Filling device for density filling of a chemical reactor

Abstract

Filling device (10) for density filling of a chemical reactor with particulate catalyst material, comprising a feed container (11) for particulate catalyst material with an upper inlet opening (12) and a lower outlet opening (13); a distribution device (14, 114) which is rotatably arranged below the feed container (11) for distributing the particulate catalyst material in the chemical reactor by centrifugal force about a vertical axis of rotation (A), wherein the distribution device (14) comprises at least a first annular distribution element (15, 16; 115, 116) which has an upper annular, substantially horizontal inlet opening (40, 41) with a clear width (w1, w2), a substantially vertical outlet opening (18, 19) directed radially outwards with respect to the axis of rotation (A) with a clear height (h1, h2) and a deflecting element (43, 44) arranged between the inlet opening and the outlet opening, wherein the deflecting element deflects a substantially vertical particle stream coming from the feed container (11) into a radially outwards particle stream; a drive bearing (33) arranged radially symmetrically to the axis of rotation (A), comprising a fixed bearing ring (56) directly or indirectly connected to the feed container (11) and a rotary bearing ring (57) connected to the distribution device (14); and a drive device (34) comprising a drive motor (35) arranged laterally offset to the vertical axis of rotation (A) outside the feed container (11) and a belt drive (36), wherein the drive motor (35) drives the rotary bearing ring (57) of the drive bearing (33) via the belt drive (36); characterized in that that the clear height (h1,h2) of the exit opening (18,19,119) is greater than the clear width (w1,w2) of the entrance opening (40,41); and / or that the drive bearing (33) is arranged within a rotating bearing housing (37) which can be supplied with a purge gas stream; and / or that the lower end of the feed container (11) has at least one ring insert (49) which directs the particle flow to the at least one distribution element (15, 16, 17).

Description

Technical field

[0001] The invention relates to a filling device for dense loading of a chemical reactor with particulate catalyst material. In particular, it relates to a device for the uniform distribution of the catalyst material by centrifugal force. Furthermore, the invention relates to novel distribution devices for dense loading of a chemical reactor using a filling device described herein. State of the art

[0002] When filling chemical reactors with catalyst material, it is essential to ensure a uniform density distribution to guarantee optimal reaction control. However, known filling devices tend to produce uneven distribution, leading to undesirable flow effects and local density fluctuations. This can negatively impact the efficiency and lifespan of the catalyst layer.

[0003] Previous solutions include various mechanical and pneumatic methods for particle distribution, which are often complex, maintenance-intensive, or insufficient in their distribution performance.

[0004] US patent US 5,687,780 A1 discloses a filling device with a multi-stage distributor rotor. The individual distributor stages are dimensioned such that the clear height of the outlet opening is smaller than the clear width of the inlet opening. This geometric design, in which the flow channel narrows, can lead to backflow or particle clogging at high throughput rates, which in turn impedes material flow and can result in increased particle abrasion.

[0005] US patent US 4,972,884 A1 discloses a device with a rotatable, radially symmetrical distributor whose surface is divided into several arc-shaped segments with sectors of increasing radial length. The aim is to simultaneously form several concentric rings of catalyst material at a constant rotational speed due to the fixed geometry of the sectors.

[0006] Patent application US 2013 / 0298507 A1 discloses a device which uses an upstream aperture with adjustable shutter flaps to regulate the particle flow into the individual annular channels of the distribution device.

[0007] Japanese patent application JP H02-14732 A describes a device for filling chemical reactors with catalyst particles, comprising two superimposed distribution plates, the upper plate having a larger diameter than the lower plate. A central opening is also provided to supply the reactor core with catalyst.

[0008] In the applicant's international patent application WO 2017 / 167957 A1, a filling device for density filling of a chemical reactor is described, which describes a feed container for particulate catalyst material and a distribution device rotatably arranged under the feed container, wherein a drive device for the distribution device is arranged outside the feed container, so that damage to the catalyst material by the drive device is avoided. Object of the invention

[0009] The present invention is based on the technical problem of further improving the filling device described in WO 2017 / 167957 A1 with regard to a gentle and uniform filling of a reactor with particulate catalyst material. Summary of the invention

[0010] The invention relates to a filling device for density filling of a chemical reactor with particulate catalyst material, comprising a central, substantially radially symmetrical feed container for particulate catalyst material with an upper inlet opening and a lower outlet opening;a distribution device which is rotatably arranged below the feed container for distributing the particulate catalyst material in the chemical reactor by centrifugal force about a vertical axis of rotation (A), wherein the distribution device comprises at least a first, annular distribution element which has an upper, annular, substantially horizontal inlet opening with a clear width (w), a substantially vertical outlet opening directed radially outwards with respect to the axis of rotation (A) with a clear height (h) and a deflecting element arranged between the inlet opening and the outlet opening, wherein the deflecting element deflects a substantially vertical particle stream coming from the feed container into a radially outwards particle stream;A drive bearing arranged radially symmetrically to the axis of rotation (A), comprising a fixed bearing ring, in particular an outer one, connected directly or indirectly to the feed container, and a rotary bearing ring, in particular an inner one, connected to the distribution device; and a drive device comprising a drive motor and belt drive arranged laterally offset to the vertical axis of rotation (A) outside the feed container, wherein the drive motor drives the rotary bearing ring of the drive bearing via the belt drive. The radially outward-directed particle stream is preferably a substantially horizontally outward-directed particle stream.

[0011] According to a first embodiment of the invention, the filling device according to the invention is characterized in that the clear height (h) of the outlet opening is greater than the clear width (w) of the inlet opening. In this embodiment, the deflecting element can have a guide surface which has a substantially vertical tangent (t1) at the inlet opening and a radially outwardly directed tangent (t2) at the outlet opening, wherein the radius of curvature of the guide surface increases continuously from the inlet opening to the outlet opening. The radially outwardly directed tangent is preferably a substantially horizontal tangent (t2).

[0012] According to a second embodiment of the invention, the filling device according to the invention is characterized in that the drive bearing is arranged within a rotating bearing housing which can be supplied with a purging gas stream.

[0013] According to a third embodiment of the invention, the filling device according to the invention is characterized in that the lower end of the feed container has at least one ring insert which directs the particle flow to the at least one distribution element.

[0014] In further variants of the invention, the features of the first and second embodiment, the first and third embodiment, the second and third embodiment or all three embodiments can be combined with each other.

[0015] The invention further relates to a distribution device that can be used in a filling device. The distribution device comprises at least one first, annular distribution element, which has an upper, annular, substantially horizontal inlet opening with a clear width (w), a substantially vertical outlet opening directed radially outwards with respect to the axis of rotation (A) and a deflecting element arranged between the inlet opening and the outlet opening, wherein the deflecting element deflects a substantially vertical particle stream, typically coming from a feed container of the filling device, into a radially outwards particle stream; wherein the clear height (h) of the outlet opening is greater than the clear width (w) of the inlet opening.The deflecting element of the distribution device can have a guide surface which has a substantially vertical tangent (t1) at the inlet opening and a radially outwardly directed tangent (t2) at the outlet opening, where the radius of curvature of the guide surface increases continuously from the inlet opening to the outlet opening.

[0016] The invention is also suitable for a method for density-filling a chemical reactor with particulate catalyst material in which the filling device according to the invention is used. The method preferably comprises the following steps: a) Feeding the particulate catalyst material into the feed container so that it flows downwards by gravity towards the distribution device; b) Rotating the distribution device around the vertical axis of rotation by means of the externally arranged drive device; c) Directing the vertical particle stream coming from the feed container into the horizontal inlet openings of the rotating distribution elements; d) Redirecting the particle flow in the distribution elements from a substantially vertical direction to a radially outward direction, wherein the particle flow passes through a flow path whose clear height at the outlet opening is greater than its clear width at the inlet opening in order to prevent backflow of the particle flow in the distribution element; and e) Accelerating the particles by the centrifugal force resulting from the rotation and carrying the particles through the outlet openings for uniform distribution over the cross-section of the reactor.

