Layered catalytic square reactor

Abstract

The utility model discloses a kind of layered catalytic square reactors, including reactor main body and the channel steel support being fixed to reactor main body;Reactor main body includes main body shell, main body liner and insulation layer, the main body shell is square structure, the main body liner is located inside main body shell, the insulation layer is filled between main body shell and main body liner;Main body liner bottom is provided with flow guide device;Main body liner upper portion is provided with discharge port, lower portion is provided with feed inlet;Main body liner inside is provided with multiple layers horizontal hollow partition, the horizontal hollow partition separates internal space into multiple reaction zone, catalyst frame is placed on each layer horizontal hollow partition;The side surface of each layer reaction zone is also installed with sampling solenoid valve;Reactor main body outside is covered with stainless steel decorative cover.The utility model realizes the integration design of layered accurate temperature control, uniform material flow and convenient catalyst management of reactor.

Description

Technical Field

[0001] This invention belongs to the field of industrial catalytic reactor technology, and particularly relates to a layered catalytic square reactor. Background Technology

[0002] In the field of industrial catalytic reactors, traditional designs (such as cylindrical or single-chamber structures) generally have significant drawbacks, severely restricting production efficiency and product quality. Firstly, regarding temperature control, most reactors rely solely on single-point temperature measurement systems, failing to comprehensively monitor internal temperature gradients. This leads to excessively large temperature differences within the reaction zone (for example, in fine chemical reactions, a temperature deviation exceeding ±5℃ can reduce product purity by 10%-15%), resulting in increased side reactions and energy waste. Secondly, material flow and mixing are ineffective. The reactor lacks an effective flow guidance mechanism, making it prone to backmixing or localized stagnation, causing uneven reactions (e.g., polymer molecular weight distribution index reaching 3.5, resulting in unstable performance). Simultaneously, the simple straight-through design of the inlet and outlet structures creates dead zones, leading to high material residue rates and difficulty in adapting to different flow rate requirements, impacting production continuity. Furthermore, catalyst management is a prominent issue. Catalysts are concentrated in a single area, preventing layered and staged utilization. Replacement requires shutdown and disassembly (taking several days), resulting in cumbersome and inefficient operations (catalyst utilization rate less than 60%). Therefore, there is an urgent need for an innovative reactor structure that integrates stratified temperature monitoring, uniform material distribution, and modular catalyst arrangement to solve a single core problem: how to achieve integrated design of stratified precise temperature control, uniform material flow, and convenient catalyst management in the reactor, so as to improve reaction efficiency, product quality, and ease of operation. Utility Model Content

[0003] The technical problem to be solved by this utility model is to provide a layered catalytic square reactor that addresses the shortcomings of the prior art, and achieves an integrated design of precise temperature control, uniform material flow and convenient catalyst management in the reactor.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: a layered catalytic square reactor, comprising: a reactor body and a channel steel support for fixing the reactor body; the reactor body includes a main shell, a main inner liner, and a heat insulation layer, wherein the main shell is square in structure, the main inner liner is located inside the main shell, and the heat insulation layer fills the space between the main shell and the main inner liner; a flow guiding device is provided at the bottom of the main inner liner, the flow guiding device including multiple conical tubes; a discharge port is provided at the top of the main inner liner, and a feed port is provided at the bottom; multiple horizontal hollow partitions are provided inside the main inner liner, the horizontal hollow partitions dividing the internal space into multiple reaction zones, and a catalyst material frame is placed on each layer of horizontal hollow partitions; a temperature measuring device is installed on the side of each reaction zone, the temperature measuring device including a temperature sensor and a temperature measuring sleeve; a sampling solenoid valve is also installed on the side of each reaction zone; the reactor body is covered with a stainless steel decorative cover.

