反(fan)應(ying)過(guo)程的基本特征決定了適宜(yi)的反(fan)應(ying)器形式(shi)。例如氣固相反(fan)應(ying)過(guo)程大致是用固定床反(fan)應(ying)器、流化床反(fan)應(ying)器或移動床反(fan)應(ying)器。但(dan)是適宜(yi)的選(xuan)型則需(xu)考慮反(fan)應(ying)的熱效應(ying)、對反(fan)應(ying)轉(zhuan)化率和選(xuan)擇(ze)率的要求、催化劑物理化學性態和失活等多(duo)種因素。
不(bu)銹鋼(gang)反(fan)(fan)應(ying)器的操作方式和加料方式也需考(kao)慮(lv)。例(li)如，對(dui)于(yu)有串(chuan)聯或(huo)平行副反(fan)(fan)應(ying)的過(guo)程，分段進料可(ke)能優(you)于(yu)一次(ci)進料。溫(wen)度序(xu)列也是反(fan)(fan)應(ying)器選型的一個重要因素。例(li)如，對(dui)于(yu)放(fang)熱的可(ke)逆反(fan)(fan)應(ying)，應(ying)采用先高后(hou)低的溫(wen)度序(xu)列，多級(ji)、級(ji)間換熱式反(fan)(fan)應(ying)器可(ke)使(shi)反(fan)(fan)應(ying)器的溫(wen)度序(xu)列趨于(yu)合理。
下面主要介紹釜式反(fan)應(ying)器、管式反(fan)應(ying)器、塔式反(fan)應(ying)器、固定床反(fan)應(ying)器、流化床反(fan)應(ying)器。
①. 釜式(shi)反應器
釜(fu)(fu)(fu)式反(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)也(ye)稱槽式、鍋式反(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)，它是各類反(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)中(zhong)結構較(jiao)為(wei)簡單且應(ying)(ying)(ying)用(yong)較(jiao)廣的(de)(de)一種(zhong)。主要應(ying)(ying)(ying)用(yong)于液(ye)-液(ye)均(jun)相反(fan)(fan)(fan)應(ying)(ying)(ying)過程，在(zai)氣(qi)-液(ye)、液(ye)-液(ye)非均(jun)相反(fan)(fan)(fan)應(ying)(ying)(ying)過程中(zhong)也(ye)有應(ying)(ying)(ying)用(yong)。在(zai)化工生產(chan)中(zhong)，既適用(yong)于間(jian)歇(xie)操作(zuo)過程，又可單釜(fu)(fu)(fu)或(huo)多(duo)釜(fu)(fu)(fu)串聯用(yong)于連續操作(zuo)過程，但在(zai)間(jian)歇(xie)生產(chan)過程中(zhong)應(ying)(ying)(ying)用(yong)最(zui)多(duo)。釜(fu)(fu)(fu)式反(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)具有適用(yong)的(de)(de)溫(wen)(wen)度(du)和壓力范圍寬、適應(ying)(ying)(ying)性強、操作(zuo)彈性大、連續操作(zuo)時(shi)溫(wen)(wen)度(du)濃度(du)容易控制、產(chan)品質(zhi)量均(jun)一等特點。但用(yong)在(zai)較(jiao)高(gao)轉(zhuan)化率工藝要求時(shi)，需(xu)要較(jiao)大容積。通常(chang)在(zai)操作(zuo)條件(jian)比(bi)較(jiao)緩和的(de)(de)情(qing)況下使用(yong)，如常(chang)壓、溫(wen)(wen)度(du)較(jiao)低且低于物料沸點時(shi)，應(ying)(ying)(ying)用(yong)此(ci)類反(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)最(zui)為(wei)普(pu)遍(bian)。
②. 管式(shi)反應器(qi)
