SCALE-UP OF A PACKED BUBBLE-COLUMN REACTOR - FROM SEMIBATCH TO CONTINUOUS-MODE IN AN INDUSTRIAL-PLANT

A simplified approach to the model development and scale-up of a packe d bubble column reactor from pilot semi-batch mode to continuous comme rcial operation has been presented. This is illustrated by choosing th e reaction of ethynylation of formaldehyde to 1,4-butynediol for which correct reaction mechanism is difficult to postulate in the compellin g safety limitations. The apparent reaction kinetics has been determin ed from the semi-batch pilot data for previous catalyst charges. The t rue kinetics has been predicted taking into account the gas-liquid, li quid-solid mass transfer and axial dispersion effects and has been exp ressed as a function of catalyst loading, temperature and 'age' of the catalyst. The actual conversion from the commercial reactor system wa s found to match the model prediction reasonably well.