CA2197655A1 - Method and apparatus for producing hydrogen peroxide from hydrogen and oxygen - Google Patents

Abstract

A method and apparatus for safely producing hydrogen peroxide by injecting dispersed minute bubbles of hydrogen (28) and oxygen (34) into a rapidly flowing liquid medium (24). The minute bubbles are surrounded by the liquid medium of sufficient volume for preventing an explosive reaction between the hydrogen and oxygen. The liquid medium is formed of an acidic aqueous solution and a Group VIII metal catalyst (14). Hydrogen (28) is sparged into the flowing medium (24) for dissolution of the hydrogen in the medium. Oxygen bubbles (34) are reacted with the dissolved hydrogen for producing hydrogen peroxide (72). Preferably, the liquid medium has a velocity of at least 10 feet per second for providing a bubbly flow regime in the reactor. Water (12) and catalyst (14) are added to tank (16). Preferably, an amount of hydrogen peroxide stabilizer is added to tank (16). The method and apparatus provide for the safe production of hydrogen peroxide with low manufacturing costs.

Description

~ WO 96/Ojl38 2 1 9 7 ~ ~ 5 p METHOD AND APPARATUS FOR PRODUCING
hY~KO~ PEROXIDB FROM nY~kO~ AND OXYGEN
BACKGROUND OF THE INVENTION
1. Field of the Invention The present invention relates to a method and apparatus for producing hydrogen peroxide by injecting minute bubbles of hydLvg~., and oxygen into a liquid stream of an aqueous solution of water and an inorganic acid and a Group VIII metal catalyst in which the liquid stream flows at high velocity.

2. Descrimtion of the Related Art It is known that a mixture of gaseous oxygen and gaseous hydrogen forms an explosive material.
Virtually all currently produced hydL~g~,- peroxide is produced by indirectly combining hydrogen and oxygen.
Thus, the primary conventional industrial method for production of hydL Ugell peroxide uses a chemical agent first for the reduction or hyd~g~l~ation. Typically, alkylanthraquinone, such as ethyl or tertiary butyl anthraquinone, is used as the chemical agent. This working solution contains organic solvents such as di-isobutylcarbinol and methyl naphthalene. Oxidation of the int ~ te product of the reduction reaction produces hYdL ~gen peroxide and the original alkylanthraquinone. The anthraquinone is recycled back through the process. This method has the shortcoming that there is a considerable loss of the anthr~l;n~nP
and the organic solvents from oxidation and thermal degradation of these organic materials. The presence of these organics with oxygen and hydrogen peroxide presents safety hazards from their potential reactions. This destruction of organics involves high operating losses for the currently practiced commercial process.
Various methods have been attempted to directly combine oxygen and hydrogen to OV~L the above-described problems. The direct combination of hydrogen and oxygen to form hydrogen peroxide has the advantage of 2~765~ ~
Wo~/0513X PCT~S95/103~

not requiring the use of any organic or combustible materials. The direct process, however, does require careful control of the gaseous mixture of oxygen and hydrogen so that they are always outside the explosive range.
There have been numerous patents issued for the direct combination of hydrogen and oxygen to produce hydrogen peroxide. U.S. Patents 4,347,232 and g,336,240 employ an two phase system through the use of organic ou-~uullds to form a second phase. However, the organics can react with oxygen or hydrogen peroxide to render these processes llneconr - ic~l.
Other patents employ a fixed bed catalyst within a reaction vessel which has low conversion per pass or low reactor productivity (see for example, U.S.
Patents 4,336,239 and 5,082,647).
U.S. Patent 5,169,618 ~'618 patent) to Marischino desaribes establishing a pulse-flow regime ln a catalyst bed. The '618 patent has the limitation of~0 low conversion of hydrogen peroxide per pass and high t costs.
u.s. Patent 4,996,039 describes first absorbing hydLuy~ll into the aqueous reaction mixture with a catalyst; dropping the pressure to remove all the hydrogen in the gas phase; and then introducing the oxygen in order to produce hy~Lugell peroxide. This technique minimizes the presence of hYdLUg~n in the gaseous phase. This process is expensive to repressure the reactor with oxygen and doesn't lend itself to continuous processing.
Continuous modes of operation for the direct combination process have also been proposed, as disclosed in U.S. Patents 4,009,252; 4,279,883; 4,681,751; and 4,772,458. These patents employ a catalyst as a slurry in an agitated reactor. These patents have the drawback of having either low conversion per pass or low volumetric efficiency either of which is nnecn~- ~c~l.