[0005] The aforementioned layered catalytic square reactor includes a flow guiding device comprising four conical tubes. Three conical tubes, which are evenly distributed on the outer side and are progressively larger, are designated as the first, second, and third flow guiding rings. The fourth conical tube is an internal flow guiding ring located in the middle of the flow guiding device. All conical tubes are installed with their smaller openings facing downwards and their larger openings facing upwards.

[0006] In the aforementioned layered catalytic square reactor, both the inlet and outlet are circular interfaces at one end and square interfaces at the other end. The circular end of the inlet is connected to an external feed pipe, while the square end is connected to the interior of the reactor body. Similarly, the square end of the outlet is connected to the interior of the reactor body, while the circular end is connected to an external outlet pipe.

[0007] In the aforementioned layered catalytic square reactor, the diameter of the circular end of the feed inlet is DN100, and the size of the square end is 200mm×200mm; the diameter of the circular end of the discharge outlet is DN125, and the size of the square end is 250mm×250mm.

[0008] In the aforementioned layered catalytic square reactor, the horizontal hollow partition consists of three layers with a spacing of 500mm between each layer. The catalyst frame is a detachable design, made of 316L stainless steel porous mesh with a mesh diameter of 3mm and an open area ratio of 40%.

[0009] In the aforementioned layered catalytic square reactor, the temperature sensor of the temperature measuring device is a type K thermocouple with a measurement range of 0-1300℃, an accuracy of ±0.5℃, and a response time ≤1s.

[0010] In the aforementioned layered catalytic square reactor, the insulation layer is made of glass fiber insulation cotton with a density of 128 kg / m³, a thermal conductivity of 0.035 W / (m·K), and a thickness of 150 mm.

[0011] The aforementioned layered catalytic square reactor features a stainless steel decorative cover made of 1.5mm thick 304 stainless steel plate. The surface of the stainless steel decorative cover is brushed and includes an opening and closing door and a high-temperature resistant silicone rubber sealing strip.

[0012] In the aforementioned layered catalytic square reactor, the channel steel support is made of 10# channel steel and is connected to the concrete foundation by M20 high-strength bolts.

[0013] Compared with existing technologies, this invention has the following advantages: The main outer shell adopts a square structure, with an insulation layer filling the space between the inner liner and the outer shell. This design provides stable physical support and thermal efficiency, ensuring the reactor structure is stable while reducing heat loss and improving overall energy efficiency. Multiple horizontal hollow partitions inside the reactor divide the space into several independent reaction zones. Catalyst feed frames are placed on each partition, achieving a layered and modular arrangement of the catalyst. This allows for flexible adjustment or replacement of the catalyst according to reaction requirements without the need for complete reactor disassembly, significantly improving operational convenience and maintenance efficiency. Temperature measuring devices (including temperature sensors and temperature measuring sleeves) installed on the sides of each reaction zone enable independent real-time monitoring of the temperature of each zone. Combined with the installation of sampling solenoid valves, this supports independent sampling and analysis of materials in each zone, ensuring precise control and timely adjustment of the reaction process. The flow guiding device at the bottom consists of multiple conical tubes, optimizing the fluid distribution of materials within the reactor, avoiding dead zones, and promoting uniform mixing and reaction efficiency. The configuration of the upper discharge port and lower inlet port, combined with the overall reactor design, achieves efficient material entry and exit, improving production continuity. Furthermore, the external stainless steel decorative cover not only enhances aesthetics but also strengthens reactor protection and extends equipment lifespan. These technical features work synergistically to address core shortcomings of traditional reactors, including difficulties in catalyst replacement, inaccurate temperature monitoring, and uneven material flow, significantly improving reaction efficiency, product quality, and operational safety.

[0014] The technical solution of this utility model will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of a layered catalytic square reactor.

[0016] Figure 2 for Figure 1 AA sectional view.

[0017] Figure 3 This is a schematic diagram of the inlet flow guiding device.

