Development of a new reactor concept for oxidation reactions

Abstract

Oxidation reactions comprises an important class of reactions. One key commercial product in DSM – Firmenich' s portfolio contains an oxidation step using 100% O2. Oxidation reactions are highly exothermic, often operated in an organic solvent. With a possible ignition source, this will lead to a high-risk potential regarding explosion. To obtain a safe process, it is desirable to avoid an explosive atmosphere, but this will cause limitations regarding process temperature and pressure. In reactions with 100% O2, very high explosion pressures must be expected. An inherently safe mode of operation is only possible if the apparatus were constructed to be pressure shock resistant and the process temperature is kept between a certain range.

The goal of this master thesis is the development of a new reactor concept for gas-liquid phase reactions with focus on oxidation reactions. Based on the design of a loop-reactor, the gaseous oxidizing agent O2 is transferred to the liquid reaction mass using membrane technology. The concept keeps the liquid phase saturated with O2, while minimizing the creation of an explosive atmosphere inside the reactor. The approach of a head space free reactor is a significantly increase of process safety while minimizing the constraints with regards to the solvent selection and process conditions.