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Structured Catalytic Packing

Structured Catalytic Packing

Efficient mass transfer, Enhanced reaction, Energy saving and Consumption reduction, Integrated process overturns the traditional process.
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Technology Introduction of Structured Catalytic Packing

Structured catalytic packing is an advanced structured material that integrates chemical reactions with distillation separation processes. Serving as both a catalyst carrier and a robust mass transfer surface for gas-liquid phases, it efficiently removes reaction products while supplying reactants. This technology significantly enhances reaction selectivity and conversion rates, while substantially reducing capital investment and energy consumption. As a core technological breakthrough in process intensification within chemical engineering, it represents a pivotal advancement in industrial equipment development.



Technical Principle of Structured Catalytic Packing

The principle of structured catalytic packing involves loading catalysts onto a material structure with excellent mass transfer properties. During distillation operation, rising vapor and descending liquid come into countercurrent contact on the packing surface, simultaneously facilitating mass transfer and chemical reactions. The products generated through reaction (particularly low-boiling-point substances) are promptly distilled out, breaking the equilibrium constraints and driving the reaction toward a positive direction. This achieves synchronized and synergistic enhancement of both "reaction" and "separation" within a single device.


Characteristics of Structured Catalytic Packing

1

Process intensification and efficiency improvement: The reaction and separation are combined into one, breaking the limitation of chemical equilibrium on conversion rate, and can significantly improve the reaction rate, selectivity and single pass conversion rate.

2

 Energy saving and consumption reduction: The reaction heat is directly used in the separation process, reducing the heat exchange in the intermediate link, and greatly reducing the overall energy consumption and operation costs of the system. 

3

Save investment and simplify process: A tower equipment replaces the traditional reactor, separation tower, heat exchanger and other devices, greatly simplifying the process, reducing the number of equipment, floor space and initial investment. 

4

Improve product and reduce by-products: The target product (usually volatile components) can be removed from the reaction zone in time, effectively inhibiting the occurrence of a series of reactions, decomposition reactions and other by-products, and improving the purity and yield of products. 

5

Easy to control, green and environmental protection: the process is more stable and controllable. At the same time, due to the reduction of by-products and energy consumption, the emission of "three wastes" is reduced from the source, which is more in line with the development requirements of green chemical industry.

Applications of Structured Catalytic Packing

Applications of Structured Catalytic Packing

Structured catalytic packing technology is widely used in chemical processes requiring reaction equilibrium disruption, separation of azeotropes, or heat utilization for separation. Key applications include: ether synthesis (e.g., MTBE and ETBE), esterification reactions (e.g., production of ethyl acetate and butyl acetate), hydrolysis reactions (e.g., methyl acetate hydrolysis), alkylation reactions, isomerization reactions, as well as the synthesis of fine chemicals and pharmaceutical intermediates. This technology stands as a hallmark of modern green chemistry and process intensification techniques.


Reaction and Separation Professional, Low Carbon Technology Partners
Reaction and Separation Professional, Low Carbon Technology Partners
Shanghai DODGEN Chemical Technology Co., Ltd.
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