反(fan)應(ying)(ying)(ying)過程(cheng)的(de)(de)基本特征決定了適宜(yi)的(de)(de)反(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)形式。例如氣固(gu)相反(fan)應(ying)(ying)(ying)過程(cheng)大致是用(yong)固(gu)定床反(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)、流(liu)化床反(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)或移動床反(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)。但是適宜(yi)的(de)(de)選型則需考慮反(fan)應(ying)(ying)(ying)的(de)(de)熱效應(ying)(ying)(ying)、對反(fan)應(ying)(ying)(ying)轉(zhuan)化率(lv)和(he)選擇率(lv)的(de)(de)要求、催化劑物(wu)理化學(xue)性態和(he)失活等多種(zhong)因素。
不(bu)銹鋼反(fan)(fan)(fan)應(ying)(ying)器(qi)的操作方(fang)式(shi)和加料方(fang)式(shi)也(ye)需考慮(lv)。例如(ru)，對于有串聯(lian)或平行副反(fan)(fan)(fan)應(ying)(ying)的過程，分段進料可能優于一次進料。溫度(du)序列也(ye)是反(fan)(fan)(fan)應(ying)(ying)器(qi)選型的一個重要因素。例如(ru)，對于放熱(re)的可逆反(fan)(fan)(fan)應(ying)(ying)，應(ying)(ying)采用先高后低的溫度(du)序列，多級、級間換熱(re)式(shi)反(fan)(fan)(fan)應(ying)(ying)器(qi)可使反(fan)(fan)(fan)應(ying)(ying)器(qi)的溫度(du)序列趨于合理。
下面主要介紹釜式反(fan)(fan)應(ying)器(qi)(qi)(qi)、管式反(fan)(fan)應(ying)器(qi)(qi)(qi)、塔式反(fan)(fan)應(ying)器(qi)(qi)(qi)、固定床(chuang)反(fan)(fan)應(ying)器(qi)(qi)(qi)、流化床(chuang)反(fan)(fan)應(ying)器(qi)(qi)(qi)。
①. 釜(fu)式反應器
釜(fu)(fu)式反(fan)應(ying)(ying)(ying)器也稱槽式、鍋式反(fan)應(ying)(ying)(ying)器，它是各(ge)類反(fan)應(ying)(ying)(ying)器中(zhong)(zhong)結構較(jiao)為簡(jian)單且(qie)應(ying)(ying)(ying)用較(jiao)廣的(de)(de)(de)一(yi)種。主要(yao)應(ying)(ying)(ying)用于(yu)液(ye)-液(ye)均相反(fan)應(ying)(ying)(ying)過程(cheng)，在(zai)氣(qi)-液(ye)、液(ye)-液(ye)非均相反(fan)應(ying)(ying)(ying)過程(cheng)中(zhong)(zhong)也有(you)應(ying)(ying)(ying)用。在(zai)化工(gong)(gong)生產(chan)(chan)中(zhong)(zhong)，既適用于(yu)間歇操作(zuo)(zuo)過程(cheng)，又可(ke)單釜(fu)(fu)或多(duo)釜(fu)(fu)串聯用于(yu)連續操作(zuo)(zuo)過程(cheng)，但在(zai)間歇生產(chan)(chan)過程(cheng)中(zhong)(zhong)應(ying)(ying)(ying)用最多(duo)。釜(fu)(fu)式反(fan)應(ying)(ying)(ying)器具有(you)適用的(de)(de)(de)溫(wen)(wen)度和(he)壓力范圍寬、適應(ying)(ying)(ying)性(xing)強、操作(zuo)(zuo)彈(dan)性(xing)大、連續操作(zuo)(zuo)時(shi)溫(wen)(wen)度濃度容(rong)易控制、產(chan)(chan)品質(zhi)量均一(yi)等(deng)特點。但用在(zai)較(jiao)高轉化率工(gong)(gong)藝要(yao)求時(shi)，需要(yao)較(jiao)大容(rong)積。通常(chang)在(zai)操作(zuo)(zuo)條件比較(jiao)緩(huan)和(he)的(de)(de)(de)情況(kuang)下使用，如常(chang)壓、溫(wen)(wen)度較(jiao)低且(qie)低于(yu)物料沸(fei)點時(shi)，應(ying)(ying)(ying)用此(ci)類反(fan)應(ying)(ying)(ying)器最為普遍。
②. 管式(shi)反應(ying)器
管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)器(qi)(qi)主要用(yong)(yong)于氣(qi)相(xiang)、液相(xiang)、氣(qi)-液相(xiang)連(lian)續(xu)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)過(guo)程，由單根(gen)（直(zhi)(zhi)管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)或(huo)盤管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)）連(lian)續(xu)或(huo)多(duo)(duo)根(gen)平行排列(lie)的(de)管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)子組成，一(yi)般設(she)有套管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)或(huo)殼(ke)管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)換(huan)熱(re)裝置。操作時，物料自一(yi)端(duan)連(lian)續(xu)加入，在管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)中連(lian)續(xu)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)，從另一(yi)端(duan)連(lian)續(xu)流出，便達(da)到(dao)了(le)要求的(de)轉化率。