[0018] Explanation of reference numerals in the attached drawings: 1-Stainless steel decorative cover, 2-Main outer shell, 3-Main inner liner, 4-Discharge port, 5-Horizontal hollow partition, 6-Temperature measuring sleeve, 7-Catalyst material frame, 8-Temperature sensor, 9-Inlet guide device, 9-1-Inlet flange, 9-2-Reaction chamber inlet pipe, 9-3-First guide ring, 9-4-Second guide ring, 9-5-Outer support plate, 9-6-Inner guide ring, 9-7-Third guide ring, 9-8-Inner support plate, 9-9-Inlet, 10-Sampling solenoid valve, 11-Channel steel bracket, 12-Insulation layer. Detailed Implementation

[0019] like Figure 1 — Figure 3 As shown, a layered catalytic square reactor includes: a reactor body and a channel steel support 11 for fixing the reactor body; the reactor body includes a main shell 2, a main inner liner 3, and a heat insulation layer 12. The main shell 2 has a square structure, the main inner liner 3 is located inside the main shell 2, and the heat insulation layer 12 fills the space between the main shell 2 and the main inner liner 3; a flow guiding device 9 is provided at the bottom of the main inner liner 3, and the flow guiding device 9 includes multiple conical tubes; a discharge port 4 is provided at the top of the main inner liner 3, and a feed port 9-9 is provided at the bottom; multiple horizontal hollow partitions 5 are provided inside the main inner liner 3, and the horizontal hollow partitions 5 divide the internal space into multiple reaction zones. A catalyst material frame 7 is placed on each layer of horizontal hollow partitions 5; a temperature measuring device is installed on the side of each reaction zone, and the temperature measuring device includes a temperature sensor 8 and a temperature measuring sleeve 6; a sampling solenoid valve 10 is also installed on the side of each reaction zone; the reactor body is covered with a stainless steel decorative cover 1.

[0020] During implementation, the reactor body is assembled first. The outer shell 2 is welded from square 316L stainless steel plates, and the inner liner 3 is made of Hastelloy alloy. Concentricity is ensured by locating pins, and the bottom is welded with argon arc welding, with a weld height of not less than 8 mm, and X-ray inspection is performed. The insulation layer 12 uses glass fiber insulation cotton with a density of 128 kg / m³, which is compacted evenly with a compaction tool until there are no gaps during filling. For example, in chemical synthesis, the operator fills the insulation cotton in layers to ensure that heat loss is reduced by 85% under 500℃ conditions, and the outer surface temperature does not exceed 60℃. The horizontal hollow partition 5 is installed by calibrating with a level to ensure that the levelness error does not exceed 1 mm, and is fixed by welding. The catalyst frame 7 is a detachable design, made of 316L stainless steel perforated mesh with a mesh diameter of 3 mm and an open area ratio of 40%. The operator only needs to clip it into the partition buckle to place or replace it. In the temperature measuring device, the temperature sensor 8 is inserted into the temperature measuring sleeve 6, which extends into the middle of the inner liner 3, and the data transmission line is connected to the external control system. The sampling solenoid valve 10 is controlled by a signal to open and close for sampling. The stainless steel decorative cover 1 is made of 304 stainless steel plate, with an opening and closing door and silicone rubber sealing strip. The operator opens the door periodically to clean the exterior. The channel steel support 11 is fixed to the concrete foundation with 10# channel steel and M20 high-strength bolts. During operation, the material enters from the feed inlet 9-9, is diffused by the flow guiding device 9, and flows through each layer of catalyst material frame 7. Temperature data is monitored in real time. For example, in energy conversion, the material flow rate is set to 5 m³ / h. The flow guiding device 9 guides the material to flow evenly upwards. If the temperature sensor 8 detects that a certain layer exceeds the temperature, the system automatically adjusts the cooling power.