[0017] Preferably, the particle flow in the distribution elements is deflected from a substantially vertical direction into a substantially horizontal radially outward direction.

[0018] In a particularly advantageous process, the bearing housing, which encloses the drive bearing, is simultaneously pressurized with a purging gas during operation to prevent the ingress of dust particles into the drive bearing and to increase its service life.

[0019] Furthermore, the particle throughput through the distribution elements can be controlled by either adjusting the rotational speed of the distribution device or by selectively reducing the flow cross-section of the inlet openings through the use of interchangeable ring orifices.

[0020] Advantageous further developments of the filling device and the distribution device for density filling are described in more detail below. Detailed description of the invention

[0021] The present invention, according to the first embodiment, provides an improved filling device for the density filling of a chemical reactor with particulate catalyst material, in which a particularly gentle, uniform, and efficient filling of the reactor can be achieved through a novel design of the distribution element. Decisive technical advantages are achieved in particular through a novel geometric design of the annular distribution elements. According to the invention, the clear height (h) of the essentially vertical outlet opening is greater than the clear width (w) of the essentially horizontal inlet opening. This specific dimensioning creates a widening flow cross-section, which enables a higher particle throughput at a lower discharge velocity.This significantly reduces the mechanical stress on the often sensitive catalyst particles, minimizes particle abrasion and breakage, and reliably prevents material buildup in the distribution element. This leads to improved structural integrity of the catalyst material and a more homogeneous packing in the reactor.

[0022] According to an advantageous embodiment, the deflecting element has a guide surface that has a substantially vertical tangent at the inlet opening and a radially outward-directed tangent at the outlet opening, where the radius of curvature of the guide surface increases continuously from the inlet opening to the outlet opening. For the purposes of this application, the term 'continuously increased' is not to be understood restrictively as 'strictly monotonically increasing'. Rather, it means that the curvature of the guide surface changes along the particle path without abrupt kinks or even jumps. This also includes embodiments in which the guide surface maintains its orientation and thus its radius of curvature over longer sections, for example, in the region of the inlet and outlet openings, where the tangent already has the desired vertical or radially outward orientation.Crucially, the transition between sections of different curvature must be smooth and without edges to ensure gentle particle deflection. In particular, the design of the ring-shaped distribution element with a specifically shaped guide surface offers significant technical advantages compared to the prior art. The annular distribution element features a guide surface that redirects the essentially vertical particle flow exiting the feed vessel into a radially outward flow directed towards the reactor's inner wall. The continuous increase in the radius of curvature of this guide surface ensures a particularly smooth and uniform redirection of the particle flow. This significantly reduces mechanical stress on the catalyst particles, which are highly sensitive to mechanical stress, and prevents particle abrasion or breakage. This contributes substantially to maintaining the structural integrity of the catalyst material.

[0023] By designing the inlet opening as a ring-shaped, essentially horizontal opening with a smaller clear width compared to the outlet opening, a flow pattern is achieved that supports a targeted and controlled transport of the particles along the guide surface, which promotes a uniform distribution of the particles across the reactor cross-section and avoids local inhomogeneities, especially "hotspots".

[0024] Because the clear height of the outlet opening is greater than the clear width of the inlet opening, an effective cross-section for particle ejection is created, enabling a higher particle flow rate at a lower flow velocity. This reduces the energy input into the particles and increases material throughput while simultaneously reducing the mechanical stress on the particles.

[0025] As already stated in WO 2017 / 167957 A1, the laterally offset drive unit outside the feed hopper prevents the risk of particle damage from collisions with central drive elements and allows free flow of material through the feed hopper. Furthermore, the maximum filling volume in the feed area is not restricted by drive components mounted inside the feed hopper.

[0026] The uniform distribution of the catalyst material in the reactor leads to a homogeneous packing density, which has a direct positive effect on reactor performance, for example through uniform temperature distribution, low pressure drop, and more defined reaction kinetics. The invention thus makes a crucial contribution to the process stability and efficiency of chemical reactors filled according to the invention.

[0027] Within the context of this application, the terms "top" and "bottom" refer to the orientation of the device in its intended operating state, where the direction of gravity serves as a reference. "Bottom" denotes the direction in which the gravitational force acts, while "top" defines the opposite direction.

[0028] Similarly, the terms "vertical" and "horizontal" should also be understood in relation to the preferred direction defined by the direction of gravity. "Vertical" refers to a direction or orientation parallel to this preferred direction, and "horizontal" to a direction or orientation perpendicular to this preferred direction.

[0029] The term "radial" denotes a direction or orientation whose principal component points outwards from a center, for example, a direction or orientation whose principal component points outwards from a reference axis, in particular the axis of rotation of the filling device. For the purposes of this application, "radial" thus denotes an orientation that forms an angle between 45° and 135° (or between 225° and 315°) with the reference axis. Directions or orientations closer to the reference axis are referred to as axial. With a vertically oriented reference axis, the term "radial" can also be defined with respect to the horizontal. "Radially outwards" then means, in the context of a vertical reference axis, that deviations from the horizontal are also permissible, as long as these deviations are less than + / - 45°, preferably less than + / - 40°, + / - 35°, + / - 30°, + / - 25°, or + / - 20°.

[0030] The term "essentially" indicates that a feature designated by this term does not have to be interpreted in the strict sense of the word, but that deviations are also included which the expert would consider uncritical for the intended function.

[0031] Within the scope of this application, the terms “essentially vertical” and “essentially horizontal” mean that the angular deviations from the vertical or horizontal are less than + / - 20°, preferably less than + / - 10° and particularly preferably less than + / - 5°.

[0032] A "feed container" within the meaning of the present invention is understood to be a component of the filling device that receives particulate catalyst material prior to distribution in the reactor and is lowered into the reactor to be filled as part of the filling device. Typically, the feed container is a radially symmetrical container about the axis of rotation (A), in particular a cylindrical container with a cylindrical side wall, a lower outlet opening located directly above the distribution device, and an upper inlet opening through which material can be filled or fed. The upper inlet opening can form the upper end face of the cylindrical feed container's cover or be located in the upper part of the cylindrical side wall of the feed container.Typically, the feed tank serves as an intermediate tank and is connected via a feed hose to a storage tank for catalyst material located outside the reactor.

[0033] The distribution unit is rotatably mounted below the feed vessel around its central axis of rotation (A), allowing particulate material to enter the annular distribution elements of the unit under the influence of gravity. As the distribution unit rotates, centrifugal force ejects the material radially outwards into the reactor interior. The flow rate of catalyst material is determined by various parameters, primarily the dimensions of the lower outlet of the feed vessel, the upper inlet openings of the distribution elements, the vertical outlet openings of the distribution elements, the fill height of the catalyst material in the feed vessel, and the rotational speed of the distribution unit.In addition, adjustable flow control devices can be provided between the feed container and the distribution device, for example, orifices with variable opening width, as described in international patent application WO 2017 / 167957 A. As described in more detail below, the flow control devices can also be designed as ring orifices that can be easily replaced by insertion.

[0034] As in international patent application WO 2017 / 167957 A, the "drive unit" in the filling device according to the invention is also arranged laterally offset to the vertical axis of rotation (A) outside the feed container and drives the distribution unit via a drive bearing by means of a belt drive. Such a belt drive has proven to be particularly reliable compared to other drive variants in the dusty environment of a chemical reactor. The belt drive can comprise a drive wheel and a drive belt. The drive wheel, located at the lower end of the drive motor, is set in rotation by the drive motor, and the rotational movement of the drive wheel is transmitted by the drive belt to the rotary bearing ring of the drive bearing.The drive motor is in particular a pneumatic bidirectional high-performance motor which, due to its slim design, does not increase the overall radial diameter of the filling device, as already described in WO 2017 / 167957 A.

