反(fan)(fan)應過(guo)程(cheng)(cheng)的基本特征決定了(le)適宜(yi)的反(fan)(fan)應器(qi)形式。例(li)如氣(qi)固相反(fan)(fan)應過(guo)程(cheng)(cheng)大致是用固定床(chuang)(chuang)反(fan)(fan)應器(qi)、流化床(chuang)(chuang)反(fan)(fan)應器(qi)或移動床(chuang)(chuang)反(fan)(fan)應器(qi)。但(dan)是適宜(yi)的選(xuan)型則需(xu)考慮反(fan)(fan)應的熱效應、對反(fan)(fan)應轉化率和選(xuan)擇率的要求、催(cui)化劑物理化學性(xing)態和失(shi)活等(deng)多種因素。
不銹(xiu)鋼(gang)反(fan)(fan)應(ying)器的(de)操作方式和加料方式也需考(kao)慮(lv)。例(li)如，對于有串聯或平行(xing)副(fu)反(fan)(fan)應(ying)的(de)過程，分段進料可(ke)能(neng)優于一次進料。溫(wen)度序(xu)列也是反(fan)(fan)應(ying)器選型的(de)一個重要因素。例(li)如，對于放熱(re)的(de)可(ke)逆(ni)反(fan)(fan)應(ying)，應(ying)采用先高后(hou)低的(de)溫(wen)度序(xu)列，多級、級間(jian)換熱(re)式反(fan)(fan)應(ying)器可(ke)使反(fan)(fan)應(ying)器的(de)溫(wen)度序(xu)列趨于合理。
下面主要介紹釜式反應器(qi)(qi)、管式反應器(qi)(qi)、塔式反應器(qi)(qi)、固定床(chuang)反應器(qi)(qi)、流化(hua)床(chuang)反應器(qi)(qi)。
①. 釜式反應(ying)器
釜式(shi)反(fan)(fan)應(ying)(ying)器(qi)(qi)也(ye)(ye)稱槽(cao)式(shi)、鍋式(shi)反(fan)(fan)應(ying)(ying)器(qi)(qi)，它是各(ge)類反(fan)(fan)應(ying)(ying)器(qi)(qi)中(zhong)(zhong)結構較(jiao)(jiao)為簡單(dan)且(qie)(qie)應(ying)(ying)用(yong)(yong)(yong)(yong)較(jiao)(jiao)廣的一(yi)種。主(zhu)要(yao)(yao)應(ying)(ying)用(yong)(yong)(yong)(yong)于液(ye)(ye)-液(ye)(ye)均相反(fan)(fan)應(ying)(ying)過程，在(zai)氣-液(ye)(ye)、液(ye)(ye)-液(ye)(ye)非均相反(fan)(fan)應(ying)(ying)過程中(zhong)(zhong)也(ye)(ye)有(you)(you)應(ying)(ying)用(yong)(yong)(yong)(yong)。在(zai)化工(gong)生產中(zhong)(zhong)，既適(shi)用(yong)(yong)(yong)(yong)于間歇操(cao)作(zuo)(zuo)過程，又可(ke)單(dan)釜或多(duo)釜串聯用(yong)(yong)(yong)(yong)于連(lian)(lian)續操(cao)作(zuo)(zuo)過程，但在(zai)間歇生產過程中(zhong)(zhong)應(ying)(ying)用(yong)(yong)(yong)(yong)最多(duo)。釜式(shi)反(fan)(fan)應(ying)(ying)器(qi)(qi)具有(you)(you)適(shi)用(yong)(yong)(yong)(yong)的溫(wen)度(du)和壓(ya)力范圍(wei)寬、適(shi)應(ying)(ying)性強(qiang)、操(cao)作(zuo)(zuo)彈性大、連(lian)(lian)續操(cao)作(zuo)(zuo)時(shi)溫(wen)度(du)濃度(du)容(rong)易控制(zhi)、產品質量均一(yi)等特點。但用(yong)(yong)(yong)(yong)在(zai)較(jiao)(jiao)高轉化率(lv)工(gong)藝要(yao)(yao)求時(shi)，需要(yao)(yao)較(jiao)(jiao)大容(rong)積。通常在(zai)操(cao)作(zuo)(zuo)條(tiao)件比較(jiao)(jiao)緩和的情(qing)況(kuang)下使用(yong)(yong)(yong)(yong)，如(ru)常壓(ya)、溫(wen)度(du)較(jiao)(jiao)低且(qie)(qie)低于物料沸點時(shi)，應(ying)(ying)用(yong)(yong)(yong)(yong)此類反(fan)(fan)應(ying)(ying)器(qi)(qi)最為普遍(bian)。
