反(fan)應過程(cheng)的基本特征決(jue)定(ding)了適宜的反(fan)應器(qi)形式。例如氣(qi)固(gu)相反(fan)應過程(cheng)大致是用固(gu)定(ding)床(chuang)(chuang)反(fan)應器(qi)、流化床(chuang)(chuang)反(fan)應器(qi)或移(yi)動床(chuang)(chuang)反(fan)應器(qi)。但是適宜的選(xuan)型則需考(kao)慮反(fan)應的熱(re)效應、對反(fan)應轉(zhuan)化率(lv)和(he)選(xuan)擇(ze)率(lv)的要求、催化劑物理化學性(xing)態(tai)和(he)失活等(deng)多(duo)種因素。

  不銹鋼反(fan)(fan)(fan)應(ying)(ying)器的(de)操(cao)作方(fang)式和加(jia)料方(fang)式也需考慮。例(li)如，對于(yu)有串聯或平行副反(fan)(fan)(fan)應(ying)(ying)的(de)過程(cheng)，分段進料可能優于(yu)一(yi)次進料。溫(wen)(wen)度序列也是反(fan)(fan)(fan)應(ying)(ying)器選型的(de)一(yi)個重要因素。例(li)如，對于(yu)放熱的(de)可逆反(fan)(fan)(fan)應(ying)(ying)，應(ying)(ying)采用先高后(hou)低(di)的(de)溫(wen)(wen)度序列，多級(ji)、級(ji)間換熱式反(fan)(fan)(fan)應(ying)(ying)器可使(shi)反(fan)(fan)(fan)應(ying)(ying)器的(de)溫(wen)(wen)度序列趨于(yu)合(he)理(li)。

下面主(zhu)要(yao)介紹釜式反(fan)應(ying)(ying)器(qi)(qi)、管式反(fan)應(ying)(ying)器(qi)(qi)、塔式反(fan)應(ying)(ying)器(qi)(qi)、固(gu)定(ding)床(chuang)反(fan)應(ying)(ying)器(qi)(qi)、流化床(chuang)反(fan)應(ying)(ying)器(qi)(qi)。

①. 釜(fu)式(shi)反應器(qi)

  釜式反(fan)(fan)應(ying)器(qi)也稱槽式、鍋式反(fan)(fan)應(ying)器(qi)，它是(shi)各(ge)類(lei)反(fan)(fan)應(ying)器(qi)中(zhong)(zhong)結構(gou)較(jiao)(jiao)為(wei)簡單且(qie)應(ying)用(yong)(yong)(yong)較(jiao)(jiao)廣的一種。主(zhu)要(yao)應(ying)用(yong)(yong)(yong)于(yu)(yu)(yu)液(ye)(ye)-液(ye)(ye)均相(xiang)反(fan)(fan)應(ying)過程(cheng)，在(zai)(zai)氣(qi)-液(ye)(ye)、液(ye)(ye)-液(ye)(ye)非均相(xiang)反(fan)(fan)應(ying)過程(cheng)中(zhong)(zhong)也有應(ying)用(yong)(yong)(yong)。在(zai)(zai)化工生(sheng)產(chan)(chan)中(zhong)(zhong)，既適(shi)用(yong)(yong)(yong)于(yu)(yu)(yu)間歇(xie)操(cao)作過程(cheng)，又可單釜或多(duo)(duo)釜串聯用(yong)(yong)(yong)于(yu)(yu)(yu)連續(xu)操(cao)作過程(cheng)，但(dan)在(zai)(zai)間歇(xie)生(sheng)產(chan)(chan)過程(cheng)中(zhong)(zhong)應(ying)用(yong)(yong)(yong)最多(duo)(duo)。釜式反(fan)(fan)應(ying)器(qi)具有適(shi)用(yong)(yong)(yong)的溫度(du)和(he)壓(ya)力范(fan)圍寬、適(shi)應(ying)性強(qiang)、操(cao)作彈性大(da)、連續(xu)操(cao)作時溫度(du)濃度(du)容(rong)易控制、產(chan)(chan)品質(zhi)量均一等(deng)特點。但(dan)用(yong)(yong)(yong)在(zai)(zai)較(jiao)(jiao)高轉(zhuan)化率工藝(yi)要(yao)求(qiu)時，需要(yao)較(jiao)(jiao)大(da)容(rong)積。通常在(zai)(zai)操(cao)作條件比(bi)較(jiao)(jiao)緩和(he)的情(qing)況下使(shi)用(yong)(yong)(yong)，如常壓(ya)、溫度(du)較(jiao)(jiao)低(di)且(qie)低(di)于(yu)(yu)(yu)物料沸(fei)點時，應(ying)用(yong)(yong)(yong)此類(lei)反(fan)(fan)應(ying)器(qi)最為(wei)普遍。