[0035] According to the invention, the vertical clear height of the outlet opening of the distribution element is greater than the horizontal clear width of the inlet opening. Since at least one of the distribution elements is annular, the horizontal inlet opening also forms a ring, and the clear width of the inlet opening therefore corresponds to the thickness of the ring.

[0036] The deflecting element, which redirects the particle flow from a vertical flow direction to a radially outward direction, for example, a substantially horizontal discharge direction, has, according to the invention, a guide surface that has a substantially vertical tangent at the inlet opening, corresponding to the flow direction of the particles as they transition from the feed container to the distribution element, and a radially outward tangent, for example, substantially horizontal, at the outlet opening, corresponding to the discharge direction of the particles. The radius of curvature of the guide surface increases continuously between the inlet and outlet openings. Preferably, the radius of curvature of the guide surface at the inlet opening corresponds substantially to the horizontal clear width of the inlet opening and at the outlet opening substantially to the vertical clear height of the outlet opening.This ensures that the available cross-sectional area for the particle flow in the distribution element between the horizontal inlet opening and the vertical outlet opening does not decrease, meaning that no constriction occurs which would otherwise reduce the throughput of particle material. "Cross-sectional area" refers to the clear area in the distribution element that is arranged perpendicular to the guide surface of the deflecting element at a specific point. Preferably, the cross-sectional area between the horizontal inlet opening and the vertical outlet opening increases continuously. The horizontal inlet opening is an annular surface that transitions continuously along the guide surface into a vertical circumferential surface.

[0037] In one embodiment of the filling device according to the invention, several distribution elements are arranged vertically offset from one another, with the horizontal inlet openings and the vertical outlet openings being arranged radially offset from one another from top to bottom with respect to the axis of rotation A, the radial distance of the inlet and outlet openings of the distribution elements from the axis of rotation A decreasing from top to bottom. Since the distribution elements rotate at the same speed about the axis of rotation A during operation, greater centrifugal forces act on particles in the uppermost distribution element than on particles in the lowermost distribution element. In order to at least partially compensate for this effect, it is preferably provided that the ratio between the clear height of the outlet opening and the clear width of the inlet opening is greater for distribution elements arranged lower down than for distribution elements arranged higher up.In the context of the present invention, “top” and “bottom” mean relative orientations with respect to the gravity-driven supply of particles from the feed container, i.e., elements arranged further “top” are located closer to the feed container than elements arranged further “bottom”.

[0038] According to one embodiment, the distribution device has at least one upper distribution element, one middle distribution element and one lower distribution element.

[0039] Preferably, the clear height of the outlet opening is at least 25% greater (1.25 times greater) than the clear width of the inlet opening. Particularly preferably, the clear height of the outlet opening is at least 50% greater (1.5 times greater) than the clear width of the inlet opening. For example, the clear height of the outlet opening can be 1.25 to 3 times greater, preferably 1.5 to 2 times greater, than the clear width of the inlet opening. This ensures that sufficient space is available for deflection from the essentially vertical flow direction of the particle stream to a radially outward flow direction, and in particular, reduces the outlet resistance after acceleration of the particles by centrifugal force. The larger outlet opening also increases the throughput (particle volume per unit time) without excessively increasing the flow velocity.Furthermore, a ratio of the height of the outlet opening to the width of the inlet opening of at least 1.25 ensures that no backflow occurs in the particle flow.

[0040] According to one embodiment of the invention, the guide surface is designed as a "clothoidal" transition surface. A clothoidal transition surface is understood to be a transition surface whose radius of curvature increases continuously. For the purposes of the present invention, a clothoidal transition surface is understood to encompass both classical clothoids, in which the radius of curvature increases linearly, and power clothoids, in which the curvature does not increase linearly. Alternatively, the profile of the radius of curvature of the transition surface can also be described by Bézier or spline segments, for example, as a cubic Bézier spline whose end tangents are vertical or horizontal, respectively.

[0041] The clothoid is characterized by a continuously increasing radius of curvature along its curve, resulting in a particularly smooth transition between vertical and horizontal flow directions. This avoids abrupt changes in direction and the associated mechanical stresses on the catalyst material. Preventing shock loads on the often porous or brittle catalyst material also leads to a significant reduction in abrasion, breakage, and fine dust formation, which in turn improves reactor performance and the material's service life. Because a clothoidal surface can be precisely described mathematically, the corresponding shapes can be easily implemented using CAD / CNC systems.In combination with the ratio of clear height to clear width of at least 1.25 provided according to the invention, a longer guide surface is provided, which in turn enables a gentler curvature progression and thus further protection of the catalyst material.

[0042] According to the second embodiment of the invention, the drive bearing is arranged within a rotating bearing housing that can be supplied with a purge gas stream. This measure serves in particular to protect and ensure the operational reliability of the bearing system and is associated with a number of technical advantages. In a filling device with freely flowing, fine-grained catalyst material, there is always a risk that particles, or especially dust (for example, from particle abrasion), will penetrate the bearing system. By supplying the bearing housing with purge gas, a continuous airflow is generated from the bearing housing to the outside, which reliably prevents the ingress of solids or carries away solids that have already penetrated. This, in turn, reduces wear on bearing components and extends the service life of the drive bearing.

[0043] In this embodiment, the purge gas can also be temperature-controlled or dried, thus preventing condensation, temperature fluctuations, and corrosion. The design of a circumferential, enclosed bearing housing further simplifies external sealing against the reactor chamber and protects sensitive components from chemical or thermal stress. Combined with the drive motor located outside the feed vessel, this results in a fully encapsulated, maintenance-friendly drive system that minimizes particle contact in the direct drive area. The drive motor can, for example, be a pneumatic motor, particularly a vane-type pneumatic motor. In this case, the purge gas supply can also be used to operate the pneumatic motor. The purge gas can be, for example, compressed air or an inert gas such as nitrogen.Particularly when using catalysts that readily react with oxygen, inert gas is preferably used for both the purge gas and the operation of the drive motor.

[0044] Advantageously, the bearing housing features a connection for supplying purge gas. This defined connection allows for the controlled and metered introduction of purge gas into the bearing housing, ensuring a stable overpressure atmosphere and thus optimizing the protection of the drive bearing. The connection also enables integration into existing compressed air or inert gas networks, or connection to a compressor located outside the reactor. The connection can be equipped with standardized control valves or sensors, allowing for monitoring and automation of the purge gas system, for example, for leak detection or adaptation to changing operating conditions.

[0045] In a further embodiment of the invention, the purge gas is at least partially diverted from the bearing housing into the particle stream inside the filling device. The purge gas therefore not only protects the drive bearing but also selectively returns the dust particles to the particle stream. At the same time, the purge gas prevents further dust deposits inside the filling device. Furthermore, the proposed flow pattern effectively prevents a backflow of particles from the feed hopper or distribution device into the bearing area.