管(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)器主要用(yong)(yong)(yong)于(yu)氣(qi)相、液相、氣(qi)-液相連(lian)(lian)(lian)續(xu)(xu)反(fan)(fan)(fan)(fan)應(ying)(ying)過(guo)程(cheng)，由(you)單根（直管(guan)(guan)或(huo)(huo)盤(pan)管(guan)(guan)）連(lian)(lian)(lian)續(xu)(xu)或(huo)(huo)多根平行排列的(de)(de)(de)管(guan)(guan)子(zi)組成，一般設有(you)套管(guan)(guan)或(huo)(huo)殼管(guan)(guan)式(shi)(shi)(shi)換(huan)熱裝(zhuang)置。操作(zuo)時(shi)，物料(liao)自(zi)一端(duan)(duan)連(lian)(lian)(lian)續(xu)(xu)加入(ru)，在管(guan)(guan)中連(lian)(lian)(lian)續(xu)(xu)反(fan)(fan)(fan)(fan)應(ying)(ying)，從另一端(duan)(duan)連(lian)(lian)(lian)續(xu)(xu)流出，便達到了要求的(de)(de)(de)轉化(hua)(hua)率。由(you)于(yu)管(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)器能承受較(jiao)高(gao)的(de)(de)(de)壓(ya)力，故用(yong)(yong)(yong)于(yu)加壓(ya)反(fan)(fan)(fan)(fan)應(ying)(ying)尤為(wei)合(he)適，例如(ru)油脂或(huo)(huo)脂肪酸加氫生(sheng)產(chan)高(gao)碳(tan)醇、裂解反(fan)(fan)(fan)(fan)應(ying)(ying)用(yong)(yong)(yong)的(de)(de)(de)管(guan)(guan)式(shi)(shi)(shi)爐便是管(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)器。此種反(fan)(fan)(fan)(fan)應(ying)(ying)器具有(you)容積小、比表面大(da)(da)、返(fan)混少、反(fan)(fan)(fan)(fan)應(ying)(ying)混合(he)物連(lian)(lian)(lian)續(xu)(xu)性變化(hua)(hua)、易于(yu)控制(zhi)等(deng)優點。但(dan)若(ruo)反(fan)(fan)(fan)(fan)應(ying)(ying)速(su)度(du)較(jiao)慢時(shi)，則有(you)所需(xu)管(guan)(guan)子(zi)長、壓(ya)降較(jiao)大(da)(da)等(deng)不足。隨著化(hua)(hua)工(gong)生(sheng)產(chan)越來越趨(qu)于(yu)大(da)(da)型化(hua)(hua)、連(lian)(lian)(lian)續(xu)(xu)化(hua)(hua)、自(zi)動化(hua)(hua)，連(lian)(lian)(lian)續(xu)(xu)操作(zuo)的(de)(de)(de)管(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)器在生(sheng)產(chan)中使用(yong)(yong)(yong)越來越多，某些傳統上(shang)一直使用(yong)(yong)(yong)間歇攪拌釜的(de)(de)(de)高(gao)分子(zi)聚合(he)反(fan)(fan)(fan)(fan)應(ying)(ying)，目(mu)前也開始改用(yong)(yong)(yong)連(lian)(lian)(lian)續(xu)(xu)操作(zuo)的(de)(de)(de)管(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)器。管(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)器的(de)(de)(de)長徑比較(jiao)大(da)(da)，與(yu)釜式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)器相比在結構上(shang)差異(yi)較(jiao)大(da)(da)，有(you)直管(guan)(guan)式(shi)(shi)(shi)、盤(pan)管(guan)(guan)式(shi)(shi)(shi)、多管(guan)(guan)式(shi)(shi)(shi)等(deng)。
③. 塔式(shi)反(fan)應器(qi)
塔式反(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)的(de)長徑比介于釜(fu)式和(he)管式之間。主(zhu)要用(yong)(yong)于氣(qi)-液(ye)(ye)(ye)反(fan)(fan)(fan)應(ying)(ying)(ying)，常(chang)用(yong)(yong)的(de)有鼓(gu)泡(pao)塔、填料塔、板(ban)式塔。