~ W096l0sl38 ~I~ 7 ~ 5 5 pcT~s95'10304 U.S. Patent 4,661,337 ('337 patent) describes a process for direct combination for producing hydlogen peroxide of increased concentration. The volume of the reaction mixture occupies a small portion of the available volume of the reactor. It is taught in the '337 patent that the layer of reaction mixture has a thickness of no more that 2 millimeters. This patent has the disadvantage that the majority of the reactor is in the gas phase in which no hydrogen peroxide if formed.
In all the above described patents, there is a separate continuous gaseous phase in which it is n~cessAry to inject an inert gas such as nitrogen, argon or helium in order to remain outside the explosive range of hydrogen and oxygen.
Other attempts for the direct formulation of hydrogen peroxide use liquid filled reactors without a continuous gas phase. U.S. Patent 5,104,635 describes a liquid filled reactor with two internal membranes which each are permeable only for hydrogen and oxygen, respectively. This reaction system requires con~ rable capital for the use of the membranes.
U.s. Patent No. 4,279,8&3 describes a process for preparing hydLug~n peroxide in an aqueous medium.
The aqueous medium contains dissolved llydLug~l and a platinum-group catalyst having absorbed thereto hydrogen.
Inert nitrogen and argon are blown into the aqueous medium so that no dissolved oxygen is present in the aqueous medium during the llydtoye~l absorbing treatment.
Oxygen gas is injected into the medium after the absorption of the hYdLUge~ on the catalyst and the gaseous zone and liquid zones are stirred. This patent has the shortcoming of requiring an injection of an inert gas into the reactor during the hydrogen absorption phase to prevent an explosion between the hydrogen and oxygen gases.
U.S. Patent No. 5,194,242 ('242 patent) describes a process for preparing hydLog~ peroxide in 2 1 9~G55 WO96/0~138 PCT~JSg~/10304 which an acidic agueous solution fills an elongated reaction zone in a tubular reactor. A catalyst is provided to the reaction zone. Oxygen together with recycled gas and then hydL~g~., are dLsp2rsed into the solution in proportions that are above the lower flammability limit for hydrogen and oxygen and are maintained at a temperature and PLe~L~ until the reaction mixture has decreased to below the lower flammability limit for the hydL~g~ll and oxygen mixture.
The parti21 pressure of hydrogen and oxygen is super-ai ~ ric in the range of about 20 to about 400 psi.
The aqueous solution flows through the reactor at liguid velocity at rate from about 4 to about 8 ft~sec.
In the '242 patent, the ratio of the flow of the aqueous medium to the aggreg2te flow of the hydrogen and oxygen is such that a g2s phase regime of large elongated bubbles may be produced, which, if reacted violently would not be surrounded by sufficient liquid volume to cool the gas mixture, resulting in elevated 20 t~ LULe and pressure which can result in an explosion of the gas mixture. Patentees provide no teaching of the importance of operating in a regime in which small discrete individual bubbles exist which can be uuell~hed by the surrounding medium. It is desirable to provide a 25 safe direct combination process for producing hYdLO~en peroxide which has low manu~acturing costs.
O~JECTS OF TF~ INV.~NTION
It i5 thus a primary object of the invention to provide a process for the reaction of oxy~en and hydL~n which is efficient and safe.
It is a further related object of the invention to provide a process which operates in the fl hl~
range of oxygen~hydrogen mixtures so as to benefit from increased reaction rate, without sacrificing the safety aspects of the process.
It is still a further related object of the invention to substantially completely react hY~L~n ~ wos6/osl38 2 ~ 9 7 6 5 5 PCT~S9sll03n4 during the process in order to maximize the efficiency of utilization of that expensive reactant.
It is still a further related object of the invention to min;m;ze or avoid entirely the necessity of recycling spent gases from the reaction to the reaction zone.
It is still a further object of the invention to carry out the process with minute bubbles of hydL ~g~
and oxygen supplied to the reaction zone at a rate and in such a way as to obviate the risk of explosion.
SUMMARY OF THE INVENTION
Briefly described, the invention comprises a method and apparatus for producing hydrogen peroxide in which hydLug~ll and oxygen are separately injected into a liquid filled reactor to form a plurality of discrete individual bubbles in a continuous rapidly flowing liquid stream. Each bubble is ~uLL~u-,ded by a continuous liquid phase such that if the hydrogen and oxygen gas reacted, there is sufficient liquid available to quench/cool down the reaction in order to prevent an explosion ~r u~ayatillg throughout the reactor. It has been found that it is critical to maintain the ratio of the volume of flow of aqueous medium to the a~yL~yate volume of flow of hYdL~gen and oxygen, at a high value so as to avoid uncontrolled reaction of 1-ydLogen and oxygen bubbles to form water. By controlling the ratio of the volume of flow of aqueous medium to the volume of flow of hydLogen and oxygen, both ;n~pppn~pntly~ and, in the aggregate, there is sufficient liquid volume present to quench any runaway reaction that might take place. It is also important to maintain the flow velocity of aqueous medium at at least ten feet per second to obtain a dispersed bubbly flow regime. The prevention of a reaction from p~n~; ng allows the concentration of unreacted hydrogen and oxygen within the reactor to be within the explosive range.