[0046] According to the third embodiment of the invention, the lower end of the feed container has at least one annular insert that directs the particle flow to the at least one distribution element. Preferably, the annular insert consists of at least one concentric ring tube arranged radially symmetrically around the axis of rotation, which directs a portion of the particle flow to each associated distribution element. The annular insert acts as a flow-guiding element, directing the particle flow exiting the feed container precisely to the desired position and with a defined cross-section at the respective distribution element. This optimizes the geometric coupling between the feed container and the distribution element and ensures a more uniform flow to the inlet opening of the distribution element.The ring insert also helps to eliminate asymmetrical or obliquely incident flow components, such as those that can arise from wall friction or uneven particle conveyance in the feed hopper. This creates a uniform axially and radially symmetrical flow, which is crucial for deflection and distribution within the distribution element. Since the ring insert advantageously comprises at least one concentrically radially symmetrical annular tube arranged around the axis of rotation, ideal flow conditions are also ensured for the deflection elements of the distribution elements, particularly for the clothoidal guide surfaces of the deflection elements within the distribution elements. The annular tubes can also be arranged relative to the respective distribution element such that they adjoin the substantially vertical section of the guide surface of the deflection element and extend the guide surface of the deflection element upwards.The annular tubes essentially form part of the guide surface, allowing the vertical section of the guide surface to be correspondingly shortened. It is understood that "adjacent" here requires a certain distance, typically in the millimeter range, between the annular tube and the guide surface to ensure the rotation of the distribution device relative to the feed hopper / ring insert is not impaired. The ring insert can be modularly adapted to the respective size of the reactor or the desired particle throughput. Preferably, the ring insert comprises at least three annular tubes, enabling multi-channel and simultaneous particle distribution on several levels of the distribution device. This increases the overall capacity of the filling device and allows for more efficient and uniform filling of the reactor.Furthermore, dividing the total particle flow into several partial flows reduces the local mass flow density in each ring tube, which reduces the mechanical stress on the particles and minimizes abrasion and breakage.

[0047] The ring tubes can be connected to each other via webs and arranged in a stepped fashion along the central axis of rotation (A), offset downwards. This creates contact surfaces for flow control devices, such as, in particular, freely insertable ring orifices with a defined central through-hole, with which the particle flow can be specifically modulated to form the flattest possible particle front in the container to be filled.

[0048] In a particularly advantageous embodiment of the invention, the inner tubes of the ring insert can be additionally provided with at least one deflector ring on their outer walls. Such a deflector ring is typically designed as a ring with an inwardly and downwardly inclined cross-sectional profile. The function of this deflector ring is to gently guide downward-flowing catalyst particles, or in particular smaller fragments, which move along the inner wall of the feed container, inwards, i.e., away from the inner wall of the tube and towards the center of the respective annular inlet opening. This effectively prevents these particles or fragments from entering the gap, which is unavoidable due to the design, between the stationary ring insert and the rotating distribution element.This prevents the gap from becoming clogged, which could otherwise lead to jamming, increased wear, or in the worst case, a complete blockage of rotation. The deflector ring thus contributes significantly to operational reliability and reduced maintenance requirements.

[0049] According to a further development of the invention, which can be combined with all embodiments, the drive motor and the drive bearing are mounted on a radial support plate arranged between the feed hopper and the distribution unit, the support plate forming the top of the bearing housing. The common support plate integrates the drive motor, bearing, and distribution unit into a mechanically rigid, precisely aligned unit, which improves the smooth operation of the distribution unit and reduces vibrations and misalignment forces. The dual function of the support plate as a mechanical support element and component of the bearing housing reduces the need for additional structural elements, making the overall design of the filling device more compact, which is particularly advantageous in confined installation spaces.

[0050] According to one embodiment in which the bearing housing can be supplied with a purge gas flow, the fixed bearing ring of the drive bearing can be connected to the carrier plate, with passages for the purge gas being provided between the carrier plate and the fixed bearing ring. These passages allow the purge gas to pass from the bearing housing into the interior of the filling device. The passages can be formed as a multitude of radially distributed channels in the surface of the carrier plate, in the surface of the fixed bearing ring, or in both components. For effective removal of the purge gas from the bearing housing into the interior of the filling device, a few passages distributed around the circumference of the contact area between the carrier plate and the fixed bearing ring are sufficient, thus maintaining the structural integrity of the mechanical connection between the fixed bearing ring and the carrier plate.

[0051] According to a further embodiment, the purge gas is selectively diverted into the particle stream via a gap formed between the rotary bearing ring of the drive bearing and the ring insert. The particle stream is thus formed between the outermost annular tube of the ring insert and the rotary bearing ring of the drive bearing. This gap prevents friction between the rigid annular tube of the ring insert and the rotating rotary bearing ring of the drive bearing. Such a gap is inherently difficult to clean, so the purge gas routing provided according to the invention not only serves to discharge the dust-laden purge gas from the bearing housing into the interior of the filling device, but also simultaneously ventilates the gap and prevents the formation of material accumulations in this area, thereby improving the cleaning and maintenance of the filling device.

[0052] In all embodiments, the drive bearing can include a ball bearing. Ball bearings are characterized by low friction and smooth, effortless running, enabling energy-efficient rotation of the distribution device. The ball bearing forms the connection between the inner slewing ring and the outer fixed ring, and sealing lips, such as rubber lips, can be provided to seal the ball bearing against unwanted dust ingress.

[0053] In embodiments where a mounting plate is provided, the drive motor can be mounted on the mounting plate so that it is radially displaceable relative to the vertical axis of rotation. This allows for simple belt tensioning or release without separate tensioning mechanisms. Furthermore, the drive motor can be flexibly positioned depending on the selected motor, pulley, or desired gear ratio, ensuring a high degree of adaptability to various performance requirements.

[0054] In embodiments where the distribution device comprises at least one upper distribution element, one middle distribution element, and one lower distribution element, the lower distribution element is preferably designed as a central lower distribution element with a central circular inlet opening, which enables optimal utilization of the axial material flow from the feed hopper. In combination with the surrounding annular distribution elements, the central element can cover an additional distribution zone in the reactor center, further improving the homogeneity of the packing. The central lower distribution element has a lower deflector element that largely redirects the vertical particle flow into a radially, preferably horizontally, outwardly directed particle flow, which exits the lower distribution element through annularly arranged, vertically oriented outlet openings.The lower deflection element can be designed as an annular deflection element, similar to the middle or upper deflection elements. Alternatively, the lower deflection element can be designed as a central, conical deflection element. Additionally, a downward-facing, horizontally oriented outlet opening can be provided in the base plate of the central distribution element. This outlet opening allows a portion of the particle flow to be directed vertically downwards into the reactor chamber, ensuring that sufficient material is also deposited in the central reactor area for uniform filling. The horizontally oriented outlet opening in the base plate can optionally be closed.

[0055] Preferably, the feed hopper and the distribution device are dimensioned such that the sum of the inlet areas of the distribution elements of the distribution device essentially corresponds to the outlet opening of the feed hopper, thus ensuring a continuous material flow, except for any flow control devices that may be present. This ensures that the dimensioning of the feed hopper and the distribution device does not impede the material flow between them. The uniform surface area distribution also promotes an even distribution of the particle flow across all distribution elements, which homogenizes the reactor filling and prevents local material accumulation in the reactor. Any influence on the material flow or the formation of a backflow of material upstream of the distribution device should instead be prevented by controllable or...Controllable flow control devices are implemented, as described, for example, in the international patent application WO 2017 / 167957 A, or by means of freely insertable special ring orifices described for the first time therein (such as in . Fig. 3 shown).

[0056] Preferably, the at least one distribution element has, in its radially symmetrical rigid central section, a plurality of rigid vertical ribs distributed around its circumference, spaced apart from one another and extending radially outwards, which divide the distribution element into a plurality of radially symmetrical sectors. Such rigid ribs act as flow-guiding ribs that guide the radially outward-exiting particle stream uniformly in several defined directions, which in turn promotes a homogeneous surface distribution in the reactor, since any disturbances in the material flow cannot propagate across the circumference of the distribution elements. Therefore, the defined sectors prevent the particle stream from spreading preferentially in individual areas and thus promote a uniform bulk density.The rigid webs also increase the mechanical strength of the distribution element and provide stabilization against torsional and bending loads during rotation, thus allowing for a reduction in material thickness compared to distribution devices without webs. The number of sectors can vary depending on the application and the shape and size of the particulate catalyst material. For example, a distribution device with three distribution elements might have 20 to 30 sectors for the top distribution element, 10 to 20 sectors for the middle distribution element, and 4 to 10 sectors for the bottom distribution element.