②. 管式反(fan)應器

  管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)主(zhu)要(yao)(yao)用(yong)于氣相、液相、氣-液相連續(xu)(xu)(xu)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)過程，由(you)(you)單(dan)根（直管(guan)(guan)(guan)(guan)(guan)(guan)或盤(pan)管(guan)(guan)(guan)(guan)(guan)(guan)）連續(xu)(xu)(xu)或多根平(ping)行(xing)排(pai)列的管(guan)(guan)(guan)(guan)(guan)(guan)子組成，一(yi)(yi)般設(she)有(you)套管(guan)(guan)(guan)(guan)(guan)(guan)或殼管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)換熱(re)裝置。操作(zuo)時，物料自一(yi)(yi)端連續(xu)(xu)(xu)加入(ru)，在(zai)管(guan)(guan)(guan)(guan)(guan)(guan)中連續(xu)(xu)(xu)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)，從另(ling)一(yi)(yi)端連續(xu)(xu)(xu)流出(chu)，便達到了要(yao)(yao)求的轉化率。由(you)(you)于管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)能承受較(jiao)高的壓(ya)力，故(gu)用(yong)于加壓(ya)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)尤(you)為合(he)適，例如油脂或脂肪酸加氫生(sheng)產高碳(tan)醇、裂解反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)用(yong)的管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)爐便是管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)。此種反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)具(ju)有(you)容積小、比表面大(da)、返混(hun)少、反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)混(hun)合(he)物連續(xu)(xu)(xu)性變化、易(yi)于控制等優點。但(dan)若反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)速(su)度較(jiao)慢(man)時，則有(you)所需管(guan)(guan)(guan)(guan)(guan)(guan)子長、壓(ya)降較(jiao)大(da)等不足。隨著化工生(sheng)產越來越趨于大(da)型化、連續(xu)(xu)(xu)化、自動化，連續(xu)(xu)(xu)操作(zuo)的管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)在(zai)生(sheng)產中使(shi)用(yong)越來越多，某些傳統上一(yi)(yi)直使(shi)用(yong)間歇攪拌釜(fu)的高分子聚(ju)合(he)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)，目前(qian)也開始(shi)改用(yong)連續(xu)(xu)(xu)操作(zuo)的管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)。管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)的長徑比較(jiao)大(da)，與釜(fu)式(shi)(shi)(shi)反(fan)(fan)(fan)(fan)應(ying)(ying)(ying)器(qi)(qi)(qi)相比在(zai)結(jie)構上差(cha)異較(jiao)大(da)，有(you)直管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)、盤(pan)管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)、多管(guan)(guan)(guan)(guan)(guan)(guan)式(shi)(shi)(shi)等。

