TURBULENT FLOW PROCESS AND MONOAL YL AROMATIC PRODUCTION

This invention is directed to a process for the alkylation of aromatic compounds to produce alkyl aromatics; to a reactor useful in such a process; and to processes which affect turbulent intermingling of reactants and a reactor useful in such processes.

Efficient mass transfer, control of reactant temperature, and co-production of a energy at a sufficient level to be useful are several of the problems confronting today's chemical processing art. In many processes, the use of corrosive reactants and catalysts require more durable, stronger apparatuses, often made from expensive corrosion-resistant materials. For example, in various prior art processes for the catalytic alkylation of hydrocarbons, acid catalyst (e.g., hydrofluoric or sulfuric acid or aluminum chloride) is transported through the reaction system and through the recovery system. Apparatuses used in such processes, such as. for example, pumps, vessels, valves, and heat exchangers are made from expensive alloys.

Temperature plays a critical role in such processes and can limit design possibilities.

The production of ethylbenzene by the traditional aluminum chloride (AlClo) catalyzed reaction of ethylene and benzene has been in commercial use for decades. Ethylbenzene is used in large quantities for the manufacture of styrene monomer, the raw material for polystyrene. Often the catalyst is a liquid, AlCl , complex. The reaction is carried out in a heterogeneous liquid medium composed of the catalyst complex and a liquid product: (1) the li.quid AlCl complex (separated and recycled to the alkylator), and (2) a mixture of unreacted benzene and reaction products such as ethylbenzene, diethylbenzene and higher polyethylbenzenes.

The overall reaction can be expressed simply as

The actual chemistry involved is complex. First, there is the alkylation which involves the reaction of benzene and ethylene to form ethylbenzene as shown above. The alkylation is complicated by the occurrence of minor side reaction such as cracking and polymerization. However, of major importance is the formation of polyethylbenzenes:

[alkylation step repated]

C ₂ H ₅

Δ<3 i 11 ιιc* ι->-) nrl <rsιτ 1-V-ιo oπnof inn -ihnun 1- V*ι * ^* _. f i t ^* Q t al 1/ rl group formed activates the aromatic nucleus so that the second alkylation proceeds more readily than the first and so on, at least until steric hindrance intervenes, although hexaethylbenzene is quite readily formed. This results in a mixture of mono, di, tri, and higher ethylbenzenes together with unreacted benzene.

Fortunately, the reaction is reversible, that is, reversible in the sense that diethylbenzene, for example, will react under the influence of AlClo to form monoethy1benzene:

Thus, this transalkylation or reshuffling of ethyl groups among the aromatic rings takes a given reaction mixture to an equilibrium composition that is dependent only on the ratio of ethyl 'group to benzene

-•*!--

rings present. It is these transalkylation reactions that permit virtually all the ethylene and benzene fed to the reactor system to be eventually converted to monoethylbenzene.

In one conventional ethylbenzene process, both the alkylation and transalkylation steps are carried out in a single back-mix reactor using relatively low contact times and low temperatures (30 to 60 min. and 110°C to 165°C). The conventional process also uses relatively high AlCl catalyst concentrations. For this i-QB cnn <- >. ___ n-i i- α l -rσ mπ c; f* H *-? _*_ r*ι _s r* *-j ⁺ * arl f'r-rim |* I* D v»Qa r _* i" 1 nn product and recycled to the reactor. U.S. Patent 3,448,161 teaches the use of short contact times (2 min.) and temperatures up to 250°C. U.S. Patent 3,766,290 discloses the use of catalyst concentrations below the level that requires catalyst recycle. The advantages of separate alkylation and transalkylation reactors are revealed in U.S. Patent 3 _* 848,012. The concept of having separate alkylation and transalkylation steps, but combined in a single piece of equipment is claimed in U.S. Patent 4,179,473. U.S. Patent 3 _* 501,536 teaches the use of a reactor with heat exchange tubes and a plurality of conduits that carry hydrocarbon reactants into a reactor space for intimate mixing and cooling of reactants and catalyst, the reactants entering through a series of spaced openings to the tubes which jet the reactants into an upward spiraling flow around the heat exchange tubes. U.S. Patent 3.817-.708 discloses a heat exchanger for use in an alkylation unit in which a heat transfer medium flows through U-tubes while an alkylation catalytic acid flows through the remaining space within a cylindrical shell that houses the U-tubes, the bends in the U-tubes

- -

approaching each other near the center of the shell in an adjacent, spaced apart, non-overlapping relationship. All of these processes have certain disadvantages which are overcome by the present invention.

Conventional alkylation reactors consist of open or baffled tanks or towers. These reactors are constructed of brick-lined steel or exotic alloys that resist corrosion by the acid catalyst. Tube or coil alkylation reactors have beerf disclosed in the literature, but have not been commercialized ^" due to a jr u i _ i-i J. *

The present invention, in one embodiment, teaches a process for producing monoalkyl aromatics by the reaction of olefinic and aromatic compounds and takes advantage of the fundamental chemistries of the two major reaction steps, alkylation and transalkylation, to improve the efficiency of known alkyl aromatic production processes. Further, while the improved process of the present invention can be readily applied to new production facilities, it is also applicable to retrofitting into and increasing the efficiency of existing plants.

The present invention teaches a turbulent flow alkylator reactor with reaction heat recovery. In one embodiment of a reactor according to the present invention in which the reaction takes place in reaction tubes within the reactor, each of two reactor heads allow for gaseous reactants to be injected into a liquid stream at the start of each pass through a reaction tube. One or more reaction tubes can be included in any particular pass through the reactor and any desired number of passes may be employed. All tubes of a given

pass can be fed with gas from a common gas chamber, and

^' a separate gas chamber can be used for each pass of the reactor. Gas flows from the gas chambers, through gas spargers, and into the reaction tubes where it turbulently contacts the liquid stream.

For each tube of a given pass, one gas sparger protrudes axially down into the tube for a short distance. This configuration allows each tube of a given pass to be individually fed with gas.

The entire liquid feed stream enters the r.eactor at the start of the first pass. The ends of the reaction tubes open into liquid chambers. There is a liquid chamber at the start of the first pass, one between each two passes, and one at the end of the final pass. As the liquid stream makes its way through the reactor, gas is sparged into the liquid within a reactor tube at the start of each pass.

With such a reactor, residence times are minimized and a uniform distribution of precise amounts of reactants to each tube is made possible. Also, there is easy access to internal parts for cleaning and maintenance. This reactor allows relatively fast and highly exothermic alkylation reactions to be carried out in a manner such that the heat of reaction is used directly to drive and ethylbenzene finishing train or to heat other streams in a process.

In one embodiment the reactor is of multi-pass, tube-in-shell design with ethylbenzene finishing tower bottoms applied to the shell as a heat transfer medium and an alkylation carried out in the tubes. Thus, the reactor shell serves as a tower reboiler. It is

preferred that linear velocities inside the tubes are such that the reactor operates near the plug-flow region. A plurality of ethylene injectors help to control the reaction exotherm. Contact times of less than one minute are possible.

In certain embodiments of the present invention processes are employed which utilize apparatuses which provide for a uniform feeding of liquid reactants to a plurality of reaction tubes of a particular pass through the reactor. This is accomplished by adjusting flow and design parameters including sparger disposition, dimensions, and reaction tube disposition and dimensions.

In preferred embodiments, reaction temperatures greater than 200°C are achieved and reaction pressures are sufficient to maintain aromatic hydrocarbons in the liquid phase. Although reactors according to this invention are particularly suited to alkylation processes such as ethylbenzene production, they may be used for producing a variety of valuable chemicals which involve reacting a gas with or in the presence of a liquid in specific molar or weight ratios and are particularly valuable for highly exothermic gas-liquid reaction systems that are advantageously carried out at elevated temperatures and/or pressures, such as the following reactions: the production of cumene by reacting propylene with benzene; the production of ethyltoluene by reacting ethylene and toluene; the alkylation of an alkene onto an aromatic compound. Processes according to the present invention are also useful in reactions involving two liquid reactants, such as, but not limited to, polymerization reactions and reactions of two liquid reactants in which different

materials are added in precise amounts at precise points in the process apparatus.