[0057] According to a variant possible in all embodiments, the at least one distribution element has a circumferential, particularly horizontal, elastic extension extending radially outwards from the outlet opening at its lower edge, which in a preferred embodiment is formed integrally. The elastic extensions serve as soft, yielding guide surfaces that guide the particles without hard collision after they leave the outlet opening. Furthermore, a filling device with such a distribution element is less bulky and therefore easier to insert into the reactor. The radial extension preferably has sectors with increasing radii around the circumference or, even more preferably, in one or more circular segments, such as 2, 3, 4, 5, or 6 circular segments.To ensure optimal smooth running at high speeds and avoid imbalances, several such asymmetrical circular segments can be arranged rotationally symmetrically to each other. To achieve dynamic balance of the entire assembly, for example, two (n=2) identical circular segments can be arranged at an angular distance of 180° to each other, or three (n=3) identical circular segments can be arranged at angular distances of 120° each. Generally, n identical, asymmetrical circular segments are arranged at regular angular intervals of 360° / n around the axis of rotation to cancel out the centrifugal forces resulting from the asymmetry of the individual segments. Each individual sector within such a segment then has a different extension length. This arrangement combines the advantage of targeted control of the ejection distance through the asymmetrical shape of the segments with the advantage of a dynamically balanced overall assembly.This allows for optimization of the homogeneous filling of the reactor even with large reactor cross-sections, while at the same time the number of distribution elements, i.e. the ejection levels, does not have to be increased.

[0058] Furthermore, elastic vertical extensions can be provided, extending radially outwards from the end of each of the vertical rigid struts. This allows for a soft, compliant guidance of the particles exiting the outlet opening across the reactor cross-section. The radial length of the vertical extensions typically corresponds to the radius of the corresponding horizontal extension, so that the vertical extensions also have a radius that increases continuously over a circumference or segment of a circle.

[0059] The elastic horizontal and vertical extensions can be made of rubber or other rubber-elastic plastic, for example, and can be detachably or permanently connected to each other.

[0060] The elastic extensions of the individual planes are preferably also designed as clothoids, in which the radius of the horizontal and / or vertical extensions on each plane decreases continuously from a starting radius to a final radius. Furthermore, it is preferably provided that the final radius of the upper plane corresponds to the starting radius of the lower plane, so that the radii of the extensions continue continuously during the transition from one plane to the next. Brief description of the drawings

[0061] The invention will be explained in more detail below with reference to an embodiment illustrated in the accompanying drawings.

[0062] The drawings show: Fig. 1 a perspective view of an embodiment of the filling device according to the invention with a first variant of a distribution device; Fig. 2 a perspective drawing in partial cross-section of the filling device of the Fig. 1; Fig. 3 a schematic representation of an annular orifice for flow control; Fig. 4 a perspective drawing in partial cross-section of the filling device of the Fig. 1 from a different perspective than Fig. 2; Fig. 5 A perspective detail view of the middle distribution element of the filling device of the Fig. 1; Fig. 6 a top view of the central distribution element of the Fig. 5; Fig. 7 an enlarged cross-sectional view of a deflection element of the distribution device of the in Fig. 2 filling device shown; Fig. 8 a schematic representation of the area ratios in the deflection elements of the filling device of the Fig. 1; Fig. 9 an enlarged detail view of the drive bearing of the in Fig. 2 filling device shown; Fig. 10 a second variant of the distribution device with upper, middle and lower distribution element in an exploded view; Fig. 11 the lower distribution element of the distribution device of the Fig. 10 in an exploded view; and Fig. 12 the middle distribution element of the distribution device of the Fig. 10 in an exploded view. Detailed description of the drawings

[0063] In Fig.Figure 1 shows an embodiment of the filling device according to the invention for filling a (not shown) chemical reactor with particulate catalyst material in a perspective side view. The filling device 10 has a cylindrical feed container 11 for (not shown in the drawings) particulate catalyst material. The feed container 11 has an upper inlet opening 12 and a lower outlet opening 13 for the particulate catalyst material.

[0064] A three-stage distribution device 14 is arranged below the feed container 11. This device is rotatably mounted about a vertical central axis of rotation A to distribute the particulate catalyst material in the chemical reactor by centrifugal force. In the illustrated embodiment, the distribution device 14 has three vertically arranged distribution elements 15, 16, 17, which deflect a substantially vertical particle stream coming from the feed container 11 into a radially, preferably substantially horizontally, outwardly directed particle stream. The rotation of the distribution device further accelerates the particulate catalyst material radially outward by centrifugal force, allowing the catalyst material to distribute itself across the cross-section of the chemical reactor being filled.The vertically concentric distribution elements 15, 16, 17 have different radii, so that the particles exiting the individual distribution elements experience different centrifugal forces and are thus carried to different distances in the radial direction into the reactor interior. This is shown in the illustration of the... Fig. 1. A particularly easily identifiable first upper distribution element 15 has outlet openings 18 that are radially furthest from the axis of rotation A, so that the corresponding particles deflected via the first distribution element are ejected into the reactor interior at the highest radial velocity. As shown in particular in Fig.As can be seen more clearly in Figure 2, the outlet openings 19 of the second, middle distribution element 16 are offset radially inwards in the direction of the axis of rotation A, while the outlet openings 20 of the third, lower distribution element 17 are offset radially even further inwards in the direction of the axis of rotation A. As can be seen in Fig. 1 at the first, upper distribution element 15 and in Fig.As can also be seen in the distribution elements 16 and 17, the distribution elements 15, 16, 17 have numerous vertical, spaced-apart, and radially outward extending rigid webs 21, 22, 23 distributed around their circumference, which divide the distribution elements into a multitude of radially symmetrical sectors 24, 25, 26. The distribution elements 15, 16, 17 also have a continuous, one-piece, horizontal elastic extension 27, 28, 29 extending radially outward from the respective outlet openings, which has a radius that increases continuously over its circumference or over a circular segment.

[0065] This allows the ejection distance of the particulate catalyst material to be additionally influenced at the level of each distribution element 15, 16, 17, and a more homogeneous distribution of the catalyst material over the cross-section of the reactor to be achieved.

[0066] The horizontal elastic extensions (27, 28, 29) have a radius that increases continuously over the circumference of the circle or at least a circular segment. This geometry is typically formed as a spiral or clothoid. This means that the radius of the extension is minimal at a starting point close to the rigid base body of the distribution element and then increases continuously over a defined angular range to an endpoint with maximum radius. As in the Fig. 5, Fig. 6 and Fig.As illustrated in Figure 10, this change in radius typically does not extend over the full 360°, but rather over a large portion of the circumference, for example, over an angular range of 300° to 350°. The increase in radius is chosen so that the particles exiting the distribution device at different angular positions are ejected to varying distances. The difference between the minimum and maximum radii can, for example, be in the range of 10% to 50% of the maximum radius to ensure effective coverage of the entire reactor cross-section. In terms of manufacturing, this extension is typically produced as a single component made of an elastic material, such as rubber or another elastomer. This component can be formed into the desired spiral shape by injection molding or cut from a flat material. Attachment to the rigid distribution element can be, as shown in Figure 10, Fig.As shown in Figure 10, this is achieved by means of a retaining ring that is welded or bolted to ensure a stable and permanent connection. This targeted variation of the ejection distance depending on the angle of rotation achieves a particularly homogeneous and complete distribution of the catalyst material, since during one full rotation of the distribution device the entire radial area between the minimum and maximum ejection radius is covered.

[0067] Although not explicitly shown in the figures, the principle described above also applies to an alternative and often more advantageous design of the extension using multi-part, rotationally symmetrical circular segments. To avoid dynamic imbalance at high speeds and ensure optimal smooth running, several identical but inherently asymmetrical circular segments can be arranged rotationally symmetrically to each other. For example, two identical segments can be offset by 180°, or three identical segments can be arranged at angular intervals of 120°. Each of these segments has a continuously increasing radius. The combination of these segments ensures that the entire radial range is covered over a full revolution, while the overall assembly remains dynamically balanced.