②. 管式反應器
管(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器主要用于(yu)氣相、液相、氣-液相連續(xu)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)過程，由(you)單根（直(zhi)管(guan)(guan)(guan)或(huo)(huo)盤(pan)管(guan)(guan)(guan)）連續(xu)或(huo)(huo)多根平行排列(lie)的(de)(de)管(guan)(guan)(guan)子組成，一般設有套管(guan)(guan)(guan)或(huo)(huo)殼管(guan)(guan)(guan)式(shi)(shi)(shi)換(huan)熱裝置。操(cao)(cao)作時，物料自一端(duan)連續(xu)加入，在(zai)管(guan)(guan)(guan)中連續(xu)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)，從另一端(duan)連續(xu)流出(chu)，便達(da)到(dao)了要求(qiu)的(de)(de)轉化(hua)(hua)率。由(you)于(yu)管(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器能(neng)承受較高的(de)(de)壓(ya)力，故用于(yu)加壓(ya)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)尤為(wei)合(he)適(shi)，例如油脂或(huo)(huo)脂肪酸加氫生(sheng)產高碳醇、裂解(jie)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)用的(de)(de)管(guan)(guan)(guan)式(shi)(shi)(shi)爐便是管(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器。此種反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器具有容積小(xiao)、比表面大、返(fan)混少、反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)混合(he)物連續(xu)性變化(hua)(hua)、易(yi)于(yu)控制等優點。但若反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)速(su)度較慢時，則(ze)有所需管(guan)(guan)(guan)子長(chang)、壓(ya)降(jiang)較大等不足。隨著化(hua)(hua)工生(sheng)產越(yue)來越(yue)趨于(yu)大型化(hua)(hua)、連續(xu)化(hua)(hua)、自動化(hua)(hua)，連續(xu)操(cao)(cao)作的(de)(de)管(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器在(zai)生(sheng)產中使用越(yue)來越(yue)多，某些傳統(tong)上一直(zhi)使用間歇攪拌釜的(de)(de)高分子聚合(he)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)，目前也(ye)開始改用連續(xu)操(cao)(cao)作的(de)(de)管(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器。管(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器的(de)(de)長(chang)徑(jing)比較大，與釜式(shi)(shi)(shi)反(fan)(fan)(fan)應(ying)(ying)(ying)(ying)器相比在(zai)結(jie)構上差異較大，有直(zhi)管(guan)(guan)(guan)式(shi)(shi)(shi)、盤(pan)管(guan)(guan)(guan)式(shi)(shi)(shi)、多管(guan)(guan)(guan)式(shi)(shi)(shi)等。
③. 塔式反應器