由于管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)器(qi)(qi)能(neng)承(cheng)受較(jiao)(jiao)(jiao)高(gao)的(de)壓力，故用(yong)(yong)于加壓反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)尤為(wei)合適，例如油脂(zhi)或(huo)脂(zhi)肪酸加氫生(sheng)產(chan)高(gao)碳醇、裂解反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)用(yong)(yong)的(de)管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)爐便是管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)器(qi)(qi)。此(ci)種(zhong)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)器(qi)(qi)具有容積小、比表面大(da)、返混(hun)少(shao)、反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)混(hun)合物連(lian)續(xu)性變化、易于控制(zhi)等優點。但若(ruo)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)速(su)度(du)較(jiao)(jiao)(jiao)慢(man)時，則(ze)有所(suo)需管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)子長(chang)、壓降較(jiao)(jiao)(jiao)大(da)等不足。隨著化工生(sheng)產(chan)越來越趨于大(da)型化、連(lian)續(xu)化、自動化，連(lian)續(xu)操作的(de)管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)器(qi)(qi)在生(sheng)產(chan)中使用(yong)(yong)越來越多(duo)(duo)，某些傳統上(shang)一(yi)直(zhi)(zhi)使用(yong)(yong)間歇攪(jiao)拌釜(fu)的(de)高(gao)分子聚(ju)合反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)，目前(qian)也開始改用(yong)(yong)連(lian)續(xu)操作的(de)管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)器(qi)(qi)。管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)器(qi)(qi)的(de)長(chang)徑比較(jiao)(jiao)(jiao)大(da)，與釜(fu)式(shi)(shi)(shi)(shi)反(fan)(fan)應(ying)(ying)(ying)(ying)(ying)器(qi)(qi)相(xiang)比在結(jie)構(gou)上(shang)差異較(jiao)(jiao)(jiao)大(da)，有直(zhi)(zhi)管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)、盤管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)、多(duo)(duo)管(guan)(guan)(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)(shi)等。
③. 塔(ta)式反應器(qi)
塔式(shi)反(fan)(fan)應(ying)(ying)器(qi)的(de)長徑比介(jie)于釜式(shi)和管(guan)(guan)式(shi)之間(jian)。主要用(yong)于氣-液(ye)(ye)反(fan)(fan)應(ying)(ying)，常用(yong)的(de)有鼓泡塔、填料塔、板式(shi)塔。最常用(yong)的(de)是鼓泡塔式(shi)反(fan)(fan)應(ying)(ying)器(qi)，底部裝(zhuang)(zhuang)有氣體(ti)(ti)(ti)分(fen)布(bu)器(qi)，殼外(wai)裝(zhuang)(zhuang)有夾(jia)套(tao)或其他形式(shi)換(huan)熱(re)(re)器(qi)或設(she)有擴(kuo)大(da)段、液(ye)(ye)滴捕集器(qi)等。反(fan)(fan)應(ying)(ying)氣體(ti)(ti)(ti)通過分(fen)布(bu)器(qi)上(shang)的(de)小孔以(yi)鼓泡形式(shi)通過液(ye)(ye)層進行化學反(fan)(fan)應(ying)(ying)，液(ye)(ye)體(ti)(ti)(ti)間(jian)歇(xie)或連(lian)續(xu)加(jia)入，連(lian)續(xu)加(jia)入的(de)液(ye)(ye)體(ti)(ti)(ti)可(ke)(ke)以(yi)和氣體(ti)(ti)(ti)并流(liu)或逆流(liu)，一般采(cai)用(yong)并流(liu)形式(shi)較多。氣體(ti)(ti)(ti)在塔內(nei)(nei)為分(fen)散相，液(ye)(ye)體(ti)(ti)(ti)為連(lian)續(xu)相，液(ye)(ye)體(ti)(ti)(ti)返(fan)混(hun)程度較大(da)。為了提高氣體(ti)(ti)(ti)分(fen)散程度和減少(shao)液(ye)(ye)體(ti)(ti)(ti)軸向循環，可(ke)(ke)以(yi)在塔內(nei)(nei)安(an)置水平多孔隔板。當吸收或反(fan)(fan)應(ying)(ying)過程熱(re)(re)效應(ying)(ying)不(bu)大(da)時，可(ke)(ke)采(cai)用(yong)夾(jia)套(tao)換(huan)熱(re)(re)裝(zhuang)(zhuang)置，熱(re)(re)效應(ying)(ying)較大(da)時，可(ke)(ke)在塔內(nei)(nei)增設(she)換(huan)熱(re)(re)蛇管(guan)(guan)或采(cai)用(yong)塔外(wai)換(huan)熱(re)(re)裝(zhuang)(zhuang)置，也可(ke)(ke)以(yi)利用(yong)反(fan)(fan)應(ying)(ying)液(ye)(ye)蒸發的(de)方(fang)法帶走熱(re)(re)量。
