)鼓(gu)(gu)泡塔(ta)、填(tian)料(liao)塔(ta)、板式(shi)(shi)(shi)塔(ta)。最常用的(de)是(shi)鼓(gu)(gu)泡塔(ta)式(shi)(shi)(shi)反(fan)(fan)應(ying)(ying)(ying)器(qi)，底部裝有(you)(you)氣(qi)體(ti)(ti)(ti)分布器(qi)，殼外(wai)裝有(you)(you)夾(jia)套或(huo)其他(ta)形式(shi)(shi)(shi)換(huan)熱(re)(re)器(qi)或(huo)設(she)有(you)(you)擴大(da)(da)(da)段(duan)、液滴捕集器(qi)等。反(fan)(fan)應(ying)(ying)(ying)氣(qi)體(ti)(ti)(ti)通過(guo)分布器(qi)上(shang)的(de)小孔以(yi)鼓(gu)(gu)泡形式(shi)(shi)(shi)通過(guo)液層進(jin)行化學(xue)反(fan)(fan)應(ying)(ying)(ying)，液體(ti)(ti)(ti)間(jian)歇或(huo)連(lian)續(xu)加(jia)(jia)入，連(lian)續(xu)加(jia)(jia)入的(de)液體(ti)(ti)(ti)可(ke)以(yi)和氣(qi)體(ti)(ti)(ti)并流(liu)或(huo)逆流(liu)，一(yi)般采用并流(liu)形式(shi)(shi)(shi)較(jiao)(jiao)(jiao)多。氣(qi)體(ti)(ti)(ti)在塔(ta)內為(wei)分散相(xiang)，液體(ti)(ti)(ti)為(wei)連(lian)續(xu)相(xiang)，液體(ti)(ti)(ti)返混程度較(jiao)(jiao)(jiao)大(da)(da)(da)。為(wei)了(le)提高氣(qi)體(ti)(ti)(ti)分散程度和減少液體(ti)(ti)(ti)軸向(xiang)循環，可(ke)以(yi)在塔(ta)內安置(zhi)(zhi)(zhi)水平(ping)多孔隔板。當吸收或(huo)反(fan)(fan)應(ying)(ying)(ying)過(guo)程熱(re)(re)效應(ying)(ying)(ying)不大(da)(da)(da)時，可(ke)采用夾(jia)套換(huan)熱(re)(re)裝置(zhi)(zhi)(zhi)，熱(re)(re)效應(ying)(ying)(ying)較(jiao)(jiao)(jiao)大(da)(da)(da)時，可(ke)在塔(ta)內增設(she)換(huan)熱(re)(re)蛇管或(huo)采用塔(ta)外(wai)換(huan)熱(re)(re)裝置(zhi)(zhi)(zhi)，也可(ke)以(yi)利用反(fan)(fan)應(ying)(ying)(ying)液蒸發的(de)方法(fa)帶走(zou)熱(re)(re)量(liang)。
④. 固(gu)定(ding)床反應器(qi)
固(gu)(gu)(gu)定(ding)(ding)床(chuang)(chuang)板反(fan)應(ying)(ying)(ying)(ying)器(qi)是(shi)指流體(ti)通過靜止不(bu)動的固(gu)(gu)(gu)體(ti)物料所形成的床(chuang)(chuang)層(ceng)(ceng)而進行(xing)化(hua)學反(fan)應(ying)(ying)(ying)(ying)的設(she)備。以氣-固(gu)(gu)(gu)反(fan)應(ying)(ying)(ying)(ying)的固(gu)(gu)(gu)定(ding)(ding)床(chuang)(chuang)反(fan)應(ying)(ying)(ying)(ying)器(qi)最常見(jian)。固(gu)(gu)(gu)定(ding)(ding)床(chuang)(chuang)反(fan)應(ying)(ying)(ying)(ying)器(qi)根據床(chuang)(chuang)層(ceng)(ceng)數的多(duo)(duo)少又可分為單段式和多(duo)(duo)段式兩種類型。單段式一(yi)般為高(gao)徑比不(bu)大的圓筒(tong)體(ti)，在(zai)圓筒(tong)體(ti)下部裝有柵板等板件，其上(shang)為催(cui)(cui)化(hua)劑床(chuang)(chuang)層(ceng)(ceng)，均(jun)勻地堆置一(yi)定(ding)(ding)厚(hou)度(du)(du)的催(cui)(cui)化(hua)劑固(gu)(gu)(gu)體(ti)顆粒。