W096/0~13~ 2 ~ q 7 6 5 ~ PCT~S9~10~4 Preferably, a pipeline reactor i5 used having a plurality of passes within the reactor. The pipeline reactor can be formed of a plurality of tubes arranged vertically or horizontally and connected with curved (elbow) tubes. The liquid stream can be formed of water, a dilute acid and a Group VIII metal catalyst. The Group VIII metal catalyst can be platinum or palladium or a mixture of the two on an inert support such as alumina, silica or carhon. The liquid stream fills the reactor.
Fine dispersed hydrogen gas bubbles can be dissolved into the flowing liquid stream. ~fter the hydrogen is dissolved, finely dispersed oxygen gas bubbles are injected into the liguid stream for reacting with hydrogen to form hydrogen peroxide. After this first reaction is complete, multiple injections of first hydrogen and then oxygen can be used to raise the concentration of h~dLO~ peroxide y~uduued to a predetermined level. The number of in~ections of hydrogen and oxygen bubbles can be varied for producing ZO the desired cuncellL~tion of the ~ydLo~ peroxide.
The present invention has the advantage of avoiding a continuous gas phase between the hydrogen and oxygen and having full utilization of the entire volume of the reactor. The production of l1YdL UY~I peroxide occurs in the liquid phase between the dissolved hydLug~l gas and oxygen in the presence of a catalyst. The method prevents an explosive reaction from PYp~n~ing, thereby allowing the concentration of unreacted hydrogen and oxygen to be within the explosive range.
The invention will be more fully described by reference to the following drawing.
RRTEF DESCRIPTION OF T~ DRAWINGS
Fig. l is a schematic diagram of an apparatus for con~in~ lc~y producing hydrogen peroxide from hydrogen and oxygen according to an environment of the invention.

~ WO96/05138 2 1 ~ 7 6 5 ~ PCT~Sg511030~

Fig. 2 is a schematic diagram of an apparatus for producing hydrogen peroxide in a semicontinuous batch process according to another Pmho~;r~nt of the invention.
DETATmTn DESCRIPTION OF T~E INVENTION
Fig. 1 illustrates a schematic view of the apparatus 10 for producing hydrogen peroxide from hydroy~n and oxygen. Water 12 and catalyst 14 are added to tank 16. Catalyst 14 is preferably a supported Group VIII metal catalyst. Preferably, catalyst 14 is palladium or platinum or mixtures thereof. Examples of a support useful for supporting the catalyst in a dispersed fashion are carbon, silica and alumina. It will be appreciated that other catalysts known in the art of hydrogen peroxide production can be used in the present invention.
Preferably, an amount of hydrogen peroxide stabilizer 15 is added to tank 16. Stabilizer 15 can be an acidic solution having a Ph in the range of about 2 to 7. Examples of acids useful for the present invention are hydrochloric, phosph~ric~ and other commercially available inorganic acids. Typically, the amount of stabilizer 15 added to water is less than about 1% of the reaction medium. Solution 17 within tank 16 can be stirred with an automatic or manual agitation means 18.
Solution stream 20 is circulated with recirculating pump 22 as input stream 24. Liquid stream 24 is received at pipeline reactor 26 and fills pipes 27 of pipeline reactor 26. Liquid stream 24 has a flow velocity of greater than 10 feet per second for avoiding the presence of a continuous gas phase or elongated bubbles within reactor 26. It is known that dispersed ~ bubble regime occurs when water has a velocity of greater that 10 feet per second. "The Flow of Complex Mixtures ~ of Pipes." G.W. Govier, Robert Kreiger pllhli~h;~g Company, Malaber, Florida, page 523. Preferably, the flow velocity of liquid stream 24 is in the range of more than 10 feet per second to about 50 feet per second.

