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A sulphation falling film reactor is the industry-standard technology for the continuous production of surfactants (detergents/cosmetics) by reacting organic feedstocks with gaseous sulfur trioxide (
). It operates by creating a thin, falling film of organic liquid inside vertical tubes, allowing for efficient, high-capacity, and high-heat-exchange sulfonation with low residence times.
Key Aspects of Falling Film Reactors (FFR)
- Operating Principle: Organic liquid enters the top, flowing down the inside of tubes while gas flows cocurrently, causing a rapid, highly exothermic reaction.
- Design & Components: These are often multi-tube shell-and-tube heat exchangers, designed to control high thermal loads through an external cooling jacket.
- Distribution: A crucial element is the distributor head, which ensures a uniform, thin film of liquid feed throughout all tubes.
- Applications: Primarily used for sulfonating linear alkylbenzene (LAB) and sulfating alcohols (e.g., SLES).
Advantages & Performance
- High Efficiency: High interfacial area between the gas and liquid phases allows for high conversion rates.
- Temperature Control: Efficient heat removal prevents product degradation due to the highly exothermic nature of sulfonation.
- Scalability: Capacity is increased by adding more tubes to the reactor.
Leading technology providers include WEIXIAN (Nanjing) Science Technology co., ltd and Chemithon Enterprises. Advanced modeling, often done in software like MATLAB, is used to optimize the complex fluid-dynamics and heat transfer of these systems.
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Falling film reactor modelling for sulfonation reactions
ScienceDirect.com
https://www.sciencedirect.com › article › abs › pii
ScienceDirect.com
https://www.sciencedirect.com › article › abs › pii
by V Russo2019Cited by 27 — The aim of the present work is the realization of a detailed reactor model able to describe sulfonation reaction in a falling film reactor.Read more
Sulphation falling film reactor
WEIXIAN (Nanjing) Science Technology co., ltd
https://www.njweixian.com › sulphation-falling-film-reac...
WEIXIAN (Nanjing) Science Technology co., ltd
https://www.njweixian.com › sulphation-falling-film-reac...
WEIXIAN sulfonator adopts multi-tube falling film reactor. Capacity range is from 1-tube to 240-tube (10t/h). Since 1995, WEIXIAN has supplied hundreds of ...Read more
FALLINg FILM REACTOR FOR SULPHONATION - PALMOILIS
PALMOILIS
https://palmoilis.mpob.gov.my › TOT
PALMOILIS
https://palmoilis.mpob.gov.my › TOT
PDF
For the sulphonation process, using the falling film reactor allows a thin film of liquid organic material to be precisely distributed in the inside wall of the ...Read more
4 pages
Falling film reactor modelling for sulfonation reactions
Harvard University
https://ui.adsabs.harvard.edu › abs › abstract
Harvard University
https://ui.adsabs.harvard.edu › abs › abstract
by V Russo2019Cited by 27 — Falling film reactors represent the actual technology to run sulfonation reaction at pilot and industrial scale. The reaction is characterized by high ...
Chemithon Detergents
Chemithon Enterprises
https://www.chemithon.com › sulf_detergents
Chemithon Enterprises
https://www.chemithon.com › sulf_detergents
The sulfation system uses a Chemithon Annular Falling Film Reactor (AFFR) designed for a nominal 4% to 6% (by volume) SO3 in air. Sulfation Plant Overview ...Read more
falling film sulphonation | PPTX
Slideshare
https://www.slideshare.net › Business
Slideshare
https://www.slideshare.net › Business
The document outlines the key components of an industrial sulfonation process, including systems for air supply, sulfur feeding, sulfur burning to generate SO3, ...Read more
Falling film reactor modelling for sulfonation reactions
ScienceDirect.com
https://www.sciencedirect.com › science › article › pii
ScienceDirect.com
https://www.sciencedirect.com › science › article › pii
by V Russo2019Cited by 27 — Falling film reactors represent the actual technology to run sulfonation reaction at pilot and industrial scale.Read more
US5911958A - Multitube falling film reactor for the ...
Google Patents
https://patents.google.com › patent
Google Patents
https://patents.google.com › patent
Multitube falling film reactors represent today a well established technology, and is frequently the preferred reactorprinciple for sulphonation and sulphation ...Read more
Improved mathematical model for a falling film sulfonation ...
ACS Publications
https://pubs.acs.org › doi
ACS Publications
https://pubs.acs.org › doi
Improved mathematical model for a falling film sulfonation reactor. Click to ... Falling film reactor modelling for sulfonation reactions. Chemical ...Read more
Scholarly articles for Sulphation falling film reactor | |
The modelling of falling film chemical reactors - Talens-Alesson - Cited by 51 Sulphonation technology in the detergent industry - De Groot - Cited by 102 … oxidation technologies by means of falling film reactor - Mehrjouei - Cited by 34 | |
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