單段式固(gu)(gu)(gu)定(ding)(ding)床(chuang)(chuang)反(fan)應(ying)(ying)(ying)(ying)器(qi)結構簡單、造價便宜、反(fan)應(ying)(ying)(ying)(ying)器(qi)體(ti)積利用(yong)率高(gao)。多(duo)(duo)段式是(shi)在(zai)圓筒(tong)體(ti)反(fan)應(ying)(ying)(ying)(ying)器(qi)內設(she)有多(duo)(duo)個催(cui)(cui)化(hua)劑床(chuang)(chuang)層(ceng)(ceng)，在(zai)各床(chuang)(chuang)層(ceng)(ceng)之間可采(cai)用(yong)多(duo)(duo)種方式進行(xing)反(fan)應(ying)(ying)(ying)(ying)物料的換(huan)熱(re)。其特點是(shi)便于控制調節反(fan)應(ying)(ying)(ying)(ying)溫度(du)(du)，防止反(fan)應(ying)(ying)(ying)(ying)溫度(du)(du)超出允許范圍。
⑤. 流化床(chuang)反應器
細(xi)小(xiao)的固(gu)體(ti)(ti)顆(ke)粒被流(liu)動著的流(liu)體(ti)(ti)攜帶(dai)，具(ju)有流(liu)體(ti)(ti)一(yi)樣自由流(liu)動的性質，此種現象稱為(wei)(wei)(wei)固(gu)體(ti)(ti)的流(liu)態化(hua)(hua)(hua)。一(yi)般(ban)把反(fan)(fan)(fan)應器(qi)(qi)(qi)和在其中呈流(liu)態化(hua)(hua)(hua)的固(gu)體(ti)(ti)催(cui)(cui)化(hua)(hua)(hua)劑(ji)顆(ke)粒合在一(yi)起(qi)，稱為(wei)(wei)(wei)流(liu)化(hua)(hua)(hua)床(chuang)反(fan)(fan)(fan)應器(qi)(qi)(qi)。流(liu)化(hua)(hua)(hua)床(chuang)反(fan)(fan)(fan)應器(qi)(qi)(qi)多(duo)用于(yu)氣-固(gu)反(fan)(fan)(fan)應過程。當原料(liao)氣通過反(fan)(fan)(fan)應器(qi)(qi)(qi)催(cui)(cui)化(hua)(hua)(hua)劑(ji)床(chuang)層(ceng)時(shi)，催(cui)(cui)化(hua)(hua)(hua)劑(ji)顆(ke)粒受氣流(liu)作用而懸浮起(qi)來呈翻(fan)滾沸(fei)騰狀(zhuang)，原料(liao)氣在處于(yu)流(liu)態化(hua)(hua)(hua)的催(cui)(cui)化(hua)(hua)(hua)劑(ji)表面(mian)進行化(hua)(hua)(hua)學反(fan)(fan)(fan)應，此時(shi)的催(cui)(cui)化(hua)(hua)(hua)劑(ji)床(chuang)層(ceng)即(ji)為(wei)(wei)(wei)流(liu)化(hua)(hua)(hua)床(chuang)，也叫沸(fei)騰床(chuang)。流(liu)化(hua)(hua)(hua)床(chuang)反(fan)(fan)(fan)應器(qi)(qi)(qi)的形式(shi)(shi)很多(duo)，但一(yi)般(ban)都由殼體(ti)(ti)、內部構(gou)件、固(gu)體(ti)(ti)顆(ke)粒裝卸設備及氣體(ti)(ti)分(fen)(fen)布(bu)、傳熱(re)、氣固(gu)分(fen)(fen)離裝置等構(gou)成。流(liu)化(hua)(hua)(hua)床(chuang)反(fan)(fan)(fan)應器(qi)(qi)(qi)也可根據床(chuang)層(ceng)結構(gou)分(fen)(fen)為(wei)(wei)(wei)圓(yuan)(yuan)筒式(shi)(shi)、圓(yuan)(yuan)錐(zhui)式(shi)(shi)和多(duo)管式(shi)(shi)等類(lei)型(xing)。
不同(tong)類型反應(ying)器在工業(ye)生產中(zhong)(zhong)的(de)適用情況(kuang)見表6.2。不同(tong)結構形式(shi)的(de)反應(ying)器在工業(ye)裝置中(zhong)(zhong)的(de)應(ying)用舉例見表6.3。