最常(chang)用(yong)(yong)的(de)是(shi)鼓(gu)泡(pao)塔式反(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)，底部(bu)裝(zhuang)有氣(qi)體(ti)(ti)分(fen)布器(qi)(qi)(qi)，殼外(wai)裝(zhuang)有夾套(tao)(tao)或(huo)(huo)(huo)其(qi)他形(xing)式換(huan)熱(re)器(qi)(qi)(qi)或(huo)(huo)(huo)設有擴大(da)段、液(ye)(ye)(ye)滴捕集器(qi)(qi)(qi)等(deng)。反(fan)(fan)(fan)應(ying)(ying)(ying)氣(qi)體(ti)(ti)通過(guo)分(fen)布器(qi)(qi)(qi)上的(de)小(xiao)孔(kong)以鼓(gu)泡(pao)形(xing)式通過(guo)液(ye)(ye)(ye)層進行化學反(fan)(fan)(fan)應(ying)(ying)(ying)，液(ye)(ye)(ye)體(ti)(ti)間歇或(huo)(huo)(huo)連(lian)續加(jia)入，連(lian)續加(jia)入的(de)液(ye)(ye)(ye)體(ti)(ti)可(ke)(ke)(ke)以和(he)氣(qi)體(ti)(ti)并流(liu)或(huo)(huo)(huo)逆流(liu)，一(yi)般采用(yong)(yong)并流(liu)形(xing)式較(jiao)(jiao)多(duo)。氣(qi)體(ti)(ti)在塔內(nei)為分(fen)散(san)相(xiang)，液(ye)(ye)(ye)體(ti)(ti)為連(lian)續相(xiang)，液(ye)(ye)(ye)體(ti)(ti)返混程(cheng)度(du)較(jiao)(jiao)大(da)。為了提高氣(qi)體(ti)(ti)分(fen)散(san)程(cheng)度(du)和(he)減(jian)少液(ye)(ye)(ye)體(ti)(ti)軸向循環，可(ke)(ke)(ke)以在塔內(nei)安(an)置水平多(duo)孔(kong)隔板(ban)。當吸收或(huo)(huo)(huo)反(fan)(fan)(fan)應(ying)(ying)(ying)過(guo)程(cheng)熱(re)效應(ying)(ying)(ying)不大(da)時，可(ke)(ke)(ke)采用(yong)(yong)夾套(tao)(tao)換(huan)熱(re)裝(zhuang)置，熱(re)效應(ying)(ying)(ying)較(jiao)(jiao)大(da)時，可(ke)(ke)(ke)在塔內(nei)增設換(huan)熱(re)蛇管或(huo)(huo)(huo)采用(yong)(yong)塔外(wai)換(huan)熱(re)裝(zhuang)置，也可(ke)(ke)(ke)以利用(yong)(yong)反(fan)(fan)(fan)應(ying)(ying)(ying)液(ye)(ye)(ye)蒸發的(de)方法帶走熱(re)量(liang)。
④. 固定(ding)床(chuang)反(fan)應(ying)器(qi)
固(gu)(gu)定(ding)床(chuang)板反(fan)(fan)(fan)應(ying)(ying)器(qi)(qi)是(shi)指流體(ti)(ti)通過靜止(zhi)不動的(de)(de)固(gu)(gu)體(ti)(ti)物料所形成的(de)(de)床(chuang)層(ceng)(ceng)(ceng)而進行化學反(fan)(fan)(fan)應(ying)(ying)的(de)(de)設(she)備。以(yi)氣-固(gu)(gu)反(fan)(fan)(fan)應(ying)(ying)的(de)(de)固(gu)(gu)定(ding)床(chuang)反(fan)(fan)(fan)應(ying)(ying)器(qi)(qi)最常見。固(gu)(gu)定(ding)床(chuang)反(fan)(fan)(fan)應(ying)(ying)器(qi)(qi)根據床(chuang)層(ceng)(ceng)(ceng)數(shu)的(de)(de)多(duo)(duo)(duo)少又可分(fen)為單(dan)段(duan)式(shi)(shi)和多(duo)(duo)(duo)段(duan)式(shi)(shi)兩種類型(xing)。單(dan)段(duan)式(shi)(shi)一般為高徑(jing)比不大的(de)(de)圓(yuan)筒(tong)(tong)體(ti)(ti)，在(zai)圓(yuan)筒(tong)(tong)體(ti)(ti)下部裝有柵(zha)板等板件，其(qi)上為催(cui)化劑(ji)床(chuang)層(ceng)(ceng)(ceng)，均(jun)勻(yun)地堆(dui)置(zhi)一定(ding)厚(hou)度(du)的(de)(de)催(cui)化劑(ji)固(gu)(gu)體(ti)(ti)顆粒。單(dan)段(duan)式(shi)(shi)固(gu)(gu)定(ding)床(chuang)反(fan)(fan)(fan)應(ying)(ying)器(qi)(qi)結構(gou)簡單(dan)、造價便宜、反(fan)(fan)(fan)應(ying)(ying)器(qi)(qi)體(ti)(ti)積利(li)用率高。