faalinffilmsulphonator-120324211915-phpapp02

7/30/2019 faalinffilmsulphonator-120324211915-phpapp02

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BY

ANAY NILESH KACHARIA&

GURUPRASADVENKATAKRISHNA RAO


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IMP NOTE

IN SULPHONATION SO3 REACTS WITH

ORGANIC MOLECULE TO PRODUCE SULPHUR

AND CARBON BOND.

SULFATION ON OTHER HAND IS FORMATION

OF SULPHUR-OXYGEN-CARBON BOND.


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SULPHONATION

SO3 is an aggressive electrophilic reagent that

rapidly reacts with any organic compound

containing an electron donor group.

Sulfonation is a difficult reaction to perform

on an industrial scale because the reaction is

rapid and highly exothermic, releasing

approximately 380 kJ/kg SO3 (800 BTUs perpound of SO3) reacted.


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SULPHONATION

Most organic compounds form a black char on

contact with pure SO3 due to the rapid

reaction and heat evolution.

Additionally, as shown in Figure, the reactants

increase in viscosity between 15 and 300

times as they are converted from the organic

feedstock to the sulfonic acid.


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SULPHONATION THIS LARGE INCREASE IN

VISCOSITY MAKES HEAT REMOVALDIFFICULT. THE HIGH VISCOSITY OF

THE FORMED PRODUCTS REDUCES

THE HEAT TRANSFER COEFFICIENT

FROM THE REACTION MASS.

EFFECTIVE COOLING OF THE

REACTION MASS IS ESSENTIAL

BECAUSE HIGH TEMPERATURES

PROMOTE SIDE REACTIONS THAT

PRODUCE UNDESIRABLE BY-

PRODUCTS.

ALSO, PRECISE CONTROL OF THE

MOLAR RATIO OF SO3 TO ORGANIC

IS ESSENTIAL BECAUSE ANY EXCESS

SO3, DUE TO ITS REACTIVE

NATURE, CONTRIBUTES TO SIDE

REACTIONS AND BY-PRODUCTFORMATION.


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Air supply system

Process requires Dry and cool air .

Air should be deficient in any kind of

disturbance

Control valves sort out disturbance problems

Air chiller cools the filtered air

Regenerated air can be recycled


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Air

supply

system


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Sulfur feed sysytem

Control of sulfur to sulfur burning unit is

important since that is going to effect mole

ratio in main unit

Sulfur feed system ensures that.

Melting of sulfur takes place here

Entire sulfur feed system is jacketed

considering freezing point of sulphur is 112.60

C.


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Sulfur burning unit

Consist of atomized sulfur burning.

Sulfur dioxide leaving burner is cooled to 4200 C& is passed through vanadium pentoxide catalyticconverter where SO

2

is converted to SO3

with 99% efficiency.

SO3 is initially cooled in a double pipe cooler byregenerated air.

Finally cooled by heat exchanger to ambienttemperature.

Inlet mist eliminator eliminates any residualoleum.


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Falling Film Reactor


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Common Types

Annular Falling Film

ReactorMultitube Falling Film

Reactor


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It employs interchangeable

organic metering flanges.

The mole ratio control ismaintained on a micro scale

throughout the sulfonator.

Cooling jackets on the reactor

remove most of the heat of the

reaction.

The additional recycle system is

a huge benefit.

The cooling process reduces the

amount of time of holding

sulfonic acid at elevatedtemperatures.


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It consists of a number of vertical

tubes as arranged in a shell and

tube heat exchanger

The tubes are generally 25mm

internal diameter and about 6m in

length.

Generally a reactor with 70 tubes

would have a capacity of about

3 tonnes of surfactant per hour.

The residence time from the top of

the reactor to the neutralizer is

between 2-3 minutes.


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Features of a FFR

Various configurations of Feedstock entry.

Thin distribution of liquid olefin to prevent localized overheating.

Short residence time owing to its instantaneous reaction completion.


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Points to Remember

Temperature gradient must be sufficent to control the extremely

vigorous intial exotherm to avoid charring.

Air temperature should be below olefin feed.

Film thickness has to be maintained in the order of (0.001-0.01 inches)

Mixture of air and S03 should contain 2%-4% of S03

Here stoichometry plays a very significant role.


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EFFECT OF MOLE RATIOS ON 1,4 DIOXANE CONTENT


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SO3 absorber

Is capable of treating the total output fromthe SO3 generation system to form 98%sulfuric acid.

It is a convenience in plant startup , shutdownand product changeover. It is alsorecommended in situations where frequentpower failures can interrupt production.

Generally used when alcohol feedstock areavailable in plant.


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Neutralizer

The neutralizer combines sulfonic acid or

organo-sulfuric acid with a neutralizing agent,

additives, and dilutent (water).

A recycle loop circulates neutral slurry through

a heat exchanger to remove heat of

neutralization, mixing and pumping.

Buffer is added to maintain pH.


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Effluent Gas Treatment System


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References

Kirk & othmer , 3rd edition

www.chemithon.com

www.ballestra.org www.google.com ( Images )

Chemistry and technology of surfactants by

Richard farn
http://www.chemithon.com/http://www.ballestra.org/http://www.google.com/http://www.google.com/http://www.ballestra.org/http://www.chemithon.com/


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