[0021] In this embodiment, the flow guiding device 9 includes four tapered tubes, of which three tapered tubes of progressively larger size are evenly distributed on the outer side, namely the first flow guiding ring 9-3, the second flow guiding ring 9-4 and the third flow guiding ring 9-7, and the fourth tapered tube is the inner flow guiding ring 9-6 set in the middle of the flow guiding device 9. All tapered tubes are installed with the small opening facing down and the large opening facing up.

[0022] When implementing the flow guiding device 9, first install the inlet flange 9-1 at the bottom of the reactor. Install the reaction chamber inlet pipe 9-2 below the inlet flange 9-1, and weld support plates (such as outer support plate 9-5 and inner support plate 9-8) to the reaction chamber inlet pipe 9-2. The conical tube is made of Hastelloy alloy. The installation sequence is as follows: first weld the inner flow guiding ring 9-6 to the inner support plate 9-8, then weld the three outer flow guiding rings in sequence (flow guiding ring 9-3, flow guiding ring 9-4, and flow guiding ring 9-7), ensuring that the smaller opening faces downwards and the larger opening faces upwards, and that they are evenly distributed. After welding, a water pressure test is performed at 15 MPa, and no leakage is observed after 30 minutes of pressure holding. For example, during material preparation, the operator uses a laser to calibrate the position of the conical tube, ensuring a uniform diffusion angle of 20°. When material enters from the inlet flange 9-1, the smaller-diameter flow guiding ring 9-3 receives the material first, diffusing it upwards to prevent accumulation at the bottom. During operation, the operator adjusts the feed pressure. For example, in the polymerization reaction, the flow rate is set to 8 m³ / h. The flow guiding device 9 divides the material into multiple streams to reduce energy loss.

[0023] In this embodiment, both the feed inlet 9-9 and the discharge outlet 4 have a circular interface at one end and a square interface at the other end, which is a structure of round top and square bottom. The circular end of the feed inlet 9-9 is connected to the external feed pipe, and the square end is connected to the inside of the reactor body. The square end of the discharge outlet 4 is connected to the inside of the reactor body, and the circular end is connected to the external discharge pipe.

[0024] During implementation, the round-and-square structure is constructed from welded steel plates. The round end of the inlet 9-9 (e.g., DN100 pipe diameter) connects to the external pipeline via the inlet flange 9-1 and the reaction chamber inlet pipe 9-2. The square end (200mm×200mm) is welded to the bottom of the reactor to ensure a smooth transition. The outlet 4 is similar, with the square end (250mm×250mm) welded to the top. High-temperature spiral wound gaskets are used for flange sealing, and bolts are tightened symmetrically. After implementation, the airtightness test pressure is 10MPa, and the leakage rate is ≤0.5% after holding the pressure for 1 hour. For example, in a synthesis reaction, the material is introduced from the round end of the inlet 9-9, distributed to the flow guide device 9, where the flow rate gradually decreases, and exits at the square end. The operator can adjust the feed rate to avoid impact. For example, when production scale changes, the round-and-square structure adapts to different flow rates, leaving minimal residue; simple rinsing by the operator is sufficient.

[0025] In this embodiment, the diameter of the circular end of the feed inlet 9-9 is DN100, and the size of the square end is 200mm×200mm; the diameter of the circular end of the discharge outlet 4 is DN125, and the size of the square end is 250mm×250mm.

[0026] During implementation, precise dimensions are manufactured (e.g., the square end of inlet 9-9 is 200mm × 200mm). The round end DN100 (inner diameter approximately 100mm) is connected to the square end via a gradient section, with laser cutting ensuring accuracy. The round end DN125 of outlet 4 is welded to the square end 250mm × 250mm. Operator testing of flow rate: For example, in energy conversion, the material flow rate is set to 6m³ / h. The inlet velocity at the round end is high, decreasing after diffusion through the square end, resulting in uniform entry into the reactor. During use, checks for deformation of the square end are performed; if it exceeds 1mm, correction is required.