④. 固定床(chuang)反應器(qi)
固定床(chuang)板反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)器是指流體(ti)(ti)通過靜(jing)止(zhi)不(bu)動的(de)(de)固體(ti)(ti)物料所形成的(de)(de)床(chuang)層而進行化(hua)學反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)的(de)(de)設備(bei)。以氣-固反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)的(de)(de)固定床(chuang)反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)器最常(chang)見。固定床(chuang)反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)器根據床(chuang)層數的(de)(de)多(duo)少又(you)可分為(wei)單(dan)(dan)段式(shi)和多(duo)段式(shi)兩種類型(xing)。單(dan)(dan)段式(shi)一(yi)般(ban)為(wei)高(gao)徑比不(bu)大的(de)(de)圓筒體(ti)(ti)，在圓筒體(ti)(ti)下部裝有柵(zha)板等板件，其上為(wei)催化(hua)劑床(chuang)層，均勻地(di)堆置一(yi)定厚度(du)的(de)(de)催化(hua)劑固體(ti)(ti)顆(ke)粒。單(dan)(dan)段式(shi)固定床(chuang)反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)器結構簡單(dan)(dan)、造價便(bian)宜、反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)器體(ti)(ti)積利用(yong)率高(gao)。多(duo)段式(shi)是在圓筒體(ti)(ti)反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)器內設有多(duo)個催化(hua)劑床(chuang)層，在各床(chuang)層之間可采用(yong)多(duo)種方式(shi)進行反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)物料的(de)(de)換熱。其特點是便(bian)于(yu)控制調節反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)溫(wen)度(du)，防止(zhi)反(fan)(fan)(fan)(fan)(fan)應(ying)(ying)溫(wen)度(du)超出允(yun)許(xu)范(fan)圍(wei)。
⑤. 流化床反(fan)應器
細(xi)小的(de)固(gu)體(ti)(ti)顆(ke)粒(li)(li)被流(liu)(liu)(liu)(liu)動著(zhu)的(de)流(liu)(liu)(liu)(liu)體(ti)(ti)攜帶，具有流(liu)(liu)(liu)(liu)體(ti)(ti)一樣自由流(liu)(liu)(liu)(liu)動的(de)性質，此種(zhong)現象(xiang)稱(cheng)為(wei)固(gu)體(ti)(ti)的(de)流(liu)(liu)(liu)(liu)態(tai)化(hua)(hua)(hua)(hua)。一般把反(fan)應(ying)器(qi)和在其(qi)中呈(cheng)流(liu)(liu)(liu)(liu)態(tai)化(hua)(hua)(hua)(hua)的(de)固(gu)體(ti)(ti)催化(hua)(hua)(hua)(hua)劑(ji)顆(ke)粒(li)(li)合在一起，稱(cheng)為(wei)流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)反(fan)應(ying)器(qi)。流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)反(fan)應(ying)器(qi)多(duo)用(yong)于氣(qi)-固(gu)反(fan)應(ying)過程(cheng)。當原料氣(qi)通(tong)過反(fan)應(ying)器(qi)催化(hua)(hua)(hua)(hua)劑(ji)床(chuang)層時(shi)，催化(hua)(hua)(hua)(hua)劑(ji)顆(ke)粒(li)(li)受氣(qi)流(liu)(liu)(liu)(liu)作用(yong)而懸浮(fu)起來呈(cheng)翻滾沸騰(teng)狀，原料氣(qi)在處于流(liu)(liu)(liu)(liu)態(tai)化(hua)(hua)(hua)(hua)的(de)催化(hua)(hua)(hua)(hua)劑(ji)表面進行(xing)化(hua)(hua)(hua)(hua)學反(fan)應(ying)，此時(shi)的(de)催化(hua)(hua)(hua)(hua)劑(ji)床(chuang)層即為(wei)流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)，也叫沸騰(teng)床(chuang)。流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)反(fan)應(ying)器(qi)的(de)形(xing)式很多(duo)，但一般都由殼體(ti)(ti)、內部(bu)構(gou)件(jian)、固(gu)體(ti)(ti)顆(ke)粒(li)(li)裝(zhuang)卸(xie)設備(bei)及氣(qi)體(ti)(ti)分(fen)布(bu)、傳(chuan)熱、氣(qi)固(gu)分(fen)離(li)裝(zhuang)置(zhi)等構(gou)成。流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)反(fan)應(ying)器(qi)也可根據床(chuang)層結構(gou)分(fen)為(wei)圓(yuan)筒式、圓(yuan)錐式和多(duo)管式等類型(xing)。
不同(tong)類(lei)型反(fan)應器(qi)在工業生產中的(de)適用(yong)情況見表6.2。不同(tong)結構形式的(de)反(fan)應器(qi)在工業裝置中的(de)應用(yong)舉例見表6.3。