塔(ta)(ta)式(shi)(shi)反應(ying)(ying)器的(de)(de)(de)長徑比介于(yu)釜式(shi)(shi)和(he)管(guan)式(shi)(shi)之間(jian)(jian)。主要用(yong)于(yu)氣-液(ye)(ye)(ye)(ye)反應(ying)(ying)，常用(yong)的(de)(de)(de)有(you)鼓(gu)泡塔(ta)(ta)、填料塔(ta)(ta)、板式(shi)(shi)塔(ta)(ta)。最常用(yong)的(de)(de)(de)是(shi)鼓(gu)泡塔(ta)(ta)式(shi)(shi)反應(ying)(ying)器，底部裝有(you)氣體(ti)(ti)(ti)(ti)分布(bu)器，殼外(wai)裝有(you)夾套或其(qi)他(ta)形式(shi)(shi)換(huan)熱(re)(re)(re)器或設(she)(she)有(you)擴大(da)段、液(ye)(ye)(ye)(ye)滴(di)捕(bu)集器等。反應(ying)(ying)氣體(ti)(ti)(ti)(ti)通(tong)過(guo)分布(bu)器上的(de)(de)(de)小(xiao)孔以(yi)鼓(gu)泡形式(shi)(shi)通(tong)過(guo)液(ye)(ye)(ye)(ye)層進行化學反應(ying)(ying)，液(ye)(ye)(ye)(ye)體(ti)(ti)(ti)(ti)間(jian)(jian)歇或連(lian)續加入(ru)，連(lian)續加入(ru)的(de)(de)(de)液(ye)(ye)(ye)(ye)體(ti)(ti)(ti)(ti)可(ke)以(yi)和(he)氣體(ti)(ti)(ti)(ti)并(bing)流(liu)或逆流(liu)，一般采用(yong)并(bing)流(liu)形式(shi)(shi)較(jiao)多。氣體(ti)(ti)(ti)(ti)在(zai)塔(ta)(ta)內(nei)為(wei)分散(san)相，液(ye)(ye)(ye)(ye)體(ti)(ti)(ti)(ti)為(wei)連(lian)續相，液(ye)(ye)(ye)(ye)體(ti)(ti)(ti)(ti)返混程度較(jiao)大(da)。為(wei)了(le)提(ti)高(gao)氣體(ti)(ti)(ti)(ti)分散(san)程度和(he)減少液(ye)(ye)(ye)(ye)體(ti)(ti)(ti)(ti)軸向循環，可(ke)以(yi)在(zai)塔(ta)(ta)內(nei)安置水平多孔隔(ge)板。當吸收或反應(ying)(ying)過(guo)程熱(re)(re)(re)效(xiao)應(ying)(ying)不大(da)時(shi)(shi)，可(ke)采用(yong)夾套換(huan)熱(re)(re)(re)裝置，熱(re)(re)(re)效(xiao)應(ying)(ying)較(jiao)大(da)時(shi)(shi)，可(ke)在(zai)塔(ta)(ta)內(nei)增設(she)(she)換(huan)熱(re)(re)(re)蛇(she)管(guan)或采用(yong)塔(ta)(ta)外(wai)換(huan)熱(re)(re)(re)裝置，也(ye)可(ke)以(yi)利(li)用(yong)反應(ying)(ying)液(ye)(ye)(ye)(ye)蒸(zheng)發的(de)(de)(de)方法(fa)帶走熱(re)(re)(re)量。
④. 固定床反應器
固(gu)(gu)定床(chuang)(chuang)(chuang)(chuang)板反(fan)(fan)(fan)應(ying)器(qi)是(shi)指(zhi)流體(ti)通過靜止(zhi)不(bu)動的(de)固(gu)(gu)體(ti)物料(liao)所形成的(de)床(chuang)(chuang)(chuang)(chuang)層(ceng)而進行(xing)化學反(fan)(fan)(fan)應(ying)的(de)設備。以氣-固(gu)(gu)反(fan)(fan)(fan)應(ying)的(de)固(gu)(gu)定床(chuang)(chuang)(chuang)(chuang)反(fan)(fan)(fan)應(ying)器(qi)最(zui)常見。固(gu)(gu)定床(chuang)(chuang)(chuang)(chuang)反(fan)(fan)(fan)應(ying)器(qi)根據床(chuang)(chuang)(chuang)(chuang)層(ceng)數的(de)多少又可分為(wei)單段(duan)(duan)(duan)式(shi)(shi)(shi)(shi)和多段(duan)(duan)(duan)式(shi)(shi)(shi)(shi)兩種(zhong)類(lei)型。單段(duan)(duan)(duan)式(shi)(shi)(shi)(shi)一(yi)般為(wei)高徑比(bi)不(bu)大(da)的(de)圓筒(tong)(tong)體(ti)，在(zai)圓筒(tong)(tong)體(ti)下(xia)部裝有(you)柵板等板件，其上為(wei)催化劑(ji)床(chuang)(chuang)(chuang)(chuang)層(ceng)，均勻地堆置(zhi)一(yi)定厚度的(de)催化劑(ji)固(gu)(gu)體(ti)顆粒。