[0027] In this embodiment, the horizontal hollow partition 5 has three layers with a spacing of 500mm between each layer, and the catalyst frame 7 is a detachable design made of 316L stainless steel perforated mesh with a mesh diameter of 3mm and an opening rate of 40%.

[0028] When implementing the horizontal hollow partition 5, Hastelloy plate is cut to a thickness of 8mm, with a spacing of 500mm, and welded after calibration with a measuring ruler. During the fabrication of the catalyst frame 7, 316L stainless steel mesh is punched with 3mm apertures, ensuring a 40% open area ratio through aperture calculation. The operator clips the frame into the partition buckle, and the mesh frame is filled with a porous alumina carrier. For example, in material preparation, the first layer of horizontal hollow partition 5 holds the high-activity catalyst frame 7, the second layer holds the medium-activity one, and the third layer holds the low-activity one. For replacement, the buckle is unlocked, the frame removed, and cleaned or replaced. During operation, the material flows through the mesh and contacts the catalyst; the 40% open area ratio ensures low flow resistance. During use, the mesh should be checked monthly for blockage and cleaned with a high-pressure water gun.

[0029] In this embodiment, the temperature sensor 8 of the temperature measuring device is a K-type thermocouple with a measurement range of 0-1300℃, an accuracy of ±0.5℃, and a response time of ≤1s.

[0030] During implementation, temperature sensor 8 is an industrial-grade K-type thermocouple, installed in the temperature sensing sleeve 6, which extends into the middle of the main body inner liner 3. A shielded data transmission line is connected, and an insulation test is performed (resistance ≥100MΩ). During initialization, it is calibrated using a second-class standard platinum resistance thermometer, with an error not exceeding ±0.3℃. For example, in pharmaceutical synthesis, a target temperature of 500℃ is set, and temperature sensor 8 monitors data every second. If a layer exceeds 502℃, the system automatically adjusts its power. During use, the response time is calibrated periodically, and a stopwatch test is used to ensure it is ≤1 second.

[0031] In this embodiment, the insulation layer 12 is glass fiber insulation cotton with a density of 128 kg / m³, a thermal conductivity of 0.035 W / (m·K), and a thickness of 150 mm.

[0032] When implementing insulation layer 12, fiberglass wool is cut into blocks with a density of 128 kg / m³, controlled by weighing. The gaps are filled and compacted layer by layer using a compaction tool to a thickness of 150 mm. For example, in high-temperature reactions, the operator fills from the bottom, compacting each 50 mm layer to ensure no gaps. Under 500℃ operating conditions, external temperature measurement shows the surface temperature does not exceed 60℃. Annual aging checks are performed; if compression occurs, the material is replaced with new material.

[0033] In this embodiment, the stainless steel decorative cover 1 is made of 304 stainless steel plate with a thickness of 1.5mm. The surface of the stainless steel decorative cover 1 is brushed and has an opening and closing door and a high-temperature resistant silicone rubber sealing strip.

[0034] During implementation, 304 stainless steel sheets are cut and brushed, and hinged doors (1200mm x 1500mm) are installed. Sealing strips are applied to the door frame. Operators open the door to clean the reactor exterior or inspect components. For example, in chemical environments, the door should be wiped with a soft cloth monthly, and the sealing strips should maintain elasticity at 500°C. During use, the integrity of the sealing strips should be checked, and any cracks should be replaced immediately.

[0035] In this embodiment, the channel steel support 11 is a No. 10 channel steel, which is connected to the concrete foundation by M20 high-strength bolts.

[0036] During implementation, 10# channel steel is cut and welded into a frame, which is then fixed to the concrete foundation using M20 bolts (8.8 strength grade) drilled through holes, with a tightening torque of 300 N·m. The operator uses a torque wrench to ensure even tightening. For example, in high-pressure reactions, the displacement measured after the equipment is running should not exceed 0.05 mm. During use, bolts should be checked regularly for looseness and retightened every six months.