_ .. . , . _ _, ,, _, ,,,,,,,,,, , . _ _ , . _ _ _ _ W0~0~l38 2 1 ~ 7 6 5 ~ pCT/US9~1030~

Most preferably, the flow velocity of liquid stream 24 is in the range of about 11 to about 20 feet per second.
Pipeline reactor 26 is preferably formed of a plurality of pipes 27 joined with a 180~ bend. Joined pipes 27 can be arranged either vertically or hori~ontally. The length and diameter 27 of pipes are predet~rm;n~d for providing the desired flow velocity.
Preferably, pipes 27 are formed of a commercially available heavy wall pipe such as a U.S. schedule 160 which has a wall thickness form 0.44 to 1.31 inches over the size range of 3 to 12 inches. Pipes 27 useful for practice of the present invention can have diameter in the range of 2 inches to at least 12 inches. The preferred length of pipeline reactor 26 can vary widely dependiny on the number of joined pipes 27 used in the reactor. Typically, joined pipes 27 have a total length in the range of about 50 to about 60,000 feet.
Preferably, joined pip2S 27 have a length of about 2,000 to about 45,00c feet.
It will be appreciated that the number of pipes 27 used in pipeline reactor 26 can be varied to change the number of injection points or passes in the pipeline reactor 26. Preferably, the number of passes of pipeline reactor 26 is between about six and about 48 passes.
The pipeline reactor 26 operates at a ~ uLa in the range of about between 30 to abou* 300 atm. The reaction t~ ~uLe normally is in the range of ooc to 60~C. The lower the temperature of the aqueous medium the higher the solubility of hydrogen is in solution.
Similarly, the higher the pressure, the greater the solubility of hydrogen is in solution. The reaction temperature can be maintained by providing jacketing on each pipe 27 or by installing the entire pipeline reactor 26 within a vessel in which a refrigerant is being evaporated or cold liquid solution is circulated.
It has now been found that it is important to maintain the ratio of the volumetric flows of the aqueous ~ WO9~0~138 2 1 97~ PCT~S9~/10304 reaction medium and the aggregate flows of the gaseous hydrogen and oxygen at of broadly from 300 to 30, preferably from 200 to 40 and most desirably from 150 to 50. If the flow ratios are maintained within these ranges and the velocity of the flowing liquid is maintained at above 10 feet per second, as described above, a regime of tiny bubbles surrounded by adequate aqueous medium is created and the risk of runaway explosion by reaction of bubbles is substantially obviated. Statistically, the local increase of the temperature due to the reaction of hydrogen and oxygen bubbles to form water is desirably less than 3~C. This is achieved with the volumetric flow rates and velocities of the invention.
Broadly, the volumetric ratio of oxygen to 11YdL ug~n may be in the range of 1:1 to 50:1. The art has recognized that higher ratios of oxygen to hydLuyen may be desirable to force the reaction to completion. It is recognized that oxygen is by far the cheaper of the reactants and accordingly, excess oxygen can be vented from the system without excessive economic penalty.
Desirably, the reaction ta~es place in the flammable range, the volume ratio of oxygen to hydrogen being from l:1 to 20:1.
The foregoing ratios of the flows of aqueous medium to the aggregate volumetric flows of hydLuge-l and oxygen, in turn set the ratios of the volume of aqueous medium to each of the volumes of hydLugen and oxygen, respectively, at the several hydrogen and oxygen gas inlets. Broadly, the ratio of the volumetric flow of aqueous medium to the volumetric flow of hydLuy~n at each hydrogen gas inlet, is broadly from 15,000 to 60. The ratio of the volumetric flow of aqueous medium to the volumetric flow of oxygen is from about 15,000 to 60.
A gaseous stream of hydrogen 28 is injected by valve 30 into a flowing liquid stream 24 at point 31.
Liquid stream 24 flows bctween points 31 and 33 of pipe ... ... . , , . , .. . . . _ _ _ _ _ _ _ _ _ _ _ . _ _ _ wo g6,05l38 2 ! 9 i7 f~i 5 5 p~ruS9ra/103~

27. Hydrogen is dissolved in a liquld stream 24. A
gaseous stream of oxygen 3g is injected by valve 32 into liquid stream 24 at point 33. Within pipeline reactor 26, the dissolved hydrogen 28 reacts with the gaseous oxygen 34 to form hydrogen peroxide in solution.
Preferably, gaseous hydLuyel~ 28 and gaseous oxygen 34 are sparged into liquid stream 24 by a small diameter nozzle for producing a plurality of minute bubbles. Preferably, the nozzle has a diameter in the range of about 0.001 inches to about 0.25 inches to produce fine minute bubbles which are ~uLLuullded by rapidly flowing liquid stream 24. The minute bubbles of hydrogen and o~ygen are of a size which is small enough to be surrounded by flowing liquid stream 24. ~he volume of liquid stream is sufficiently large and continuous so that in the event of any explosion of a single bubble the ~uLLuunding liguid can expeditiously quench the ~Yplosi~n within the bubble to prevent the propagation of the explosion thL uuyhuu~ the entire regime of the reactor.
The flow rate of liquid stream 24 and the injection of minute bubbles provide a dispersed bubbly regime in liquid stream 24.
Addltional gaseous hydL~y~n 28 can be injected at a plurality of passes through pipeline reactor 26 with 25 respective valves 35, 46, 50, 55 and 59 at points 36, 47, 51, 56 and 60 for dissolution into liquid stream 24.
Additional gaseous oxygen 34 can be injected downstream of hydrogen in~ection points 36, 47, 51, 56 and 60 with respcctive valves 40, 48, 53, 57 and 61 at respective points 41, 49, 54, 58 and 62 for reacting with the dissolved hydrogen.
Desirably, the point of oxygen introduction is sufficiently distanced from that of l~ydLùyull injection to permit the hyd~ug~ll to have become distributed throughout the aqueous medium as tiny dispersed bubbles and to dissolve in the aqueous medium. Desirably, the second volume of hydrogen and subsequent volumes of IIYdLUYU~I