The processes and apparatuses taught by the present ^" invention include, but are not limited to, processes involving only liquid reactants; only gas reactants; or endothermic reactions.

Certain embodiments of a process and apparatus according to the present invention have the following features:

- High efficiency recovery of reaction heat to directly drive an ethylbenzene finishing train. Conventional processes, at best, raise low-grade steam with a portion of reaction heat.

- Reduction of by-product and heavy residue formation (i.e. increasing yield) by conducting alkylation and transalkylation steps under optimum conditions, allowing optimization of each process and maximization of yield of each process as well as increasing catalyst efficiency. Various conventional processes carry out both reaction steps at the same temperature and catalyst concentration.

Short contact time (residence time in reaction tubes) and high turbulence in alkylation reduce or eliminate plugging and fouling.

Reduction of ethylene polymerization (e.g., tar) by providing optimum mixing of reactants.

Polyethylbenzenes are not recycled to the 5 alkylator thereby increasing yield and reducing the amount of transalkylation required.

As the reactor approaches plug-flow, 10 alkylation kinetics improve monoethylbenzene selectivity.

Precise control of the alkylation reaction exotherm result in improved yields and 15 reduced solid formation (fouling and plugging) .

High turbulence on the alkylator tube side and boiling on the shell side result in 20 uniform, extremely high heat transfer efficiency thereby minimizing the cost of special alloy equipment.

Multiple injections of one or more reactants 25 along the path of the reactor reduce or eliminate uncontrolled exotherms and result in much more isothermal operation.

Uniform distribution of precise amounts of 30 gaseous and liquid reactants to each tube helps control reactant ratios and optimizes product distributions. While reducing liquid or gas maldistribution (non equal

- 1*0-

amounts of liquid or gas flowing into various tubes of a given pass).

Reactor size is reduced or minimized due to higher operating temperatures, turbulent mixing of the reactants, high heat transfer rates, and increased reaction rates.

One aspect of the present invention is a process for reacting reactant materials in a reaction, the process comprising: feeding first reactant material into a first chamber of a reactor vessel, the reactor vessel having a first end, a second end, and a reaction product outlet from which products of the reaction flow from the reactor vessel, flowing the first reactant material from the first chamber turbulently into a hollow reaction tube having an exterior surface, the reaction tube communicating with the first chamber and extending between the first and second ends of the reactor vessel, feeding second reactant material through a hollow sparger into the reaction tube, the hollow sparger partially extending into the reaction tube, the second material flowing turbulently into the reaction tube, the reaction tube communicating with the reaction product outlet- so that produces of the reaction of the first and second reactant material flow from the reaction tube and out of the reactor vessel through the reaction product outlet.

Another aspect of the present invention is a process for reacting reactant materials in a reaction to produce reaction products, the process comprising:

feeding first reactant material into a first chamber of a reactor vessel, the reactor vessel having a first end, a second end, and a reaction product outlet from which products of the reaction flow from the reactor vessel, flowing the first reactant material from the first chamber at the first end of the reactor vessel uniformly and turbulently into a plurality of hollow reaction tubes, each tube having an interior and an

10 exterior surface and communicating with the first chamber, each tube extending between the first chamber and the second end of the reactor vessel, feeding second reactant material through hollow spargers into the reaction tubes, one sparger disposed 15 partially in each reaction tube, the second reactant material flowing turbulently through the spargers and into the reaction tubes, flowing a heat transfer medium through a heat transfer inlet into the reactor so that it contacts the

20 exterior surfaces of the reaction tubes in a heat exchange relationship therewith, flowing the heat transfer medium through a heat transfer outlet out of the reactor, and _pc : flowing products of reaction from the reaction tubes through the reaction product outlet with which the tubes communicate.

Still another aspect of the present invention

30 is a process for producing ethylbenzene, the process comprising: feeding ethylene, catalyst, and benzene into reaction tubes in an alkylation reactor vessel in which they react exothermically producing a first stream with benzene, catalyst, ethylbenzene and polyethylbenzenes as

reaction products, flowing the first stream into a transalkylation reactor a reaction in the transalkylation reactor producing a second stream with a higher ethylbenzene content and a lower polyethylbenzene than the first stream the second stream containing catalyst, ethylbenzene, benzene, and polyethylbenzene, flowing the second stream to separation means for separating out its components, including ethylbenzene, flowing a heat transfer medium in heat exchange relationship with the reaction tubes in the reactor vessel to recover heat produced by the reaction of the ethylene and benzene, and flowing the thus heated transfer medium to the separation means to provide heat for operating the separation means.

A still further aspect of the present invention is a reactor for a reaction of reactant materials, the reactor comprising: a hollow reactor vessel having a first end. a second end, and a reaction product outlet from which products of the reaction flow from the reactor vessel, at least one reaction tube having an interior, an exterior surface, a first end and a second end and mounted within the reactor vessel extending from the first end of the reactor vessel to the second end of the reactor vessel, a first chamber disposed at the first end of the reactor vessel for receiving first reactant material, the first end of each of the at least one reaction tube communicating with the first chamber so that first reactant material flows turbulently with a

pressure drop from the first chamber into the interior of the at least one reaction tube through its first end, a hollow sparger disposed partially in each of the at least one reaction tube into and through which second reactant material flows turbulently with a pressure drop into the interior of the at least one reaction tube for reaction therein with the first reactant material, the second end of the at least one reaction tube communicating with the reaction product outlet so that reaction product of the reaction will flow from the interior of the reaction tube, into and through the reaction product outlet and out of the reactor vessel.

A still further aspect of the present invention is a reactor for a reaction of reactant materials, the reactor comprising: a hollow reactor vessel having a first end, a second end, and a reaction product outlet from which products of the reaction flow from the reactor vessel, at least one reaction tube having an interior, an exterior surface, a first end and a second end and mounted within the reactor vessel extending from the first end of the reactor vessel to the second end of the reactor vessel, a first chamber disposed at the first end of the reactor vessel for receiving first reactant material, the first end of each of the at least one reaction tube communicating with the first chamber so that first reactant material flows turbulently with a pressure drop from the first chamber into the interior of the at least one reaction tube through its first end, a hollow sparger disposed partially in each of

the at least one reaction tube into and through which second reactant material flows turbulently with a pressure drop into the interior of the at least one reaction tube for reacting therein with the first reactant material, the second end of the at least one reaction tube communicating with the reaction product outlet so that reaction product of the reaction will flow from the interior of the reaction tube, into and through the reaction product outlet and out of the reactor vessel, the reactor vessel having a heat transfer medium inlet and a heat transfer medium outlet for flowing a heat transfer medium into and out of the reactor vessel, the vessel configured and the at least one reaction tube disposed so that the heat transfer medium contacts the exterior of the reaction tube in heat exchange relationship and 'does not contact the first or second reactant materials, the reaction in the at least one reaction tube is exothermic and the heat transfer medium is heated via its heat exchange relationship with the at least one reaction tube which itself Is heated by the heat of the reaction, a second chamber for receiving the second reactant material the hollow sparger for each of the at least one reaction tub ^' es communicating with and extending from the second chamber so that the second reactant material flows from the second chamber, into and through the sparger, the at least one reaction tube including a plurality of reaction tubes, a hollow sparger corresponding to each tube, a portion of the first reactant material flowable into each of the reaction tubes, pressure of the first reactant material

decreasing in a first pressure drop between the first chamber and the interior of the reaction tubes, pressure of the first reactant material decreasing in a second pressure drop as it flows across the first chamber to each of the reaction tubes, the first pressure drop sufficiently greater than the second pressure drop so that a uniform amount of the first reactant material flows into each of the reaction tubes, the ratio of the first pressure drop to the second pressure drop is greater than 10, the hollow sparger for each reaction tube communicating with a second chamber disposed at the first end of the reactor vessel for receiving the second reactant material and from which the second reactant material flows into and through the spargers and out through a hole in an end of each sparger disposed in each reaction tube, pressure of the second reactant material decreasing in a primary pressure drop as it flows from the second chamber and out of the hole in each sparger, pressure of the second reactant material decreasing in a secondary pressure drop as it flows across the second chamber to each of the spargers, the primary pressure drop sufficiently greater than the secondary pressure drop so that a uniform amount of second reactant material flows into each of the spargers, the at least one reaction tube uniformly heated by the reaction along a major portion of their lengths.