[0068] How to in Fig.As can be seen particularly in the first upper distribution element 15, elastic vertical extensions 30, 31, 32 are also provided, which extend radially outwards at the end of each vertical rigid web 21, 22, 23 of the distribution elements 15, 16, 17 and have essentially the same radius, which increases continuously over the circumference or a circular segment. The sectoral subdivision of the distribution elements 15, 16, 17 is therefore also continued at the level of the elastic extensions 27, 28, 29.

[0069] A drive bearing 33 is arranged between the feed container 11 and the distribution device 14, which rotatably connects the rigid feed container 11 to the rotatable distribution device 14. The drive bearing 33 is described in more detail in Fig. 2 shown.

[0070] The filling device 10 also comprises a drive unit 34, which has a drive motor 35 arranged laterally offset to the vertical axis of rotation A outside the feed container 11 and a belt drive 36 that can rotate the distribution device 14 via the drive bearing 33. As shown in particular in Fig. As can be seen in Figure 4, the belt drive 36 comprises a drive wheel 36a connected to the drive motor 35 and a drive belt 36b, which transmits the rotary motion of the drive wheel 36a to the drive bearing. The drive bearing 33 and the belt drive 36 are surrounded by a bearing housing 37, which can be supplied with compressed air or inert gas via a purge gas connection 38. The feed hopper 11 and the drive motor 35 are mounted on a support plate 39, which forms the top of the bearing housing 37. A pneumatic vane motor is used as the drive motor 35.

[0071] Fig.Figure 2 shows a perspective partial view of the filling device 10 of the Fig. 1 in the partial cross-section. Elements already mentioned in connection with the representation in Fig. The items explained in section 1 are designated with the same reference numbers. Fig. 2. The vertically and radially staggered structure of the distribution device 14 is particularly evident, comprising the first or upper distribution element 15, the second or middle distribution element 16, and the third or lower distribution element 17. The upper distribution element 15 is designed as an annular rigid distribution element, which has an upper, annular, substantially horizontal inlet opening 40 and the already described in Fig.Figure 1 shows a cylindrical vertical outlet opening 18, which is subdivided into individual sectors 24 by the vertical rigid webs 21. Accordingly, the central annular rigid distribution element 16 has an upper, essentially horizontal inlet opening 41 and the already described in connection with Fig. 1 mentioned, but not visible there, a rectangular vertical outlet opening 19, which is subdivided into individual sectors 25 by vertical webs 22. Finally, the lower annular rigid distribution element 17 has an upper, essentially horizontal inlet opening 42 and the also related to Fig.Figure 1 shows a vertical rectangular outlet opening 20, which is not immediately apparent and is divided into individual sectors 26 by vertical webs 23. Each of the distribution elements 15, 16, 17 has a deflecting element 43, 44, 45, which deflects the essentially vertical particle flow coming from the feed container 11 into an essentially horizontal particle flow. The rigid distribution elements 15, 16, 17 can be manufactured, for example, by injection molding, 3D printing, or milled from a block of plastic.

[0072] According to the invention, the clear heights h1, h2, h3 of the vertical outlet openings 18, 19, 20 of the distribution elements are greater than the clear widths w1, w2, w3 of the associated horizontal inlet openings 40, 41, 42 of the distribution elements; that is, the ratios h1 / w1, h2 / w2, and h3 / w3 are always greater than 1. For the sake of clarity, the clear height h1 and the clear width w1 are shown only in the detailed view of the Fig.Figure 7 shows the outlet opening 18 and the inlet opening 40 of the first or uppermost annular distribution element 15. A corresponding geometry with a clear height h2 and a clear width w2 results for the second or middle annular distribution element 16. In the example shown, however, the third or lower distribution element 17 does not have an annular inlet opening, but rather a circular inlet opening 42 centered on the axis of rotation A. In this case, the "width" w3 is considered to be half the inner diameter of the circular inlet opening 42, i.e., the distance between the axis of rotation A and the inner wall of the lower deflection element 45 at the level of the horizontal inlet opening 42.

[0073] The deflection elements 43, 44, 45 each have guide surfaces for the particulate material 46, 47, 48, which have a substantially vertical tangent at the inlet opening and a substantially horizontal tangent at the outlet opening, with the radius of curvature of the guide surfaces increasing continuously from the respective inlet openings to the outlet openings. The guide surfaces 46, 47, 48 can, for example, be configured as clothoidal transition surfaces.

[0074] How to Fig.The lower end of the feed container 11 has a ring insert 49, which consists of three concentric, radially symmetrical ring tubes arranged around the axis of rotation A. Each of these tubes directs a partial flow of the particle stream flowing vertically from the feed container 11 to a corresponding distribution element 15, 16, 17. The lower ring tube 52, which is located above the inlet opening 42 of the lower distribution element 17, is connected via webs 53 to the middle ring tube 51, which is located above the inlet opening 41 of the middle distribution element 16. The middle ring tube 51 is in turn connected via webs 54 to the upper ring tube 50, which is located above the inlet opening 40 of the upper distribution element 15. The upper ring tube 50 has a circumferential rim 55, to which the entire ring insert 49 is screwed to the support plate 39.The lower ring tube 52 has inwardly projecting lugs 73 on its inner wall.

[0075] In the presentation of the Fig. 2. Furthermore, the drive bearing 33 is better than in Fig.The drive bearing 33 has a fixed bearing ring 56, which is connected to the underside of the support plate 39, and a rotary bearing ring 57, which is rotatable relative to the fixed bearing ring and is connected to the distribution device 14 via ring elements 58, 59, which form a guide for the belt drive 36. The fixed bearing ring 56 and the rotary bearing ring 57 define a ball bearing chamber 60 in which a ball bearing 61 is arranged to reduce friction during relative movement between the fixed bearing ring 56 and the rotary bearing ring. The ball bearing chamber 60 is closed at the top and bottom by elastic sealing lips 62, 63, with the upper sealing lip 62 being connected to the fixed bearing ring and bearing against the top of the rotary bearing ring, while the lower sealing lip 63 is connected to the rotary bearing ring and bearing against the underside of the fixed bearing ring. The drive bearing 33 with its individual components is shown in the enlarged view of the Fig.9 more easily recognizable.

[0076] In Fig. Figure 2 also shows that the third, lower distribution element 17 has a base plate 67 in which a bottom opening 68 is recessed, so that particulate material from the lowest distribution element 17 can not only exit laterally from the outlet openings 20 under the influence of centrifugal force, but can also fall downwards through the bottom opening 68 into the center of the container to be filled under the influence of gravity. This measure prevents a funnel from forming in the center of the container during the filling process.

[0077] How to in Fig. 2. Furthermore, the lower deflecting element 45 of the lower distribution element 17 is designed as a central cone with a conical lower guide surface 48.

[0078] Fig.Figure 3 shows a schematic representation of an annular orifice for flow control. For each of the horizontal inlet openings 40, 41, 42, there is a set of annular orifices that allow the flow through the inlet openings 40, 41, 42 to be controlled in predefined steps. The in Fig.The three exemplary ring orifices 72 have an inner radius r1 and an outer radius r2. The ring orifices 72 are dimensioned so that they can be placed on the shoulders of the ring insert 49. The ring orifices 72 intended for flow control of the horizontal inlet opening 40 have an outer diameter r2 that corresponds to the inner diameter of the upper ring tube. The ring orifices can therefore be placed on the shoulder of the ring insert 49 defined by the webs 54. The inner diameter r1 of the ring orifices 72 intended for flow control of the horizontal inlet opening 40 then varies in predetermined steps between the outer diameter of the middle ring tube 51 (which corresponds to a complete closure of the inlet opening 40) and a value that is slightly smaller than the outer radius r2 (which corresponds to a nearly open inlet opening 40).Accordingly, the annular orifices 72 intended for flow control of the horizontal inlet opening 41 have an outer diameter r2 corresponding to the inner diameter of the middle annular tube and an inner diameter r2 corresponding to the outer diameter of the lower annular tube 52, so that this set of annular orifices can be placed on the webs 53. The annular orifices 72 intended for flow control of the horizontal inlet opening 42 have an outer diameter r2 corresponding to the inner diameter of the lower annular tube, so that the annular orifices can be placed on the lugs 73 of the lower annular tube 52. The inner diameter can even be zero in this case, which corresponds to a complete closure of the inlet opening 42. Typically, 10 annular orifices per inlet opening 40, 41, 42 can be provided, dimensioned so that the flow rate can be varied between 0 and 90%.If no ring aperture 72 is inserted, the entrance aperture is fully open (100%).