~ WO96/05l38 2 1 9 7 6 5 5 PcTn59s/l0304 introduced along the elongated reaction zone are introduced after about 50% of the previously introduced hydrogen has been reacted with oxygen and preferably after at least 75% of the previously introduced hydrogen has been reacted.
After the multi-pass reaction, stream 64 flows from pipeline reactor 26. In the event the off-gas from the reactor is in the flammable range, a diluent gas 66 can be added to stream 64. An example of a diluent gas useful for practice of the invention is nitrogen.
A pressure letdown valve 68 can be used before gas-liquid separator 70 for reducing the pressure of the inlet mlxture 69 to gas-liquid separator 70. Gas liquid separator 70 separates liquid 72 from gas 74. Gas 74 containing unreacted oxygen, nitrogen and some unreacted hydlu~ell from separator 70 can be recycled with recycled gas compressor 78 and can be injected at point 75 into liquid stream 24. Alternatively, separated gas 74 can be purged with valve 76. It will be appreciated that a gas liquid separator useful for practice of the present invention is known in the art. Stream 64 can be received at additional pipeline reactors 26 for cnnnectin~ the reactors in series before gas liquid separator 70.
Separated liquid 72 containing the l-ydLugell peroxide product in the aqueous solution of catalyst and acid is passed to filter 80 for recovering the catalyst as a filter cake 82. Filter cake 82 can be-added to tank 16 for recycling the catalyst. Filtrate 84 includes the hydrogen peroxide product and the aqueous acid water solution. Filtrate 84 is received at ion exchange apparatus 86 for removing the acid from the filtrate.
Hydrogen peroxide product 88 from ion exchange apparatus 8~ can be directly used as a hydrogen peroxide ~ product. Alternatively, hydrogen peroxide product 88 can be received at column 90 for conc~l,LL~Ling the hYdLU~
peroxide product 88 in order to produce a cuncenLL~ted hydrogen peroxide product 94. Column 90 can be an WO~6~5138 2 1 9 7 6 5 5 evaporation or distillation column. Water 92 removed from column 9C can be recycled into water stream 12 as make-up water.
The concentration of hydrogen peroxide product 82 produced by pipeline reactor 26 depends on the number of injections of hydrogen and oxygen in the passes of pipeline reactor 26. Preferably, hydrogea peroxide product 82 has a concentration in the range of about 2%
to about 30~ of hydrogen peroxide in solution.
Preferably, hydrogen peroxide product 94 has up to 70 concentration.
The present invention has the advantage of providing an economical and safe process for producing hydrogen peroxide. The process does not specifically inject an inert gas or chemical agent within the reactor, thereby reducing costs. The entire regime of the pipeline reactor comprises a dispersed bubbly regime in a rapidly flowing liquid stream for preventing the formation of an explosive gas phase with the reactor.
The entire pipeline is utilized for the production of the hydrogen peroxide. In addition, the high surface to volume relationship of the reactor provides l~Yr~nqive removal of heat from the reactor.
F~Y~MPT.~
Continuous Proces~
A circulating aqueous stream of a suqp~n~d group VIII metal catalyst deposited on an inert carrier with an acid stabilizer is delivered at a pressure of 200 di -sphFres (3000 psi) to the first of two tubular reactors operated in series at a flow rate of 195,000 pounds per hour per reactor in the reactor shown in Fig.
1. The reactor consists of 4" c~h~d~ 160 pipes 100 feet long, each connected together by 180~ U bends. The liquid flow rate has a liquid velocity of 13 feet/second.
The liquid stream is introduced into the reactor at 15~C.
At the reactor inlet 27.2 pounds per hour of h~uge,- gas is injected through a nozzle to form fine ~ WO96~5138 2 ~ 9 7 6 5 5 PCT~S95/10304 individual bubbles in the liquid stream flowing at 13 feet/second. This produces a bubbly flow regime with a continuous liquid phase and small evenly dispersed individual bubbles. Recycled gas from the gas-liquid separator can be injected into the process fluid. This is followed by the injection of 432 lbs/hr. of oxygen as finely dispersed bubbles which reacts with the hYdL Ug~ll to form hydL~g~l~ peroxide. This is followed by repeated injections for each reactor of firct hydrogen and the oxygen to form hydrogen peroxide of increasing concentration. The heat of reaction is removed by the circulation of cooled water (or refrigerant) outside the reactor pipes.
After passing through the second reactor, the effluent flows through a pressure letdown valve before a gas-liquid separator. Nitrogen or other diluent gas is added to the reactor effluent as needed to assure the exit gas from the separator is outside the explosive/flammable limits of hydrogen and oxygen. This gas can be either recycled to the first reactor or vented to ai ,~-re.
The liquid phase is filtered to remove the 5llcppn~pd catalyst slurry so that it can be r~cllcpPn~Pd in the aqueous medium. This is done in a mix tank where the concel,LL~tion of each ingredient is checked and adjusted as needed. This includes the acid used as a stabilizer for hydrogen peroxide. The filtrate from the filter that contains the desired hydrogen peroxide product passes over an ion exchange or equal agent to remove residual acid values from the hydrogen peroxide product. This product can then be used directly or can be concentrated in an evaporator or distillation column to concentrated in an evaporator or distillation column to conc~nLL~tions up to 70% following conventional practice. A total production of 100,000,000 pounds per year of hydrogen peroxide can be produced from these two reactors.