So that the manner in which the above-recited features and advantages of the invention, as well as other which will become clear, are attained and can be understood in detail more particular descriptions of the invention briefly summarized above may be had by

reference to certain embodiments thereof which are illustrated in the appended' drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective equivalent embodiments.

Figure 1 is a schematic view of a reactor system according to the present invention.

Figure 2 is an end view of the reactor system of Figure 1.

Figure 3 is a cross-sectional schematic view of a portion of a reactor system according to the present invention.

Figure 4 is a schematic view of a portion of a reactor system according to the present invention.

Figures 5a and 5b are schematic end views of a reactor system according to the present invention.

Figures 6a and 6b are schematic end views of a reactor system according to the present invention.

Figure 7 is a schematic view of a process according to the present invention.

Figure 8 is a graph showing product distribution for a theoretical prior art process.

Figure 9 is a graph showing product distribution for a process conducted according to the present invention.

Figure 10 is a graph comparing a prior art process and a process according to the present invention.

Figures 11 and ^' 12 present data from a run of a 5 single tube reactor according to the present invention.

Figure 13 is a cross-sectional view of a gas sparger used in reactors according to the present invention. *

10

Figure 14 presents data from a process according to the present invention.

Figure 15 presents data from a process A - according to the present invention.

Referring now to Figures 1 and 2, a reactor system 10 according to the present invention has a shell section 12, a head 56 on a left end 14, and a head 58 on

_P » a right end 16. The shell section 12 (made e.g. from carbon steel) has a variety of inlets and outlets including: reactant entry nozzle 68: heat transfer medium inlet nozzles 18 and 20; drains 22 and 24 a relief outlet 26; instrument access nozzles 28 and 30;

25 ethylene feed inlets for the head 56: inlets 32, 34, 36 and 38; ethylene feed inlets for the head 58: 42, 44, 46 and 48; a product discharge outlet 40; and a tube side relief outlet 70; and a heat transfer medium outlet 54.

30 A primary tube sheet 50 is disposed between the shell section 12 and the head 56. Tube sheet 50 is made from Hastelloy B-2 ^,M material or a multi-layer member made from layers of carbon steel, nickel, and Hastelloy B-2 explosion bonded or welded together; e.g. 5/8 inch (16 mm) Hastelloy B-2, 1/8 inch (3.2 mm) nickel, and 7

to 9 inches (180 to 230 mm) of carbon steel. A primary tube sheet 52 is disposed between the shell section 12 and the head 58. End plates close off each head. An end plate 60 with a sealing gasket 64 is secured to the head 56. An end plate 62 with a sealing gasket 66 is secured to the head 58. It is preferred that whatever in the reactor encounters the reactants is made from Hastelloy B-2 material.

As shown in Figure 2, each ethylene feed inlet 32, 34, 36, 38 feeds into a particular section of the reactor system 10. The reactor system 10 has eight sets of transverse reaction tubes (not shown). Each set of tubes is fed by an individual ethylene feed; hence there are eight such inlets 32, 34, 36, 38 and 42, 44, ^' 46, 48. At the initial end of each set of reaction tubes, ethylene is fed into the tubes by feeding ethylene into a chamber and from it into spargers extending into each reaction tube from the chamber. Ethylene and other reactants (benzene and catalyst complex) move through the tubes, reacting and producing heat and reaction products. At the other end of the tubes, the tubes end in another liquid chamber from which extends another set of reaction tubes. Ethylene is again injected by spargers into the beginning of the new set of reaction tubes and the added ethylene, reactants, and products move back in the other direction through the shell section with the reaction proceeding as the materials move through the tubes. In the reactor system 10 of Figures 1 and 2, the materials make eight passes through the shell section; hence there are eight ethylene feeds.

Ethylene feed inlet 38 at a first end of the reactor as shown in Figure 2 feeds ethylene into an ethylene chamber 39 from which it is fed via spargers

(not shown) to a first set or pass of reaction tubes (not shown) containing benzene and catalyst complex. After these materials move across the shell section 12 in the first pass through the first set of reaction tubes, additional ethylene is injected via ethylene feed

³ inlet 48 at the other end (a second end) of the reactor which feeds into another ethylene chamber (not shown). From this chamber ethylene flows thorugh spargers (not shown) into the second set or pass of reaction tubes

10 (not shown) which extend to and intercommunicate with liquid chamber 37 (Figure 2). Via ethylene feed inlet nozzle 36, .additional ethylene is injected into a third set of reaction tubes which extend from chamber 37 to the second end of the reactor to another chamber (not

15 shown). A fourth set of reaction tubes extending from this chamber are fed with ethylene from ethylene feed inlet nozzle 46 (via spargers) and the tubes extend back to a chamber 33. A fifth set of reaction tubes (not shown) extending from the chamber 33 are fed with

20 ethylene from an ethylene feed inlet nozzle 34, the ethylene entering the tubes through spargers (not shown). These tubes (the fifth set) extend to a chamber (not shown) at the second end, of the reactor. The next

- - set of tubes (the sixth set) extending from this chamber are fed with ethylene from ethylene feed inlet nozzle 44 (via spargers). These tubes (the sixth set) extend to the first end of the reactor and end in a chamber 31. Additional ethylene is injected into spargers (not

30 shown) disposed in a seventh set of reaction tubes (not shown) via ethylene feed inlet nozzle 32 and spargers (not shown). The seventh set of reaction tubes extend from the chamber 31 in the first end of the reactor to another chamber (not shown) from which the eighth and final set of reaction tubes extends. Ethylene is fed

via an ethylene feed nozzle 42 through spargers (not shown) into the final (eighth) set of reaction tubes. The eighth set of reaction tubes extend from the chamber adjacent ethylene feed nozzle 42 in the second end of the reactor to a chamber 35 (Figure 2) from which products of the reaction exit the reactor via product outlet 40.

Shown schematically in Figure 3 is a four-pass reactor system 71 according to the present invention 0 having four sets or passes of reaction tubes, with tubes

1 ι 1ι < ^* _)- , n i £-.c , -i i -i. "l*j* , 1 i 1i C u . v - π3i1.-u..mιι "y\ . Λ v _* _*. — : T C ^* .-. ., — . Λ acαu I U ι a _scu u. «i. c —u i. > —u a _. shell section 72 by securing a flange 78 of the shell section 72 to a flange 82 of the head 76 by bolts (not - _t - shown) extending through bolt holes 84, 85 (in flange 82) and bolt holes 80, 81 (in -flange 76).

A secondary tube sheet 86, a gas chamber channel wall 88, and gas chamber inner walls 90 and 98

20 (made e.g. from Hastelloy B-2 alloy and welded together) define two ethylene gas chambers 94 and 96 each fed by an ethylene feed nozzle (not shown, like feed 32-38, 42- 48). Ethylene is conveyed from the ethylene gas chambers 94 and 96 by sparger feed tubes 100 and 102, 25 respectively,- which extend into reaction tubes 114 and 112, respectively. The secondary tube sheet 86 is spaced apart from a primary tube sheet 74 by a benzene chamber channel wall 124 which (with extensions of the gas chamber inner walls 90 and 98 extending through the

30 secondary tube sheet 86 to contact the primary tube sheet 74) define reactant entry chambers 118 and liquid chambers 120 and 122.