單段(duan)(duan)(duan)式(shi)(shi)(shi)(shi)固(gu)(gu)定床(chuang)(chuang)(chuang)(chuang)反(fan)(fan)(fan)應(ying)器(qi)結(jie)構簡單、造(zao)價便宜、反(fan)(fan)(fan)應(ying)器(qi)體(ti)積(ji)利用率高。多段(duan)(duan)(duan)式(shi)(shi)(shi)(shi)是(shi)在(zai)圓筒(tong)(tong)體(ti)反(fan)(fan)(fan)應(ying)器(qi)內設有(you)多個催化劑(ji)床(chuang)(chuang)(chuang)(chuang)層(ceng)，在(zai)各床(chuang)(chuang)(chuang)(chuang)層(ceng)之間可采(cai)用多種(zhong)方式(shi)(shi)(shi)(shi)進行(xing)反(fan)(fan)(fan)應(ying)物料(liao)的(de)換熱。其特點是(shi)便于控制調節反(fan)(fan)(fan)應(ying)溫度，防(fang)止(zhi)反(fan)(fan)(fan)應(ying)溫度超出允許范(fan)圍。
⑤. 流(liu)化床反(fan)應器(qi)
細小(xiao)的(de)固體顆(ke)粒(li)被流(liu)(liu)(liu)(liu)動著(zhu)的(de)流(liu)(liu)(liu)(liu)體攜帶(dai)，具有流(liu)(liu)(liu)(liu)體一樣自由流(liu)(liu)(liu)(liu)動的(de)性(xing)質(zhi)，此種現象(xiang)稱(cheng)為固體的(de)流(liu)(liu)(liu)(liu)態(tai)化(hua)(hua)(hua)。一般把反(fan)應(ying)(ying)器(qi)(qi)(qi)和在(zai)其(qi)中呈(cheng)流(liu)(liu)(liu)(liu)態(tai)化(hua)(hua)(hua)的(de)固體催(cui)化(hua)(hua)(hua)劑(ji)顆(ke)粒(li)合在(zai)一起，稱(cheng)為流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)反(fan)應(ying)(ying)器(qi)(qi)(qi)。流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)反(fan)應(ying)(ying)器(qi)(qi)(qi)多用(yong)于(yu)氣(qi)(qi)-固反(fan)應(ying)(ying)過程。當原(yuan)料(liao)氣(qi)(qi)通(tong)過反(fan)應(ying)(ying)器(qi)(qi)(qi)催(cui)化(hua)(hua)(hua)劑(ji)床(chuang)層時，催(cui)化(hua)(hua)(hua)劑(ji)顆(ke)粒(li)受氣(qi)(qi)流(liu)(liu)(liu)(liu)作用(yong)而懸浮起來呈(cheng)翻滾沸騰狀(zhuang)，原(yuan)料(liao)氣(qi)(qi)在(zai)處于(yu)流(liu)(liu)(liu)(liu)態(tai)化(hua)(hua)(hua)的(de)催(cui)化(hua)(hua)(hua)劑(ji)表(biao)面進行化(hua)(hua)(hua)學反(fan)應(ying)(ying)，此時的(de)催(cui)化(hua)(hua)(hua)劑(ji)床(chuang)層即為流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)，也(ye)叫沸騰床(chuang)。流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)反(fan)應(ying)(ying)器(qi)(qi)(qi)的(de)形(xing)式(shi)(shi)很多，但一般都由殼(ke)體、內(nei)部構件、固體顆(ke)粒(li)裝卸設備及氣(qi)(qi)體分布(bu)、傳熱、氣(qi)(qi)固分離裝置等(deng)構成。流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)反(fan)應(ying)(ying)器(qi)(qi)(qi)也(ye)可根(gen)據床(chuang)層結(jie)構分為圓筒式(shi)(shi)、圓錐式(shi)(shi)和多管式(shi)(shi)等(deng)類(lei)型。
不同類型反(fan)應器在工業生產(chan)中(zhong)的適用情況見表6.2。不同結(jie)構形式的反(fan)應器在工業裝置中(zhong)的應用舉例見表6.3。