WO9~05138 2 ~ q 7 6 5 '~ PCT~Sg~lo~ --~MPLE II
8atch Semicontinuous Process Fig. 2 illustrates an alternate method of operating the process of the invention in a batch, semicontinuous fashion. A fresh batch of reaction medium consisting of a group VIII metal catalyst on an inert support in an acidic aqueous solution, is charged through valve 1 to separator 2. The solution is charged to the reactor via valve 3 and recirculating pump 4. Once the system is filled, flow of fresh solution is stopped by closing valve l. The ~les~u ~ in the system is increased by closing valve 5.
The velocity of the medium is maintained at 10 feet per second or more. Hydrogen is injected at injection system 6. The amount of hydrogen introduced i5 at or less than the solubility limit in the flowing medium. Oxygen is introduced at point 8, at a sufficient distance downstream (pipe length 7) to ensure the absorption of hydrogen. At full capacity, hydrogen flow is about 15 pounds per hour and oxygen flow is approximately 250 pounds per hour. Sufficient pipe length 9 is provided downstream of the oxygen injection to permit the maximum conversion to hYdL~g~ll peroxide.
The pipeline is cooled by a coolant on the outside of the pipe to maintain an operating temperature between 5 and 30~C.
The reactor effluent passes to separator 2 to disengage the gas 10 from the liquid. The exit gas is outside the flammable range so it can be recycled back to the reactor by recycle ~_ u55u~ 11. As needed, fresh oxygen 12 is added to the recycle stream before it is injected at point 8. If the exit gas is in flammable region, nitrogen 13 is injected into the effluent stream.
Effluent gas 14 is then vented from the system.
Pump 4 recirculates the liquid medium until thc hydrogen peroxide reaches its desired concentration, desirably between 4-15% by weight, preferably 5-8%. Gas ~ W096/0s138 6 5 ~ PCT~S~5/10304 injection will continue for from one to three hours. The reactor system, including the separator, pump and piping is then drained. The system is then refilled with a fresh reactor charge following the procedure outlined above. This batch semicontinuous procedure produces from l,000,000-l,500,000 pounds per year of hydrogen peroxide product. With smaller or larger diameter pipe of the same length, lower or higher quantities, respectively, of hydrogen peroxide are produced.