Reactants, e.g. liquid benzene and a catalyst complex, flow through a reactant inlet nozzle 108

extending through the shell section 72 and through the primary tube sheet 74, into the reactant entry chamber 118 at a first end of the shell section 72. From this chamber 118, the reactants flow into the reaction tube 112 in which they turbulently encounter ethylene gas fed into the reaction tube 112 through the sparger feed tube 102. These materials then flow turbulently through the reaction tube 112 to the other end (a second end not shown) of the shell section 72, ending in another reactant entry chamber (not shown) from which another reaction tube 126 extends back to the head 76 in the first end of the shell section. Before the materials leave the second end of the shell section, additional ethylene is injected into reaction tube 126 and the reactants then flow through reaction tube 126 to the liquid chamber 120. Thus the reactions proceed with materials moving from the chamber 120; into and through reaction tube 114; into another chamber (not shown) at the other end of the shell section; into reaction tube

116; into chamber 122; and out through product outlet nozzle 110. Through an ethylene sparger 100, ethylene from an ethylene chamber 94 is injected into reaction tube 114. Similarly at the other (second) end of the reactor, ethylene is sparged into the reaction tube 116.

Although only four reaction tμbes are shown in Figure 3- a schematic drawing, a plurality of reaction tubes can extend from each of the chambers 118, 120 and 122.

The reaction tubes within shell section 72 are surrounded by a heat transfer medium 104 (e.g. but not limited to liquid polyethylated benzene or water) to which is transferred the heat of the ethylene-behzene reaction. Via heat transfer medium inlet and outlet nozzles (not shown; like nozzles 18, 20 and 54 in Figure

1 ) the heat transfer medium circulates due to a thermosiphon effect or by the action of a conventional pump and thus the heat exchange medium 104 is moved through the shell section 72. The heat is extractable and can be used, e.g. to heat a stream in the process; to provide, heat for, the distillation of the various products ^' present in the product stream flowing from the outlet nozzle 110; or to generate steam for other uses.

As shown in Figure 4, a reactor system 131 (partially shown) similar to reactor systems 10 and 71 , niαjr s_.___p__.i_/_y o μαi 6 *=** u <-_ uc_. i j -_. emu I -) **t Ulld U CA U CIIU X U U O reaction tubes 142 and 144 that are flush with, but do not extend beyond, a primary tube sheet 136. The spargers extend from a secondary tube sheet 130 on the other side of which (left side in Figure 4) is an ethylene gas chamber 147 like, e.g. the chamber 96 in the reactor system 71 shown in Figure 3- The sparger tubes 132 and 134 extend across a liquid reactant chamber 146 from which reactants flow into the reaction tubes 142 and 144.

There are three pressure drops in an apparatus such as the reactor system 131 which affect material distribution — the pressure drop P-* from the liquid chamber 146 to the interior of the reactor tubes 142 and 144; the pressure drop ?2 across the liquid chamber 146, i.e. the pressure drop across the spargers 132 and 134; and the ethylene pressure drop P at the exit holes 133 and 135 in the ethylene spargers. To maximize the uniformity of the amount of liquid flowing down each reactor tube, pressure drop P-* should be significantly greater than pressure drop ^2 - ^' *** ⁿ °t ^her words, the opening of the reactor tube 142 should experience liquid pressure at almost the same pressure as the pressure of

liquid at the opening to the reactor tube 144. For example, if the liquid pressure at the opening to the reactor tube 142 is 370 p.s.i. (2500 kPa) and ? - is 3 p.s.i. (21 kPa) , the pressure of the liquid at the opening to the reaction tube 144 should not be significantly less than 370 p.s.i. (2500 kPa) . It is preferred ^' that it be at least about 369.7 p.s.i. (2500 kPa) . Similarly, the pressure drop P at the holes -133 and 135 in the ethylene spargers 134 and 132, respectively, should be signi icantly greater than a pressure drop Pj _j across the ethylene chamber 147. In other words, the effect of ethylene existing sparger 134 should not be so great that it significantly reduces the pressure of ethylene pressure experienced at the opening to the sparger 132. Liquid flows into the chamber 146 through reaction tubes 138, 140.

Figures 5a, 5b, 6a and 6b show two different chamber arrangements for reactors according to the present invention. Figures 5a and 5b show a "ribbon" chamber arrangement in which ethylene gas chambers and reactant chambers extend from one side of the head to the other; a plurality of reaction tubes intercommunicate with the reactant chambers and a plurality of sparger tubes extend across- the reactant (liquid) chambers. Figures 6a and 6b show a "quadrant" chamber arrangement (as in Figure 2). The chamber arrangement refers to the way in which partitions (made e.g. from Hastelloy B-2 material) in the heads are oriented, and consequently affects the liquid flow geometry through the heads. A ribbon chamber arrangement (Figures 5a, 5b) is superior to a quadrant chamber arrangement (Figures 6a, 6b) for two reasons. Both reasons are related to the inherent lower liquid

chamber crossflow velocities in the ribbon layout relative to that in the quadrant layout. First, lower crossflow velocities reduce or prevent vibration of the unsupported spargers which extend into the head. Second, lower crossflow velocities result in a lower liquid chamber crossflow pressure drop (?£)• A lower crossflow pressure drop results in improved liquid flow distribution to the reaction tubes, resulting in improved yields. The advantages of the chamber 0 arrangement become more significant as the scale of the reactor increases.

As shown in Figures 5a and 5b, a ribbon arrangement, each section of a reactor shell 160 z - represents a reactant entry chamber 162 (like chamber 118, Figure 3); liquid chambers I64a-g (like chamber 120, Figure 3); or a chamber 166 from which product exits (like chamber 122, Figure 3). Eight reaction passes of reactants take place in the shell 160; i.e.

20 passes between sections:

162 to 164a

2. 164a to 164b

25 3- 164b to 164c 4. 164c to I64d 5. I64d to I64e 6. I64e to I64f

30 7. I64f to 1δ4g 8. I64g to 166

As in the systems of Figures- 1 and 3. ethylene is injected into reaction tubes on each reaction pass.

In each of the sections of the shell 160, reaction tubes are arranged as the tubes 168 and 169 shown in section 164c. Reactants enter section 164c (a liquid chamber) through the reaction tubes 168 and leaves the section through the tubes 169. The height of the section 164c is H and the reactants from the tubes 168 must traverse the majority of the height H to enter the tubes 169. As shown there are six tubes 168 and six

- * t-- , , u < ,=*, r*. Λ i u <~ n 7 , .. 4υ- ± ^• yu- o - iz. υzA .u. x- u z> \ u- c z. , li. i —iu ^ c z. —i . - x- - uzA u zi o- Hzci. xu. * _. n j ;. ώ .*, invention is applicable to systems with one tube and systems with more than one tube, e.g. five hundred tubes or more.

As shown in Figures 6a and 6b, a quadrant arrangement, a reactor shell 180 is also divided into chambers or sections, a reactant entry chamber 182: liquid chambers 1δ4a-g; and a product exit chamber 186. Again, as in the system of Figures 5a and 5b, there are eight reaction passes: .

This chamber arrangement is like that of the system of Figures 1 and 2. Focusing on chamber 184c and comparing it to chamber 164c of the system of Figures 5a and 5b,. it is apparent that part of the reactants flowing into chamber 184c from a set of reaction tubes 188 and across the chamber 184c to another set of reaction tubes 189 traverses a greater distance D than the height H of the chamber 164c. Because of this difference in -the length of the flow path and the difference in the relative dispositions of the sets of tubes it is more difficult to achieve uniform flow distribution in the tubes 189 than in the tubes 169. Crossflow velocities of reactants in the shell 160 are lower than those in the shell 180. The small unnumbered circles in Figures 5a, 5b, 6a and 6b represent reaction tubes.

In preferred embodiments of reactor systems according to the present invention there are a number of critical design parameters. The discussion of these parameters that follows is with respect to a 1,500 million pound/year system for ethylbenzene production according to the present invention.