[0037] The above description is merely a preferred embodiment of the present utility model and does not constitute any limitation on the present utility model. Any simple modifications, alterations, or equivalent structural changes made to the above embodiments based on the technical essence of the present utility model shall still fall within the protection scope of the present utility model.

Claims

1. A layered catalytic square reactor comprising: The reactor body and the channel steel support (11) for fixing the reactor body; the reactor body comprises a body shell (2), a body liner (3) and a heat preservation layer (12), characterized in that: the body shell (2) is a square structure, the body liner (3) is located inside the body shell (2), and the heat preservation layer (12) is filled between the body shell (2) and the body liner (3); the bottom of the body liner (3) is provided with a flow guide device (9), the flow guide device (9) comprises a plurality of tapered pipes; the upper part of the body liner (3) is provided with a discharge port (4), and the lower part is provided with a feeding port (9-9); a plurality of layers of horizontal hollow partition plates (5) are arranged inside the body liner (3), the horizontal hollow partition plates (5) divide the internal space into a plurality of reaction intervals, a catalyst frame (7) is arranged on each layer of horizontal hollow partition plates (5); a temperature measuring device is installed on the side of each layer of reaction intervals, the temperature measuring device comprises a temperature sensor (8) and a temperature measuring sleeve (6); a sampling electromagnetic valve (10) is also installed on the side of each layer of reaction intervals; the outside of the reactor body is covered with a stainless steel decorative cover (1).

2. The layered catalytic square reactor of claim 1, wherein: The flow guide device (9) comprises four tapered pipes, wherein three tapered pipes of gradually increasing sizes are uniformly distributed on the outside, which are a first flow guide ring (9-3), a second flow guide ring (9-4) and a third flow guide ring (9-7), and the fourth tapered pipe is an internal flow guide ring (9-6) arranged in the middle of the flow guide device (9), and all the tapered pipes are installed in a manner that small openings face downward and large openings face upward.

3. The layered catalytic square reactor of claim 1, wherein: The feeding port (9-9) and the discharge port (4) are both circular interfaces at one end and square interfaces at the other end, wherein the circular end of the feeding port (9-9) is connected with an external feeding pipeline, and the square end is in communication with the inside of the reactor body; the square end of the discharge port (4) is connected with the inside of the reactor body, and the circular end is connected with an external discharge pipeline.

4. The layered catalytic square reactor of claim 3, wherein: The pipe diameter of the circular end of the feeding port (9-9) is DN100, and the size of the square end is 200mm*200mm; the pipe diameter of the circular end of the discharge port (4) is DN125, and the size of the square end is 250mm*250mm.

5. The layered catalytic square reactor of claim 1, wherein: The horizontal hollow partition plates (5) are three layers, and the spacing between each layer is 500mm; the catalyst frame (7) is designed to be detachable, is made of 316L stainless steel porous mesh, has a mesh diameter of 3mm and an opening rate of 40%.

6. The layered catalytic square reactor of claim 1, wherein: The temperature sensor (8) of the temperature measuring device is a K-type thermocouple, has a measurement range of 0-1300℃, an accuracy of ±0.5℃ and a response time of ≤1s.

7. The layered catalytic square reactor of claim 1, wherein: The heat preservation layer (12) is glass fiber heat preservation cotton, has a density of 128kg / m³, a thermal conductivity of 0.035W / (m*K) and a thickness of 150mm.

8. The layered catalytic square reactor of claim 1, wherein: The stainless steel decorative cover (1) is made of a 304 stainless steel plate with a thickness of 1.5mm, the surface of the stainless steel decorative cover (1) is subjected to wire drawing treatment, and the stainless steel decorative cover (1) is provided with an opening and closing door and a high-temperature-resistant silicone rubber sealing rubber strip.

9. The layered catalytic square reactor of claim 1, wherein: The channel steel support (11) is a 10# channel steel and is connected with a concrete foundation through M20 high-strength bolts.

Images