Nodified Batch Semicontinuous Process The batch semicontinuous process described in Example II can be carried out in a modified way to reduce both the capital costs and operating costs of the reaction system. The basic flow diagram of Fig. 2 is used with the exception that a second reaction medium charge pump is provided in parallel with recirculating pump 4 in order to fill the system and the pressure let down valve 5, rather than being at the effluent of the reactor pipeline upstream of the separator, is downstream of the separator in the gas effluent line.
In operation, the operating ~L~s~uLe in the separator remains high (1,000-4,000 psi) throughout the course of the reaction. Pressure is maintained by "head"
gas above the separator liquid. The gas to be recycled enters recycle ~ essor upstream of the pressure letdown valve. The exit gas in line lO pas~es through a PLeS~ULe letdown valve. By configuring the process -in this way, any residual dissolved gas in the reactor effluent stays in solution while passing through the separator because the latter remains at pressure. Thus, ~ it is not n~c~qs~ry to redissolve gases in the recirculating reactor effluent and both the separated liquid and unreacted gas need not be repressurized as in Example II. Configuring the process thusly should reduce the capital and operating costs of the recirculating W~09C/05138 2 1 9 ~ 6 5 5 Pc~/usgs/~03o~ -pump, the recycle compressor, the separator and other parts of the process.
While the invention has been described with reference to the preferred ~mhcd;r-~t, this description is not intended to be limiting. It will be appreciated by those of ordinary skill in the art that modificaticns may be made without departing from the spirit and scope of the invention.

Claims (33)

CLAIMS:

1. A method for producing hydrogen peroxide in an aqueous medium having a catalytically effective amount of a catalyst comprising the steps of:
filling the reaction zone with a rapidly flowing aqueous medium, injecting hydrogen gas into said medium as individually dispersed hydrogen bubbles for dissolving said hydrogen into said acidic aqueous medium; and injecting oxygen gas into said medium as dispersed oxygen bubbles at a point downstream from the injection of said hydrogen gas for reacting said oxygen with said dissolved hydrogen to produce said hydrogen peroxide, wherein the velocity of said aqueous medium is at least 10 feet per second, thereby providing a continuous regime of finely dispersed gas bubbles in a continuous liquid phase.

2. The method of claim 1 further comprises the step of:
repeating said steps of injecting hydrogen gas and injecting oxygen gas into said medium at multiple points in said reaction zone.

3. The method of claim 2 where in said acidic aqueous medium flows through a pipeline reactor having a plurality of connected pipeline paths and said multiple points of said reaction zone are along said pipeline paths.

4. The method of claim 3 wherein said hydrogen bubbles have a diameter of a size which is small enough to be surrounded and quenched by said rapidly flowing medium.

5. The method of claim 4 wherein said oxygen bubbles have a size small enough to be surrounded and quenched by said rapidly flowing medium.

6. The method of claim 5 wherein said aqueous medium is acidic.

7. The method of claim 5 further comprising the step of:
separating the resulting reaction mixture into a gas phase comprising the spent oxygen and hydrogen and a liquid medium comprising the produced hydrogen peroxide and injecting said spent oxygen into said medium as dispersed bubbles before said step of injecting oxygen gas into said medium.

8. An apparatus for producing hydrogen peroxide in an aqueous medium having a catalytically effective amount or a catalyst comprising:
a pipeline reactor;
means for filling said pipeline reactor with a rapid flowing aqueous medium;
means for injecting hydrogen gas as dispersed hydrogen bubbles into said pipeline reactor to dissolve said hydrogen gas in said aqueous medium; and means for injecting oxygen gas into said pipeline reactor at a point downstream from the dissolved hydrogen gas to produce said hydrogen peroxide, wherein the velocity of said aqueous medium is at least about 10 feet per second, thereby providing a continuous region of finely dispersed gas bubbles in a continuous liquid phase.

9. The apparatus of claim 8 wherein said pipeline reactor comprises:
a plurality of connected pipeline paths wherein each path is connected to an adjacent path with a 180°
bend and said means for injecting hydrogen gas provides hydrogen gas at a plurality of points on said pipeline paths and said means for injecting oxygen gas provides oxygen at a plurality of points downstream of the respective injections of hydrogen gas.

10. The apparatus of claim 9 wherein said means for injecting said hydrogen comprises:
a nozzle having a diameter which is small enough to provide bubbles which are small enough to be surrounded and quenched by said rapidly flowing medium.

11. The apparatus of claim 10 wherein said means for sparging said oxygen gas comprises:
a nozzle which is small enough to provide bubbles which are small enough to be surrounded and quenched by said rapidly flowing medium.

12. The apparatus of claim 11 wherein the velocity of said acidic aqueous medium is in the range of about 11 to about 20 feet per second.

13. The apparatus of claim 12 further comprising means for recycling spent oxygen and hydrogen gas as dispersed bubbles into said aqueous medium.