Liquid Chamber Width - The liquid chamber width is defined as the inside distance between the primary and secondary tubesheets (e.g. between sheets 74 and 86 in Figure 3). In preferred embodiments, the liquid chamber width is critical to achieving uniform liquid flow distribution among all tubes of a given pass. One key to improving uniform liquid flow distribution is to increase the ratio of the pressure drop of the liquid entering the tubes to the pressure drop of the liquid flowing across the extended gas spargers. It is preferred that this pressure drop ratio, e.g., P-| P2

Figure 4 be greater than 10, but most preferably equal to or greater than 25 to reduce liquid maldistribution to less than 15 percent and most preferably less than

3.5 percent. In terms of the pressure drops P- _| and P ₂ discussed in relation to the system of Figure 4, the ratio P- _j P2 should be preferably greater than 10 and most preferably greater than 25.

An increase in the liquid chamber width results in an increase in the pressure drop ratio. For the following conditions:

76" (1930 mm) I.D. liquid channel, (heads and shell section)

8 pass reactor,

Ribbon pass arrangement,

.750" (19 mm) 18 BWG reaction tubes,

500 tubes/pass,

1.25 pitch ratio, 30° layout,

.375" (9.5 mm) O.D. gas spargers,

Liquid Benzene + Catalyst feedrate = 400,000 lb/hr (182,000 kg/hr),

Liquid density - 37.5 lb/ft ³ (600.7 kg/m ³ )

Liquid viscosity = 0.14 cp, (1.4 x 10~ ⁴ Pa-s)

the liquid chamber width should be at least 4" (102 mm) (resulting in a pressure drop ratio of 20) to reduce liquid maldistribution to less than 3.5 percent. Because the pressure drop ratio is not a function of

total liquid flowrate, liquid flow, distribution and the choice of a suitable liquid ^' chamber width are not affected by reactor capacity.

"Pitch ratio" and layout refers to the disposition of and spacing between reaction tubes. Reaction tubes in a triangular layout result in a higher heat transfer coefficient than tubes in a square layout, and also require a smaller diameter shell for a given number of tubes. In a squared layout one tube may mask flow to or around another tube. It is preferred that

*-..l- -_ I -.£•£> _- _ ^* •. - -- _-!_ M n - II _ _- _l _* - u u ue o uc u _. j. c_ c υ l utu e<_n-;_ι U LIIB , r x u uπ i s uiit; distance between two tubes. "Pitch ratio" is the ratio of pitch to the outside diameter of the tubes. A "30° layout" refers to equiangularly spaced tubes in a generally triangular array; i.e. connecting three adjacent tubes from a triangle with one tube at the top and two on the base, a line drawn from the top tube to the base bisects the top angle of the triangle, i.e. forming two 30° angles.

Sparger Diameter - In preferred embodiments, the ethylene sparger tube outer iameter is critical to achieving uniform liquid flow distribution among all tubes of a given pass. As the sparger outer diameter increases for a given reaction tube inner diameter, the pressure drop of the liquid entering a reaction tube increases. The ratio of this pressure drop to the pressure drop of the liquid flowing across the extended gas spargers increases, and liquid flow distribution improves. However, as the sparger outer diameter increases, the overall pressure drop though the reactor increases as well as P-*. For the previously listed operating conditions, a sparger tube outer diameter of at least 3/8" (9.5 mm) reduces liquid maldistribution to

less than 3.5 percent. It is preferred that this diameter in combination with other design factor be such that, e.g. in the system of Figure 4, P- _| be signi icantly greater than p2 _* i.e. greater than 10 and preferably greater than 25.

Sparger Hole Size - The sparger hole is the opening at the end of the sparger tube through which gas (or liquid in other processes) flows into the reaction tube (e.g. holes 133» 135, Figu e 4). In preferred embodiments, the sparger hole size is critical to aCiiiβving unixorm gas now uiSL-.-iui_tis--.ui a.ia _ig of a given pass. As the sparger hole diameter decreases, gas flow distribution improves. For a total ethylene feedrate of 54,000 lb/hr (20,000 kg/hr) and the reactor configuration described previously, a sparger hole diameter of 0.0625" (1.6 mm) limits gas flow maldistribution to less than 2 percent. It is preferred that sparger hole size be adjusted so that gas flow maldistribution is at least less then 15 percent.

Reaction Tube Diameter, Reaction Tube Length, Number of Passes, and Number of Reaction Tubes Per Pass - The reactor configuration parameters of tube diameter, tube length, number of passes, and number of tubes per pass can be optimized simultaneously. Four criteria considered in optimizing preferred embodiments of this invention are: minimizing residence time in the reactor; maintaining a recommended heat transfer flux across the tubes and maximizing heat recovery; and ensuring maximum or complete reaction of ethylene. For the following conditions:

Ethylene feedrate = 54,000 pounds/hour (20,000 kg/hr)

Benzene feedrate = 400,000 pounds/hr (182,000 kg/hr),

Ethylene inlet temperature = 50°C

Benzene inlet temperature = 220°C,

Reactor pressure at inlet = 395 psia (2720 kPa)

Shellside boiling temperature (vaporization begins) = 208°C,

Shellside exit vapor fraction ( % vapor of exiting heat transfer medium) = 0.200,

optimum values for tube length and number of tubes per pass are 23 feet (7 m) and 500, respectively. Tube diameter is held to a minimum of 0.75" (19 mm) O.D., and the number of passes was held at a maximum of 8. A preferred heat transfer flux is between 2000 and 8000 Btu/hour/square foot of heat transfer surface area. For this embodiment it is aobut 4000 Btu/hr/ft ² .

Sparger Tube Penetration Length - The sparger tube penetration length is defined as the axial distance that an ethylene sparger protrudes down into the start of a reaction tube. In preferred embodiments, the sparger tube penetration length should be no less than .5 inches (12.7 mm) to ensure that no ethylene backs out of a reaction tube. The sparger tube penetration length accounts for only about 10 percent of the total pressure drop of the liquid tube-entry pressure drop, and so plays only a minor role in_ determining liquid flow

distribution and total pressure drop through the reactor.

As shown in Figure 13 an ethylene gas sparger 400 according to the present invention, made from a piece of Hastelloy B-2 material tubing, has a nozzle end 402 which is swaged down so that a hole 404 of desired size ^' provides an exit opening for ethylene gas to flow into a reaction tube. The sparger 400 is shown as welded to a tube sheet 406 of a thickness B. The sparger's overall length is A, the length of the nozzle end is D, oue sparger uUue ouι>er uiameυer ^* is r, siue wall thickness is G, the hole opening size is E, and the sparger extends to a length C beyond the tube sheet for ease of welding. In one preferred embodiment these dimensions are:

A = 7 inches ( 178 mm)

B = 1 inch (25.4)

C = one eighth inch (0.125 mm)

D = one half inch (12.7 mm)

E ^*** .063 ± .002 inches (1.60 ± 0.051 _. mm)

F = three eighths inch (9.525 mm)

G = .065 inches (1.65 mm)

It is within the scope of this invention to have more than one ethylene feed nozzle feeding into a single ethylene chamber and, in one preferred embodiment, two ethylene feed nozzles feed each ethylene chamber producing a more uniform feed to the gas spargers. Also, liquid distribution may be more uniform

with a plurality of product outlets rather than one and, in one preferred embodiment four product outlets communicating with a single chamber are employed.

. Similar.ly, liquid distribution to the reaction tubes of a particular chamber may be more uniform with a plurality of liquid inlets into the chamber and, in one preferred embodiment, four liquid inlets feed into a single liquid (benzene and catalyst) chamber.