③. 塔式反應器

  塔(ta)(ta)式(shi)(shi)反(fan)應(ying)(ying)(ying)(ying)(ying)(ying)器的(de)長(chang)徑(jing)比介于釜式(shi)(shi)和管式(shi)(shi)之間。主要用(yong)于氣(qi)(qi)(qi)(qi)-液(ye)(ye)反(fan)應(ying)(ying)(ying)(ying)(ying)(ying)，常用(yong)的(de)有鼓泡塔(ta)(ta)、填料(liao)塔(ta)(ta)、板(ban)式(shi)(shi)塔(ta)(ta)。最常用(yong)的(de)是(shi)鼓泡塔(ta)(ta)式(shi)(shi)反(fan)應(ying)(ying)(ying)(ying)(ying)(ying)器，底部裝(zhuang)有氣(qi)(qi)(qi)(qi)體(ti)(ti)分(fen)(fen)布(bu)器，殼外裝(zhuang)有夾套(tao)或(huo)其他形式(shi)(shi)換(huan)熱(re)(re)器或(huo)設有擴大段(duan)、液(ye)(ye)滴捕集器等。反(fan)應(ying)(ying)(ying)(ying)(ying)(ying)氣(qi)(qi)(qi)(qi)體(ti)(ti)通(tong)過(guo)分(fen)(fen)布(bu)器上的(de)小(xiao)孔以(yi)鼓泡形式(shi)(shi)通(tong)過(guo)液(ye)(ye)層進行(xing)化學反(fan)應(ying)(ying)(ying)(ying)(ying)(ying)，液(ye)(ye)體(ti)(ti)間歇(xie)或(huo)連(lian)(lian)續加(jia)入(ru)，連(lian)(lian)續加(jia)入(ru)的(de)液(ye)(ye)體(ti)(ti)可(ke)(ke)以(yi)和氣(qi)(qi)(qi)(qi)體(ti)(ti)并(bing)流(liu)或(huo)逆流(liu)，一般采(cai)用(yong)并(bing)流(liu)形式(shi)(shi)較(jiao)多。氣(qi)(qi)(qi)(qi)體(ti)(ti)在(zai)塔(ta)(ta)內為(wei)分(fen)(fen)散相，液(ye)(ye)體(ti)(ti)為(wei)連(lian)(lian)續相，液(ye)(ye)體(ti)(ti)返混程度較(jiao)大。為(wei)了提高氣(qi)(qi)(qi)(qi)體(ti)(ti)分(fen)(fen)散程度和減少液(ye)(ye)體(ti)(ti)軸向循環，可(ke)(ke)以(yi)在(zai)塔(ta)(ta)內安置(zhi)水(shui)平多孔隔板(ban)。當吸收或(huo)反(fan)應(ying)(ying)(ying)(ying)(ying)(ying)過(guo)程熱(re)(re)效應(ying)(ying)(ying)(ying)(ying)(ying)不大時，可(ke)(ke)采(cai)用(yong)夾套(tao)換(huan)熱(re)(re)裝(zhuang)置(zhi)，熱(re)(re)效應(ying)(ying)(ying)(ying)(ying)(ying)較(jiao)大時，可(ke)(ke)在(zai)塔(ta)(ta)內增設換(huan)熱(re)(re)蛇管或(huo)采(cai)用(yong)塔(ta)(ta)外換(huan)熱(re)(re)裝(zhuang)置(zhi)，也可(ke)(ke)以(yi)利用(yong)反(fan)應(ying)(ying)(ying)(ying)(ying)(ying)液(ye)(ye)蒸發的(de)方法帶走(zou)熱(re)(re)量。

④. 固定床反(fan)應器

  固(gu)定床(chuang)(chuang)板反(fan)(fan)應(ying)(ying)器(qi)是指流體(ti)(ti)(ti)通過靜(jing)止(zhi)不動的(de)固(gu)體(ti)(ti)(ti)物料所形成(cheng)的(de)床(chuang)(chuang)層而進行化學反(fan)(fan)應(ying)(ying)的(de)設備。以氣(qi)-固(gu)反(fan)(fan)應(ying)(ying)的(de)固(gu)定床(chuang)(chuang)反(fan)(fan)應(ying)(ying)器(qi)最常見(jian)。固(gu)定床(chuang)(chuang)反(fan)(fan)應(ying)(ying)器(qi)根(gen)據床(chuang)(chuang)層數的(de)多少(shao)又可分(fen)為單(dan)段(duan)(duan)式和多段(duan)(duan)式兩(liang)種(zhong)類型(xing)。單(dan)段(duan)(duan)式一(yi)般為高徑比不大的(de)圓(yuan)筒體(ti)(ti)(ti)，在(zai)圓(yuan)筒體(ti)(ti)(ti)下部裝(zhuang)有柵板等板件，其上為催化劑(ji)床(chuang)(chuang)層，均勻地堆置一(yi)定厚度的(de)催化劑(ji)固(gu)體(ti)(ti)(ti)顆粒。單(dan)段(duan)(duan)式固(gu)定床(chuang)(chuang)反(fan)(fan)應(ying)(ying)器(qi)結構簡單(dan)、造價便宜、反(fan)(fan)應(ying)(ying)器(qi)體(ti)(ti)(ti)積利用率高。多段(duan)(duan)式是在(zai)圓(yuan)筒體(ti)(ti)(ti)反(fan)(fan)應(ying)(ying)器(qi)內設有多個催化劑(ji)床(chuang)(chuang)層，在(zai)各床(chuang)(chuang)層之間可采用多種(zhong)方式進行反(fan)(fan)應(ying)(ying)物料的(de)換(huan)熱。其特點是便于控制調節反(fan)(fan)應(ying)(ying)溫度，防(fang)止(zhi)反(fan)(fan)應(ying)(ying)溫度超出允許(xu)范圍。

