Systems and methods for producing chlorine dioxide in a two stage system and single stage system that provides high chlorate to chlorine dioxide efficiency with a compact design and low sulfuric acid requirements.

A process for a continuous condensation reaction with feedstocks derived from bio-renewable resources, e.g., pine chemical derived feedstock, is disclosed. The process employs at least a multi-stage mixing reactor, selected from any of a multi-stage continuous stirred tank reactor (CSTR), a multi-stage horizontal continuous stirred tank reactor (HCSTR), or a continuous oscillating baffle reactor (COBR). The multi-stage mixing reactors are provided with a plurality of baffles for creating a mixing in a number of stages or cells created by the baffles, allowing the condensation reaction to proceed at a production rate at least twice that of a batch process with reactors of equivalent volume. The feedstocks derived from bio-renewable resources is selected from gum rosin, wood rosin, tall oil rosin and mixtures thereof; and polymeric fatty acids derived from bio-renewable resources such as tall oil.

A bioreactor for growing micro-organisms in a reaction mixture including a reaction medium and micro-organisms. The bioreactor includes a first reaction chamber, a second reaction chamber and means for connecting the first reaction chamber to the second reaction chamber. The first reaction chamber has first volume for containing first number of micro-organisms, a first input for providing reaction mixture thereto, and a first output for removing excess gases therefrom. The second reaction chamber, arranged downstream from first reaction chamber, has a second volume for containing a second number of micro-organisms, a second input for providing gases thereto, and a second output for removing reaction mixture therefrom. The means for connecting is the sole input for allowing the reaction mixture to flow from the first reaction chamber to the second reaction chamber and for gases to flow from the second reaction chamber to the first reaction chamber.

A process includes periodically or continuously introducing an olefin monomer and periodically or continuously introducing a catalyst system or catalyst system components into a reaction mixture within a reaction system, oligomerizing the olefin monomer within the reaction mixture to form an oligomer product, and periodically or continuously discharging a reaction system effluent comprising the oligomer product from the reaction system. The reaction system includes a total reaction mixture volume and a heat exchanged portion of the reaction system comprising a heat exchanged reaction mixture volume and a total heat exchanged surface area providing indirect contact between the reaction mixture and a heat exchange medium. A ratio of the total heat exchanged surface area to the total reaction mixture volume within the reaction system is in a range from 0.75 in.sup.−1 to 5 in.sup.−1, and an oligomer product discharge rate from the reaction system is between 1.0 (lb)(hr.sup.−1)(gal.sup.−1) to 6.0 (lb)(hr.sup.−1)(gal.sup.−1).

Methods and apparatus for introducing a gas into the reaction zone of a reactor. Such methods and apparatus can more evenly distribute the gas throughout the reaction zone. Spargers for introducing a gas into the reaction zone of a reactor can be employed in systems and methods for carrying out the liquid-phase oxidation of an oxidizable compound, such as para-xylene.

A system for continuously treating recycled polymeric material includes a hopper configured to feed the recycled polymeric material into the system. An extruder can turn the recycled polymeric material in a molten material. In some embodiments, the extruder uses thermal fluids, electric heaters, and/or a separate heater. The molten material is depolymerized in a reactor. In some embodiments, a catalyst is used to aid in depolymerizing the material. In certain embodiments, the catalyst is contained in a permeable container. The depolymerized molten material can then be cooled via a heat exchanger. In some embodiments, multiple reactors are used. In certain embodiments, these reactors are connected in series. In some embodiments, the reactor(s) contain removable static mixer(s) and/or removable annular inserts.

The present invention relates to an optimized process for preparing methacrylic acid, wherein methacrolein is prepared in a first stage from propionaldehyde and formaldehyde by means of a Mannich reaction and oxidized in a second stage to methacrylic acid. More particularly, the present invention relates to the reduction in the amounts of catalyst to be used in the first stage, especially to the reduction in the amounts of acid to be used here, by virtue of the additional installation of recycling streams suitable for the purpose.

A system and method is provided for upgrading a continuously flowing process stream including heavy crude oil (HCO). A reactor receives the process stream in combination with water, at an inlet temperature within a range of about 60° C. to about 200° C. The reactor includes one or more process flow tubes having a combined length of about 30 times their aggregated transverse cross-sectional dimension, and progressively heats the process stream to an outlet temperature T(max)1 within a range of between about 260° C. to about 400° C. The reactor maintains the process stream at a pressure sufficient to ensure that it remains a single phase at T(max)1. A controller selectively adjusts the rate of flow of the process stream through the reactor to maintain a total residence time of greater than about 1 minute and less than about 25 minutes.

A method and system for continuous production of contaminant free and size specific biochar using downdraft gasification of variable quality feedstock. The system and process of the present invention includes the transfer of biochar from a gasifier after gasification to a temperature-controlled cooling screw conveyor, into a drum magnet for ferrous metal removal into multiple diverters to separate and remove ungasified materials and non-ferrous metal contaminants, then transferred into a granulator for grinding and screening the biochar to a pre-selected size. By directly attaching a novel and continuous product treatment process to the biochar stream as it exits the gasifier, the particle size, moisture content, carbon content and yield of a contaminant free biochar product can be narrowly controlled and improved to meet strict product quality specifications required by specialty applications.

The present invention provides improved processes for preparing halogenated alkanes. The processes comprise reacting an alkene, a halogenated alkene, or combinations thereof and a halogenated methane with at least one chlorine atom, while using an absorption device.