Figure 7 illustrates schematically a process 0 300 for producing ethylbenzene according to the present x _ _* u- _* .v.e —i —i —Li 2 uπ . τ vr i_ d- <_± r*_ _ _i *» ; -_ _ "l ι _J *__ -ι x. _ ι_ _._i. linn I BBU l n s JU I , Cd ϋdi b L i _^ ϋbu u L. -tuu pounds per hour (181 g/hr)-25°C), such as aluminum chloride - HC1 catalyst for this reaction, is fed into z - an end head (not shown; like head 56, Figure 1 or head 76, Figure 3) of a reactor 303 via a feed line 302. Via a feed line 302 ethylene gas at about 25°C is fed into the head of the reactor 303- Via a feed line 304 benzene at about 220°C is fed into the reactor 303. It

20 is preferred that an excess of benzene, at least 100 percent, but preferably 200 percent or more, (e.g. 3 molecules of benzene for each molecule of ethylene) be fed to the reactor. The reactor 303 is like the previously described reactors according to the present

25 invention.

Reaction products and other materials (ethylbenzene, polyethylated benzenes, benzene, catalyst) exit from the reactor 303 via line 305 at

30 about 230°C. A valve 306 in line 305 controls the pressure in the reactor 303 (set, e.g. at about 350 p.s.i.g. (2400 kPa gauge)). The materials in line 305 are relatively hot (230°C in this example) and they are fed through a heat exchanger 307 in heat transfer relationship with benzene at 90°C from a line 308. This

benzene is heated from 90°C to 220°C (line 304). The reaction products and materials (now cooled to 145°C) flow from the heat exchanger 307 in line 309. Via line 309 this stream then flows to a heat exchanger 340 wherein heat is transferred from the materials in line 309 to a stream 323 (primarily benzene) from a benzene recovery tower 322. The materials from line 309 exit the heat exchanger in line 341 at about 125°C. Prior to joining materials in line 310, the materials in line 341 are cooled by a cooler (e.g. fan) 342 to about 65°C.

31 •? c one r cau i/ i un y i uu u υ o — α_-..n—u.-. υ _ ucι materials in line 341 mix with polyethylated benzenes recovered by a tower 311 and flow through line 312 to a transalkylation reactor 313. The transalkylation reactor 313 is operated at 65°C. It produces a product in line 314 in which the amount of polyethylated benzenes from line 312 have been reduced and the amount of ethylbenzenes has been increased. Line 314 also contains unreacted catalyst.

The materials in line 314 are fed to a catalyst settler 315 run at, 3 e.g., 50°C, wherein recyclable catalyst which can be fed back to the transalkylation reactor 313 via a line 316 (at 50°C); and a materials stream which exits the settler 315 via a line 317 are produced. Line 317 contains ethylbenzene, benzene, polyethylated benzenes, ^' and catalyst. It is fed to a wash system into which water is fed via a line 3 9 and from which water and dead catalyst exit via a line 320.

The materials exiting from the wash system 318 flow via a line 321 (at 50°C) to the benzene recovery tower 322. The material stream in line 321 is, e.g., about 53 percent benzene, about 40 percent ethylbenzene

and about 7 percent polyethylated benzenes. Benzene exits from the top of this distillation tower and flows via a line 323 to a benzene drying tower 324. The materials remaining from line 321 (ethylbenzene and polyethylated benzenes) flow via a line 325 at 124°C to an ethylbenzene finishing distillation tower 326. Ethylbenzene at 150°C exits from the top of the tower 326 via a line 327. Polyethylated benzenes exit the tower 326 via a line 329. A portion of them (e.g. about 0 1 percent) flow, via a line 330 to the polyethylated benzenes recovery distillation tower 311. Another portion of the polyethylated benzenes at 208°C are flowed via a line 328 to act as the heat transfer medium in the reactor 303 ("EB TOWER BOTTOMS"). These 5 polyethylated benzenes are heated in the reactor 303 by the exotherm from the ethylene - benzene reaction in the reactor's reaction tubes. The heated polyethyleated benzenes at, e.g., about 210°C flow from the reactor 303 via a line 331 back to the ethylbenzene finishing tower 0 326 to provide heat energy for the tower 326. The EB TOWER BOTTOMS in line 328 are essentially 100 percent liquid. A vapor/liquid combination exits the reactor 303 via line 331 and it is preferred that it be 5 _pc - percent to 50 percent vapor, most preferably about 15 percent vapor and about 85 percent liquid.

The reaction products and other materials in line 312 may be present as follows (percent by weight):

30 60 percent benzene; 30 percent ethyl benzene; 10 percent polyethylated benzenes; negligible amount of catalyst. The benzene content might range as low as 30 percent; the ethylbenzenes as low as 5 percent and as high as 45 percent; and the polyethylbenzenes as high as 30 percent. The stream in line 314 is preferably: about

53 percent benzene; about 40 percent ethylbenzene; and about 7 percent polyethylated benzenes - all ranging as dependent on the ranges stated regarding line 312. From the polyethylated benzenes recovery tower 311 polyethylated benzenes exit via a line 310 and proceed - to join with the products from the reactor 303 (in line

309) to flow to the transalkylation reactor 313- A condenser 343 cools the materials in line 310. Tar-

(residue) flows from the tower 311 via a line 332,

10 The graphs in Figures 8, 9, and 10 present a mδθι-θι,ica.ι (Oiuμ ison uj. a priur a i*. process in πicfl polyethylated benzenes are recycled to an alkylator reactor and a process according to the present invention

A - in which produced polyethylated benzenes are not recycled to the alkylator reactor (as they are e.g. in feed line 310 to reactor 313 in Figure 7). The abscissa of these graphs, epsilon, represents the process' ratio of ethylene to benzene in the reactor feed; e.g. .333

20 would indicate 1 molecule of ethylene per 3 molecules of benzene. These figures show the theoretical composition of an alkylator system's product as a function of epsilon where epsilon is the ratio of moles of ethyl groups to moles of aromatic rings in the alkylator.

25 These figures represent processes which -are closed loop processes between alkylator, transalkylator, and the finishing section with (and without) the recycle of polyethylated benzenes to the alkylator. In the

30 processes reactions between ethylene and polyethylbenzenes to produce further polyethylbenzenes are more likely on an equal molar basis than reactions between ethylene and benzene to produce ethylbenzene.

As the amount of ethylene increases in the prior art process of Figure 8, the amount of

ethylbenzene produced (the "E" line) begins to diminish after about .5. The vertical axis (Figures 8 and 9) is in units of weight percent of a total of 100 percent.

In contrast, as shown in Figure 9, with a process according to the present invention (e.g. as that shown in Figure 7) not only does the amount of ethylbenzene produced exceed that of the prior art process of Figure 8 at almost every point on the paragraph, it also does not diminish significantly. These graphs also show that the amount of polyethylated benzenes produced is greater in the prior art process.

The graph of Figure 10 illustrates a comparison of the conversion of ethylene and benzene to ethylbenzene in a prior art process employing a larger reactor for both alkylation and transalkylation and a process according to the present invention employing a reactor according to the present invention as previously described. The "S" line is for a CSTR, a prior art continuous stirred tank reactor in which back mixing occurs; i.e. the undesirable formation of polyethylbenzenes occurring when ethylbenzenes and previously-formed polyethylbenzenes are recirculated in the tank reactor to again react with ethylene to form more polyethylbenzenes. Reaction times in such a reactor are typically 45 to 60 minutes. In a reactor according to the present invention, e.g. an eight-pass reactor, the total residence time in the reactor would be about 1 minute, or slightly less than 8 seconds (7.5 seconds) per pass. It is preferred that residence times be 15 seconds or less. This process is represented as the "P" line in Figure 10 since it approaches plug-flow. As shown the conversion to ethylbenzene is significantly higher for the process (P) according to the present

invention. The vertical axis in Figure 10 represents percent approach to equilibrium (equilibrium is the point at which no further reaction occurs).