多(duo)(duo)(duo)段(duan)式(shi)(shi)是(shi)在(zai)圓(yuan)筒(tong)(tong)體(ti)(ti)反(fan)(fan)(fan)應(ying)(ying)器(qi)(qi)內設(she)有多(duo)(duo)(duo)個催(cui)化劑(ji)床(chuang)層(ceng)(ceng)(ceng)，在(zai)各床(chuang)層(ceng)(ceng)(ceng)之間可采用多(duo)(duo)(duo)種方(fang)式(shi)(shi)進行反(fan)(fan)(fan)應(ying)(ying)物料的(de)(de)換熱。其(qi)特點是(shi)便于控制調節(jie)反(fan)(fan)(fan)應(ying)(ying)溫(wen)度(du)，防止(zhi)反(fan)(fan)(fan)應(ying)(ying)溫(wen)度(du)超(chao)出(chu)允許范圍。
⑤. 流化(hua)床反應(ying)器
細小(xiao)的(de)固(gu)(gu)體(ti)顆粒被流(liu)(liu)(liu)(liu)(liu)動著的(de)流(liu)(liu)(liu)(liu)(liu)體(ti)攜(xie)帶，具有(you)流(liu)(liu)(liu)(liu)(liu)體(ti)一(yi)(yi)樣(yang)自由(you)流(liu)(liu)(liu)(liu)(liu)動的(de)性質(zhi)，此種現象稱為(wei)固(gu)(gu)體(ti)的(de)流(liu)(liu)(liu)(liu)(liu)態化(hua)(hua)(hua)。一(yi)(yi)般把反(fan)(fan)應器(qi)(qi)(qi)和在其中呈流(liu)(liu)(liu)(liu)(liu)態化(hua)(hua)(hua)的(de)固(gu)(gu)體(ti)催(cui)(cui)化(hua)(hua)(hua)劑顆粒合在一(yi)(yi)起，稱為(wei)流(liu)(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)(chuang)(chuang)反(fan)(fan)應器(qi)(qi)(qi)。流(liu)(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)(chuang)(chuang)反(fan)(fan)應器(qi)(qi)(qi)多(duo)(duo)用于氣(qi)-固(gu)(gu)反(fan)(fan)應過程。當原(yuan)料氣(qi)通過反(fan)(fan)應器(qi)(qi)(qi)催(cui)(cui)化(hua)(hua)(hua)劑床(chuang)(chuang)(chuang)層時，催(cui)(cui)化(hua)(hua)(hua)劑顆粒受氣(qi)流(liu)(liu)(liu)(liu)(liu)作用而懸浮起來呈翻(fan)滾沸騰(teng)(teng)狀(zhuang)，原(yuan)料氣(qi)在處于流(liu)(liu)(liu)(liu)(liu)態化(hua)(hua)(hua)的(de)催(cui)(cui)化(hua)(hua)(hua)劑表(biao)面進行化(hua)(hua)(hua)學反(fan)(fan)應，此時的(de)催(cui)(cui)化(hua)(hua)(hua)劑床(chuang)(chuang)(chuang)層即為(wei)流(liu)(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)(chuang)(chuang)，也(ye)叫沸騰(teng)(teng)床(chuang)(chuang)(chuang)。流(liu)(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)(chuang)(chuang)反(fan)(fan)應器(qi)(qi)(qi)的(de)形式很多(duo)(duo)，但一(yi)(yi)般都由(you)殼體(ti)、內部構(gou)件、固(gu)(gu)體(ti)顆粒裝卸設備及(ji)氣(qi)體(ti)分布、傳熱(re)、氣(qi)固(gu)(gu)分離裝置(zhi)等(deng)構(gou)成。流(liu)(liu)(liu)(liu)(liu)化(hua)(hua)(hua)床(chuang)(chuang)(chuang)反(fan)(fan)應器(qi)(qi)(qi)也(ye)可根據床(chuang)(chuang)(chuang)層結構(gou)分為(wei)圓筒式、圓錐式和多(duo)(duo)管式等(deng)類型。
不同類型反(fan)應器(qi)(qi)在工業生產中(zhong)的適用(yong)情況見表(biao)6.2。不同結構形式的反(fan)應器(qi)(qi)在工業裝(zhuang)置中(zhong)的應用(yong)舉(ju)例見表(biao)6.3。