⑤. 流化床(chuang)反(fan)應(ying)器(qi)

  細小的(de)固(gu)(gu)體(ti)顆(ke)(ke)粒被(bei)流(liu)(liu)(liu)(liu)動著的(de)流(liu)(liu)(liu)(liu)體(ti)攜(xie)帶，具(ju)有流(liu)(liu)(liu)(liu)體(ti)一(yi)樣(yang)自由流(liu)(liu)(liu)(liu)動的(de)性質，此種現象稱為固(gu)(gu)體(ti)的(de)流(liu)(liu)(liu)(liu)態化(hua)(hua)(hua)(hua)。一(yi)般把反(fan)應(ying)器(qi)和(he)(he)在其中呈(cheng)流(liu)(liu)(liu)(liu)態化(hua)(hua)(hua)(hua)的(de)固(gu)(gu)體(ti)催(cui)(cui)化(hua)(hua)(hua)(hua)劑顆(ke)(ke)粒合在一(yi)起，稱為流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)(chuang)(chuang)(chuang)反(fan)應(ying)器(qi)。流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)(chuang)(chuang)(chuang)反(fan)應(ying)器(qi)多用(yong)于氣(qi)-固(gu)(gu)反(fan)應(ying)過程。當原(yuan)料(liao)氣(qi)通過反(fan)應(ying)器(qi)催(cui)(cui)化(hua)(hua)(hua)(hua)劑床(chuang)(chuang)(chuang)(chuang)層時(shi)，催(cui)(cui)化(hua)(hua)(hua)(hua)劑顆(ke)(ke)粒受(shou)氣(qi)流(liu)(liu)(liu)(liu)作用(yong)而懸浮起來呈(cheng)翻滾(gun)沸騰(teng)狀，原(yuan)料(liao)氣(qi)在處于流(liu)(liu)(liu)(liu)態化(hua)(hua)(hua)(hua)的(de)催(cui)(cui)化(hua)(hua)(hua)(hua)劑表面進行化(hua)(hua)(hua)(hua)學反(fan)應(ying)，此時(shi)的(de)催(cui)(cui)化(hua)(hua)(hua)(hua)劑床(chuang)(chuang)(chuang)(chuang)層即(ji)為流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)(chuang)(chuang)(chuang)，也叫沸騰(teng)床(chuang)(chuang)(chuang)(chuang)。流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)(chuang)(chuang)(chuang)反(fan)應(ying)器(qi)的(de)形(xing)式很多，但一(yi)般都由殼體(ti)、內部構(gou)件、固(gu)(gu)體(ti)顆(ke)(ke)粒裝卸設備及氣(qi)體(ti)分(fen)布、傳(chuan)熱、氣(qi)固(gu)(gu)分(fen)離(li)裝置等構(gou)成。流(liu)(liu)(liu)(liu)化(hua)(hua)(hua)(hua)床(chuang)(chuang)(chuang)(chuang)反(fan)應(ying)器(qi)也可根據床(chuang)(chuang)(chuang)(chuang)層結(jie)構(gou)分(fen)為圓筒式、圓錐(zhui)式和(he)(he)多管式等類型(xing)。

  不同(tong)類型(xing)反應(ying)器在工(gong)業(ye)生產中的適(shi)用情況見(jian)表6.2。不同(tong)結構形式的反應(ying)器在工(gong)業(ye)裝置(zhi)中的應(ying)用舉例(li)見(jian)表6.3。