Tables I and II present data obtained from a run of a single tube ("showtube") unit described to indicate performance of ethylene injection, reaction, and heat transfer according to the present invention. The reactor for this unit was a 13-5 foot by 1.5 inch Hastelloy alloy pipe jacketed with a 2.5" (63.55 mm) diameter carbon steel pipe. Catalyst used for this run was rtsu u l ^• CunϊμieX prepa e i rum al u inum iiiθ L-li _t

HC1 gas and liquid ethylated benzenes. In this preferred embodiment the catalyst composition is prepared in a separate vessel as follows: aluminum metal (solid) fed at 5 weight percent; liquid polyethylbenzene fed at 57 weight percent; HC1 gas fed at 38 weight percent; fed at 75°C and 30 p.s.i.g. (207 kPa gauge) with a contact time of 30 minutes. The aluminum concentration in the reactor was 442 parts per million. The reactants entered the showtube at about 195°C and exited at 211°C. As can be seen in Table II, essentially 100 percent of the ethylene was reacted with a Liquid Hourly Space Velocity of 330 hour"' (reciprocal of the residence time) at reaction conditions. Thermocouples were placed every 2 inches (50.8 mm) in the reaction tube and every 4 inches: (101.6 mm) in the heat transfer medium surrounding the reaction tube. The pressure at the liquid entrance to the reaction tube was about 279.4 p.s.i. (1925 kPa); that of the heat transfer medium was about 85.0 p.s.i. (585 kPa) .

As shown in Table I, the reaction temperature approached 205°C at a distance of about 46 inches (1170 mm) into the tube and stayed between 205°C and 210°C

until about 138 inches (3500 mm) into the tube. The heat transfer medium in the shell (jacket) approached

150°C 32 inches (813 mm) into the shell and remained around 155°C to 160°C. This fairly consistent temperature profile along the tube indicated that such a tube and such materials under these conditions would efficiently transfer heat from the reaction in the tube to the heat transfer material, heat which could then be utilized elswhere in the process.

Table III presents data for a process to produce ethylbenzene in accordance with the present invention in a reactor system according to the present invention as illustrated in Figures 1, 2 and 6a. For this process flow parameters are as follows:

Shell Internal Temperature

207 C (heat transfer medium)

Benzene Feed Temperature 225 C Benzene Feed Pressure 357.5 psig (2465 kPa gauge)

Product Outlet Pressure 348.2 psig (2400 kPa gauge)

Shell Pressure 7.08 psig (49 kPa gauge)

Total Ethylene Feed Rate 571 pounds/hour (259 kg/hr) Benzene Feed Rate 4495, pounds/hour (2040 kg/hr;

Catalyst Feed Rate 8.88 pounds/hour (4 kg/hr)

HC1 (gas) Feed rate 11.08 pounds/hour (5 kg/hr)

This is an eight pass reactor (eight sets of six reaction tubes in each pass), and it has eight ethylene chambers with six spargers in communication with each chamber. The flow of ethylene in pounds per hour (kg/hr) to each of these chambers is as follows:

10

The exit temperature (in degrees Celsius) of ic- reactant materials and products for each pass

(temperature measured at the end of each pass in the liquid chambers) is as follows:

0

5

0

The heat transfer coefficient for this process is 197 Btu/hour/ft ² /°F (1119 W/(m ² -k)). The data -in Table III as well as the data above indicate: (a) essentially all ethylene is reacted in each pass; (b) the temperature profile of the reactants is relatively

flat which shows that the heat of the reaction is being uniformly and efficiently transferred to the heat transfer medium; (c) a uniform amount of ethylene is being fed to each of the eight passes; and (d) the epsilon in the alkylator is approximately 0.35, i.e., about one.ethyl group per each three aromatic rings.

Table IV presents data from a process according to the present invention in a reactor system according to the present invention as illustrated in Figures 5a and 7. For this process, flow parameters are as

Shell Internal Temperature 216.6 C

Ethylene Feed Temperature 21.6°C

Benzene Feed Temperature 230.8°C

Benzene Feed Pressure 391.7 psig (2700 kPa gauge)

Shell Pressure 28.3 psig (195 kPa gauge)

Benzene Feed Rate 353,100 pounds/hour

(160,166 kg/hr)

Catalyst Feed Rate 2799 pounds/hour (1270 kg/hr)-

HC1 (gas) Feed Rate 82.9 pounds/hour (38 kg/hr)

Total Ethylene Feed Rate 49,910 pounds/hour (22600 kg/hr)

Heat Transfer Coefficient 160 (900) Btu/Hour/Ft ² /°F (W/m ² *k) *

AlCl concentration (ppm) 1805

Liquid temperatures (°C) for each pass OJ reactant materials are:

Ethylene feeds for each pass 1000 pounds/hour( 1000 kg/hour) are

The data in Table IV indicates: (a) essentially all ethylene is reacted in each pass; (b) the temperature profile of the reactants is relatively flat which shows that the heat of the reaction is being uniformly and efficiently transferred to the heat transfer medium; (c) a uniform amount of ethylene is being fed to each of the eight passes; and (d) epsilon

in the alkylator is approximately 0.40, i.e.. about two - ethyl groups for each five aromatic rings.

In processes according to the present invention, e.g. Figure. 7, the alkylation and transalkylation steps are carried out separately and thus each step can be individually optimized. Because of the nature of reactors according to the present invention, the alkylation process can be optimized to reduce or negate the effects of back mixing which occur 0 even in prior art processes in which transalkylation and alkylation are carried out in two separate reactors. In various prior art processes the catalyst concentration exceeds the solubility limit of catalyst in the liquid

,j- reactants producing a heterogeneous reaction mixture which contains two liquid phases (and therefore requires more catalyst). Two liquid phases moving down reaction tubes would perform inefficiently. Catalyst concentrations in preferred processes according to the

20 present invention (e.g. in the particular processes described above) are below the solubility limit and are therefore homogeneous. The fact that in processes according to the present invention relatively high reaction temperatures are achievable contributes to the

25 fact that the catalyst solubility limit is not exceeded (i.e., at higher temperatures the solubility limit is higher). Further contributing to the efficiency of processes according to the present invention is the

30 relatively low temperature of the transalkylation reaction. It is preferred that this temperature be less than 75°C and more than 40°C, with 65°C preferred. This relatively cooler temperature will produce a two-phase reactant mixture in the transalkylator. "Yield" is the ratio of ethylbenzene produced to the sum of ethylene

and benzene fed to a plant.- Yields for processes and alkylators according to this invention, are very high. For example, in a process carried out in a reactor such as that of Figures 1 and 2 and alkylator, yield of 99.7 percent (which would correspond to an overall plant yield of 99.6 percent) was achieved. For this particular process other parameters were as follows:

Epsilon •

.36/.45 Alkylator/Transalkylator

Ethylene Fixation (Amount 100% of Ethylene reacted)

Benzene Feed Temperature 222"C

Liquid Product Temperature 238°C

Residence Time (Total In about 1 minute Reactor)

Heat Transfer Coefficient 168 (954) Btu/(hour*foot ² °F (w/m ² *k))

Liquid Product Outlet 350 psig (2400 kPa gauge) Pressure

Pressure Drop Through Tubes 10.6 psi (73 kPa)

Benzene Feed Rate 4500 pounds/hour (2040 kg/hr)

Total Ethylene Feed Rate 577 pounds/hour (262 kg/hr)

Catalyst Cocentration 900 to 1200 (parts per million)

This plant operated for 1131 hours with no evidence of fouling with residue (tar).

In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein are well adapted to carry out the objectives and obtain the ends set forth at the outset. Certain changes can be made in the method and apparatus without departing

from the spirit and the scope of this invention. It is realized that changes are possible and it is further intended that each element or step recited in any of the following claims is to be understood as referring to all equivalent elements or steps for accomplishing substantially the same results in substantially the same or equivalent manner. It is intended to cover the invention broadly in whatever form its principles may be utilized. The present invention is, therefor, well adapted to carry out the objects and obtain the ends and advantages mentioned as well as others inherent therein.