[0079] Fig. Figure 4 shows a perspective view of the filling device 10 of the Fig. 1 in partial cross-section from a different perspective, in which the drive unit 34 with the drive motor 35 and the belt drive 36 is particularly clearly visible. For the sake of simplicity, only the upper distribution element 15 of the three distribution elements of the distribution unit 14 is shown here. Furthermore, the illustration of the Fig. 4. The bearing housing 37 is only indicated by a partial element 37a so that the belt drive 36 is more easily recognizable. Furthermore, the drive bearing 33 is only shown schematically. For the construction of the drive bearing 33, reference is made in particular to the detailed view of the Fig. 9 referred to. Otherwise, elements already related to the Fig. 1 and Fig.As explained in section 2, the same reference numerals are used again. It can be seen in particular that the belt drive 36 comprises a drive wheel 36a driven by the drive motor 35 and a drive belt 36b, which transmits the rotary motion of the drive wheel 36a to the drive bearing 33.

[0080] Fig. Figure 5 shows a perspective detail view of the central distribution element 16 of the filling device of the Fig. 1 and Fig. Figure 6 shows a top view of the central distribution element 16 of the Fig. 5. It can be seen by way of example how the outer radius of the distribution element 16, defined by the outer circumference of the horizontal elastic extensions 28, increases from its rigid, radially symmetrical central part around the circumference in the manner of a clothoid, so that different ejection distances for the particulate material are achieved for different sectors 25. The same applies to the distribution elements 15 and 17.

[0081] Fig.Figure 7 shows an enlarged view of the upper distribution element 15 of the distribution device 14. It is particularly evident that the clear height h1 of the outlet opening 18 is significantly greater, in particular approximately 25-50% greater, than the clear width w1 of the inlet opening 40 of the upper distribution element. This view also shows more clearly that the upper guide surface 46 of the upper distribution element 15 has a substantially vertical tangent t1 at the inlet opening 40 and a substantially horizontal tangent t2 at the outlet opening 18.The greater height of the outlet opening is ensured by the continuous increase in the radius of curvature of the guide surface 46 from the inlet opening 40 to the outlet opening 18. "Continuous" in this context means "monotonic" as opposed to "strictly monotonic," meaning the radius of curvature should increase. However, sections where the radius of curvature remains constant are also possible, particularly in the inlet and outlet areas where the horizontal or vertical tangent has already been reached. Such a guide surface can, for example, be designed as a clothoidal transition surface.

[0082] Fig. Figure 8 shows a schematic representation of the area ratios in the deflection elements of the filling device. Fig. 1. It can be seen that an essentially trapezoidal entrance area F e with clear width w1 into a larger exit area F awith clear height h1 transitions.

[0083] In Fig. 9 is the one already mentioned in connection with Fig. The described design of the drive bearing 33 is shown in more detail in Figure 2. For example, an advantageous guidance of the drive belt 36b through the drive bearing 33 can be seen. A guide ring 69 is inserted between the rotary bearing ring 57 and the ring element 58. This guide ring projects radially outwards and forms an upper guide for the drive belt 36b. Furthermore, the radial thickness of the ring element 59 is greater than the radial thickness of the ring element 58, creating a shoulder 70 which forms a lower guide for the drive belt 36b. In addition, Fig.Figure 9 shows in more detail the routing of the purge gas from the bearing housing 37 into the interior of the distribution device 14. When the interior of the bearing housing 37 is supplied with a purge gas flow, the purge gas can escape from the bearing housing 37 essentially in two ways, which are described in Fig.9 are indicated by thick arrows S1 and S2. Firstly, narrow passage openings 64 are recessed in the underside of the support plate 39, distributed around the circumference between the support plate 39 and the fixed bearing ring 56 connected to the support plate. These openings allow the purge gas flow to flow from the bearing housing 37 via flow path S1 and through a space 66 recessed between the outer surface 65 of the upper ring tube 50 into the inner area of ​​the sectors 24 of the upper distribution element 15, in order to be carried back into the interior of the reactor together with the particulate catalyst material. Secondly, a gap 71 is provided between the stationary bearing housing 37 and the rotating ring element 59, which allows the purge gas flow to flow from the bearing housing 37 into the outer area of ​​the sectors 24 of the upper distribution element 15 via the flow path S2.

[0084] In the Fig.10, Fig. 11 to Fig. Figure 12 shows a second, alternative embodiment of a distribution device which can be used in a filling device according to the invention.

[0085] This distribution device 114 can be used instead of the one described in the Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8 to Fig. The first variant shown in Figure 9 can be used in an otherwise identical or similar filling device. To clarify the analogy to the first embodiment, elements that perform the same or similar function are designated with the same reference numerals, increased by 100.

[0086] Fig.Figure 10 shows the second variant of the distribution device according to the invention in a perspective exploded view from a low angle. The distribution device 114, like the first variant, is designed as a three-stage arrangement. It comprises a first, upper distribution element 115, a second, middle distribution element 116, and a third, lower distribution element 117.

[0087] Particularly noticeable are the upper horizontal elastic extension 127 of the upper distribution element 115 and the middle horizontal elastic extension 128 of the middle distribution element 116. Similar to the first embodiment, these horizontal extensions 127, 128 have a radius that increases continuously around their circumference. This clothoidal shape allows for targeted control of the particle ejection distance at each level, contributing to a particularly homogeneous distribution of the catalyst material across the entire reactor cross-section. The horizontal extensions 127, 128 are also provided with upper vertical extensions 130 and middle vertical extensions 131, respectively, which extend from the ends of the vertical webs of the distribution elements 115, 116 and guide the particle flow to the discharge point. The horizontal extensions can be attached in various ways.For example, the upper horizontal extension 127 can be screwed to the upper distribution element 115 by means of an upper retaining ring 175, while the middle horizontal extension 128 is screwed to the middle distribution element 116 by means of a middle retaining ring 176 to facilitate assembly.

[0088] The lower distribution element 117, also in Fig. Figure 11, shown in detail, has a central upper inlet opening 142 and lateral outlet openings 120. In this embodiment, the lower distribution element 117 has no horizontal extensions, but could be equipped with them in other variants. It is divided into several sectors 126 by vertical webs 123, which open into vertical outlet openings 120. A special feature of this lower distribution element 117 is that the sectors 126 (in contrast to the sectors of the middle and upper distribution elements) are of different lengths.

[0089] As in Fig.As can be seen in Figure 11, the vertical webs 123 and the intervening outlet openings 120 extend radially outwards to different distances. This integral design effectively replaces the function of the separate horizontal extension, which is not present on this element. The different radial extensions of the sectors also allow for a targeted variation in the discharge distance of the catalyst material, ensuring a homogeneous distribution in the innermost region of the reactor. Another key feature is the central base plate 167, which has a bottom opening 168. This bottom opening can be closed by a rotatably mounted cover plate 177. When open, some of the catalyst material can fall directly into the central region of the reactor through the bottom opening 168 under the influence of gravity, effectively preventing funneling in the catalyst bed.A deflection element 178 is arranged below the base plate 167. This element consists of a substantially horizontal deflection plate 179 and a curved, vertical guide plate 180. The deflection plate 179 may have a recess to allow a portion of the particle stream to pass through unimpeded, while the remainder is gently deflected by the guide plate 180 into a larger radial area. This ensures even more uniform filling of the reactor center. Three feet 181 are also attached to the underside of the base plate 167, serving as stable supports should the entire filling device need to be set down.