14. The apparatus of claim 13 wherein the aqueous medium is acidic.

15. The apparatus of claim 14 wherein the pressure in said reactor is between about 30 and about 300 atmospheres and the reaction temperature is from about the freezing point of the aqueous medium to about 60°C

16. A process for preparing hydrogen peroxide by reaction of hydrogen and oxygen in the presence of a catalyst, comprising the steps of:
(a) establishing a continuous flow of aqueous reaction medium containing finely divided catalyst for the said reaction in an elongated reaction zone at temperature and pressure conditions favorable to said reaction;
(b) sparging from one to fifty volumes of oxygen and one volume of hydrogen into said continuously flowing aqueous medium, said hydrogen and oxygen being sparged at points distanced from one another along the path of said continuous flow and thereby forming dispersed tiny bubbles of hydrogen and oxygen, respectively, in said aqueous medium;
(c) maintaining the ratio of the volumetric flow of said aqueous medium to the aggregate of the volumetric flows of said gaseous hydrogen and oxygen at a sufficiently high value maintaining the linear flow of aqueous medium at at least 10 feet per second to ensure that the bubbles of hydrogen and oxygen are in a continuous, aqueous phase and;
(d) introducing the said reaction medium into a gas-liquid separator and therein separating unreacted gases from the aqueous reaction medium containing hydrogen peroxide; and (e) recovering hydrogen peroxide from said aqueous medium.

17. A process as recited in claim 16 wherein the ratio of the volume of flow of aqueous medium to the aggregate volume of flow of hydrogen and oxygen is sufficiently high that any reaction of hydrogen and oxygen bubbles to form water is substantially immediately quenched by the volume of aqueous medium surrounding the reacting bubbles.

18. A process as recited in claim 16 wherein, statistically, the local increase in temperature due to a runaway reaction of hydrogen and oxygen to form water, is less than 3C°.

19. A process as recited in claim 16 wherein the reaction takes place in the flammable range of hydrogen and oxygen mixtures, the volume ratio of oxygen to hydrogen being from 1:1 to 20:1.

20. A process for preparing hydrogen peroxide by reaction of hydrogen and oxygen in the presence of a catalyst, comprising the steps of:
(a) establishing a continuous flow of aqueous reaction medium containing finely divided catalyst for the said reaction in an elongated reaction zone;
(b) sparging from one to twenty moles of oxygen and one mole of hydrogen into said continuously flowing aqueous medium, said hydrogen and oxygen being sparged at points distanced from one another along the path of said continuous flow and thereby forming dispersed tiny bubbles of hydrogen and oxygen, respectively, in said aqueous medium;
(c) maintaining i) the ratio of the flow of said aqueous medium to the aggregate flow of said gaseous hydrogen and oxygen, at from 300 to 30;
(ii) the linear flow rate of aqueous medium at at least 10 feet per second; and (iii) the temperature and pressure conditions of the flow medium so as to cause the bubbles of hydrogen and oxygen to react catalytically to form hydrogen peroxide;

(d) introducing the said reaction medium into a gas-liquid separator and therein separating unreacted gases from the aqueous reaction medium containing hydrogen peroxide; and (e) recovering hydrogen peroxide from said aqueous medium.

21. A process as recited in claim 20 wherein the reaction takes place in the flammable range, the volume ratios of oxygen to hydrogen being from 1:1 to 20:1.

22. A process as recited in claim 20 wherein the ratio of the volumetric flow of aqueous medium to the volumetric flow of hydrogen at any given hydrogen gas inlet point, is from 15,000 to 60.

23. A process as recited in claim 20 wherein the ratio of the volumetric flow of aqueous medium to the volumetric flow of oxygen at any given oxygen inlet point is from 15,000 to 30.

24. A process as recited in claim 20 wherein more than 50% of the hydrogen is reacted in the elongated reaction zone before residual hydrogen is vented to the atmosphere.

25. A process as recited in claim 20 wherein more than 75% of the hydrogen is reacted in the elongated reaction zone before residual hydrogen is vented to the atmosphere.

26. A process as recited in claim 20 wherein the hydrogen is introduced first.

27. A process as recited in claim 20 wherein oxygen is introduced after the hydrogen has become distributed throughout the aqueous medium as fine bubbles and has substantially dissolved therein.

28. A process as recited in claim 20 wherein a second volume of hydrogen is introduced after at least 50% of the hydrogen passing the previous point of oxygen introduction has been reacted.

29. A process as recited in claim 20 wherein a second volume of hydrogen is introduced after more than 75% of the hydrogen previously introduced at the previous point of oxygen introduction has reacted.

30. A process as recited in claim 20 wherein the velocity of the aqueous medium is greater than 20 ft/sec.

31. A process as recited in claim 20 wherein nitrogen is added to the reaction mixture at the affluent of the elongated reaction zone in order to ensure that the vented gases are not in the flammable range.

32. A process as recited in claim 20 wherein the reaction is carried out continuously.

33. A process as recited in claim 20 wherein the reaction is carried out in a batch semicontinuous manner.