Table I OW UBE UN CONDITIONS

Table I (continued) TFA SHOWTUBE RUN CONDITIONS

Control Temperatures (Celsius) ² 5 Ethylene 40.9

Aromatic 196.0 HC1 39.4

Flows Benzene in 1247.0 #/HR. (pounds/hour) Ethylene 89.9 #/HR 30 shell Polys 2258.0 #/HR (Heat Transfer Medium) "Red Oil" 18.6 #/HR (Catalyst)

Table II TFA SHOWTUBE FEED AND PRODUCT COMPOSITIONS

FEED PRODUCT

WEIGHT % MOLE % WEIGHT % MOLE %

Ethylone 3.82385 10.07955 0.00000 0.00000

Uni enlified 1.75699 2.59857 1.64192 2.69848

Benzene 85.47470 80.92187 77.62641 81.66578 methyicyclohexane ' 0.00301 0.00229 0.13291 0.11245

Toluene 0.56605 0.45435 0.49352 0.44019

Undentified 0.21574 0.15954 0.09933 0.08163

Ethylbenzene 7.50299 5.22598 6.04497 12.41865

Cuniene 0.00347 0.00214 0.00641 0.00438 n-propylbenzene 0.00998 0.0061 0.01367 0.00935 m-ethyltoluene 0.00626 0.00385 0.04885 0.03340 p-ethy1toluene 0.00021 0.00013 0.02941 0.02011 o-ethyllυlucne 0.00010 0.00006 0.04456 0.03046 iso-bu ylbenzene 0.00946 0.00521 .0.01893 0.01159 sec-butylbenzene 0.00310 0.00171 0.04531 0.02774 m-Diethylbenzene 0.02456 0.01353 1.50422 0.92101

Table II (continued)

FEED PRODUCT

WEIGHT % MOLE % WEIGHT % MOLE % p-diethylbenzene 0.00772 0.00425 0.72177 0.44193 o-diethylbenzene 0.00059 0.00033 0.45638 0.27943

Diethyltoluenes 0.00744 0.00371 0.00000 0.00000 m-elhylcumene 0.00016 0.00008 0.00000 0.00000 p-ethylcumcne 0.00005 0.00003 0.00000 0.00000 o-ethylcumene 0.00000 0.00000 0.00000 0.00000 m-ethy1-n-propylbenzene 0.00090 0.00045 0.00396 0.00219 p-ethyl-n-propylbenzene 0.00043 0.00021 0.01070 0.00593 o-ethyl-n-pdropy]benzene 0.00004 0.00002 0.00000 0.00000 tetral in 0.00150 0.00084 0.00836 0.00520 m-ethyl-iso-butylbenzene 0.00102 0.00047 0.00840 0.00425 p-ethyl-iso-bu ylbenzene 0.00047 0.00022 0.00242 0.00123 o-ethy1-iso-butylbenzene 0.00001 0.00001 0.00000 0.00000 m-ethy1-sec-butylbenzene 0.00062 0.00028 0.00000 0.00000 p-et hy1-sec-butylbenzene 0.00017 0.00008 0.00242 0.00123

o-ethyl-sec-bu ylbenzene

Unidenti ied

135- ie hy1benzene

124-triethylbenzene

123-triethylbenzene

Diethylcumenes

Diethyl-n-propylbenzenes

Phenylcyclohexane

Diethyl-iso-butylbenzenes

Diethyl-sec-butylbenzenes

1235- etrae hy1benzene

1245-tetraethylbenzene

1234-tetraethylbenzene

Diphony1muL ane

Unidentified

Table II (continued)

FEED PRODUCT

WEIGHT % MOLE % WEIGHT % ^• MOLE %

1 , 1-di phenylethane 0.00581 0.00236 0.03251 0.01466 1 ,2-diphenylethane 0.00000 0.00000 0..00000 0.00000 Pentaethylbenzene 0.00000 0.00000 0.00000 0.00000 Hexaethylbenzene 0.00000 0.00000 0.00000 0.00000 Ethyldi phenylethane 0.00000 0.00000 0.00391 0.00153 Unidentified 0.00961 0.00309 0.00000 0.00000 Aluminum chloride 0.21014 0.11654 0.21854 0.13468 Hydrogen chloride 0.13995 . 0.28393 0.13995 0.31550 Water 0.00000 0.00000 0.00000 0.00000

Compound

m-diethylberi2ene p-di thylb nzene o-diethylbenzene diethy1 toluenes in- ethylcuinent. p*-ethylcumene o-ethylcumene m-ethyl-n-propylbenzene p-ethy 1-n-propy 1 benzene o-ethyl-n-propyl benzene te ral in in- ethy1-iso-buty1benzene p-ethyl-iso -butylbenzene o-ethyl-iso-butylbenzene

Table III (continued)

R-1 Feed Pass 1 Pass 2 Pass 3 Pass 4 Pass 5 Pass 6 Pass 7 Pass 8

Compound Weight % Weight % Weight % Weight % Weight % Weight % Weight . Weight % Weight % in-ethyl-sec-butylbenzene p-ethyl-sec-butylbenzene o-e hyl-sec-butylbenzene

Unidentified

135-triethylbenzene

124-triethy1benzene

123-triethylbenzene

Diethylcumenes

Diethyl-n-propylbenzene

Phenylcycloheκanes

Diethyl-iso-butylbenzenes

Diethyl-sec-butylbenzenes

1235-tetraeth lbenzene

1245-tetraethylbenzene

Compound

1234-tetrae hylbenzene

Di henylme hane

Unidentified

1,1-Diphenylethane

1,2-Diphenylethane Pentaethylbenzene Hexaethylbenzene E hyI iphenyle hane Unidentified Aluminum chloride Hydrogen chloride Water

Table IV

R-1 Feed Pass 1 Pass 2 Pass 3 Pass 4 Pass 5 Pass 6 Pass 7 Pass 8

Compound Weight % Weight % Weight % Weight % Weight % Weight % Weight % Weight % Weight %

Unidentified 1 Benzene

Methcyclohexane Toluene Unidentified 2 Ethylbenzene Cumene π-propylbenzene m-ethy1toluene p-ethyl oluene o- ethyltoluene iso-butylbenzene sec-bu ylbenzene in-diethylbenzene

Table IV (continued)

R-1 Feed Pass 1 Pass 2 Pass 3 Pass 4 Pass 5 Pass 6 Pass 7 Pass 8

Comoound . . . .

^ Weight % Weight % Weight % Weight % Weight % Weight % Weight % Weight % Weight % -diethylbenzene o-diethylbenzene

Di- ethyl-tol m-ethylcuinene p-ethylcumene o-ethylcumene m-ethyl-n-propyl p-ethyl-n-propyl o-ethyl-n-propylbenzene

Tetralin m-ethyl-iso-butyl p-ethyl-iso-butyl o-ethyl-iso-butyl in-me hyl-sec-bu yl

Table IV ( cont i nued )

R-1 Feed Pass 1 Pass 2 Pass 3 Pass 4 Pass *5 Pass 6 Pass 7. Pass 8 ° ^mp0Un Weight % Weight % Weight % Weight % Weight % Weight % Weight % Weight % Weight % p-ethyl-sec-bu yl o-ethyl-sec-butyl

Unidentified 3

135-tribenzene

124-triethylbenzene

123-1riethyIbenzene

Diethylcumenes

Diethyl-n-propyl

Phenylcyclohexane

Diethyl-iso-butyl

Diethylrsec -butyl

1235- etraethyIbenzene

1245-tetraeth Ibenzene

1234-tetrae hylbenzene

Table IV (continued)

R-1 Feed Pass 1 Pass 2 Pass 3 Pass 4 Pass 5 Pass 6 Pass 7 Pass 8

Compound Weight % Weight % Weight % Weight % Weight % Weight % Weight % Weight % Weight %

Diphenylethane Unidentified 4 1,1-Diphenylethane 1,2-Diphenyletha Pen aethyIbenzene Hexae hyIbenzene EthyIdiphenylethane Unidentified 5