[0090] How the exploded view in Fig.As illustrated in Figure 11, the particle flow through the bottom opening 168 can be controlled in a simple and robust manner. For this purpose, interchangeable, passive ring orifices 172 with central inner openings of different diameters can be inserted into the bottom opening 168. Their inner diameter defines the effective flow cross-section of the opening, thus precisely modulating the material flow to the center.

[0091] Fig.Figure 12 shows an exploded view of the central distribution element 116 from a top-down angle. The vertical ribs 122, which divide the radial particle flow into individual sectors 125 defined by two adjacent ribs 122, each with its associated outlet opening 119, are visible. This figure illustrates in detail the assembly of the central vertical extensions 131. These are not glued, but rather attached via a robust plug-in connection: First, the extensions 131 are inserted into separate retaining pins 182 made of a resistant material. This assembly is then inserted from above into corresponding longitudinal slots 183 in the radially symmetrical base body of the central distribution element 116. For final locking and stabilization, the extensions 131 have lateral locking tabs 184, which are positively pressed into designated horizontal recesses 185 in the central horizontal extension 128.This detachable connection facilitates maintenance and the replacement of individual components of the distribution device. A similar assembly is also provided for the upper vertical extensions 130 on the upper distribution element 115, as shown in . Fig. 10 is indicated by the locking tabs 186 and the notches 187.

[0092] The non-circularly symmetric, clothoidal shape of the horizontal extensions 127 and 128 can lead to an imbalance during rotation of the distribution device. To ensure smooth and vibration-free operation, this imbalance can be compensated for, for example, by placing counterweights in a cover ring 188 mounted on the central distribution element 116. As a design alternative, the horizontal extensions could also be configured as at least two rotationally symmetrical segments, each extending over an angular segment, to achieve an inherent mass balance.

[0093] Finally, for clarification, it should be noted that the information in the Fig. 10 and Fig. The central through-opening 189 of the upper distribution element 115 and the central through-opening 190 of the middle distribution element 116, as shown in Figure 12, do not, in themselves, represent the actual inlet openings for the particle material into the respective distribution element. Rather, annular inlet openings for the upper distribution element 115 and the middle distribution element 116 are only formed in conjunction with the ring insert (not shown here), analogous to the first embodiment. Based on Fig. 12 makes it clear that when inserting a ring insert such as the one used, for example, in the Fig.As shown in Figure 2, a lower cylindrical ring tube engages in the through-opening 190. The inlet opening for the middle distribution element 116 is then formed by an annular gap between the outer wall of the lower ring tube (corresponding to an imaginary upward extension of the inner edge of the central through-opening 190) and the inner edge of the cover ring 188. An analogous principle applies to the formation of the inlet opening of the upper distribution element 115.

[0094] Furthermore, the detailed presentation of the Fig.Figure 12 shows a special design of the vertical webs of this second variant of the distribution device 114. The vertical webs 122 of the central distribution element 116 shown here have an inner edge 191 facing the axis of rotation, which is chamfered or tapered. As a result, the webs 122 do not extend completely to the outer edge of the central through-opening 190 of the distribution element 116. In the radially inner region, immediately at the point where the particle flow enters the sectors 125, a continuous, annular space is thus created when the (not shown) ring tube is inserted, in which adjacent sectors 125 are fluidically connected. This common annular space serves as a kind of buffer or equalization zone. It ensures that the particle flow entering from above can distribute itself evenly across all sectors 125 before the particles are guided through the webs 122 and radially accelerated.Any local irregularities in the material flow are thus compensated for, which further improves the homogeneity of the distribution. The base surface of sectors 125 is formed by the essentially horizontal section of the guide surface. The base surface can therefore be inclined towards the outlet opening 119, for example with an angle of inclination of less than ±20°, preferably less than ±10°, and particularly preferably less than ±5°.

[0095] Naturally, the embodiments described above and illustrated in the figures are merely exemplary realizations of the invention. Those skilled in the art will recognize that numerous modifications, combinations, and variations are possible without departing from the scope of protection defined by the accompanying claims. The description and drawings should therefore be understood not as limiting, but as explanatory. The scope of protection of the invention is defined solely by the following claims. Reference symbol list 10 Filling device 11 feed container 12 upper inlet opening of the feed container 13 lower outlet opening of the feed container 14 114 Distribution system 15 115 first, upper distribution element 16 116 second, middle distribution element 17 117 third, lower distribution element 18 Outlet opening of the first, upper distribution element 19 119 Outlet opening of the second, middle distribution element 20 120 Outlet opening of the third, lower distribution element 21 vertical web of the first, upper distribution element 22 122 vertical bridge of the second, middle distribution element 23 123 vertical web of the third, lower distribution element 24 Sector of the first, upper distribution element 25 125 Sector of the second, middle distribution element 26 126 Sector of the third, lower distribution element 27 127 upper horizontal extension of the upper distribution element 28 128 mean horizontal extension of the middle distribution element 29 lower horizontal extension of the lower distribution element 30 130 upper vertical extension of the upper distribution element 31 131 mean vertical extension of the middle distribution element 32 lower vertical extension of the lower distribution element 33 drive bearing 34 drive unit 35 drive motor 36 Belt drive 36a drive wheel 36b drive belt 37 Bearing housing 37a Partial component of the bearing housing 38 Purge gas connection 39 carrier plate 40 Inlet opening of the upper distribution element 41 Inlet opening of the middle distribution element 42 142 Inlet opening of the lower distribution element 43 upper deflection element 44 middle deflection element 45 lower deflection element 46 upper guide surface 47 medium guide surface 48 lower guide surface 49 Ring insert 50 upper ring tube 51 middle ring tube 52 lower ring tube 53 Bridge between lower and middle ring tube 54 Bridge between middle and upper ring tube 55 Edge of the upper ring tube 56 fixed bearing ring 57 Swivel bearing ring 58 Ring element 59 Ring element 60 ball bearing space 61 ball bearings 62 upper sealing lip 63 lower sealing lip 64 Passage opening 65 outer surface of the upper ring tube 66 space 67 167 base plate 68 168 floor opening 69 Leadership ring 70 Paragraph 71 gap 72 172 Ring aperture 73 Nose 175 upper retaining ring 176 middle retaining ring 177 Cover plate 178 Deflection element 179 horizontal deflection plate 180 vertical guide plate 181 Foot 182 Retaining pin 183 longitudinal slot 184 Locking tab of the middle vertical extension 185 horizontal incision of the central horizontal extension 186 Locking tab of the upper vertical extension 187 horizontal incision of the upper horizontal extension 188 Cover ring 189 central through-openings of the upper distribution element 190 central through-openings of the middle distribution element 191 beveled inner edge of the vertical web 122 A axis of rotation h1 Clear height of the first distribution element h2 Clear height of the second distribution element h3 Clear height of the third distribution element w1 clear width of the first distribution element w2 clear width of the second distribution element w3 clear width of the third distribution element t1 vertical tangent t2 horizontal tangent S1 first purge air stream S2 second purge air stream r1 Inner radius of the ring aperture r2 Outer radius of the ring aperture QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 5,687,780 A1

[0004] US 4,972,884 A1

[0005] US 2013 / 0298507 A1

[0006] JP H02-14732 A

[0007] WO 2017 / 167957 A1 [0008, 0009, 0025] WO 2017 / 167957 A [0033, 0034, 0055]

Claims

[1] Filling device (10) for density filling of a chemical reactor with particulate catalyst material, comprising a feed container (11) for particulate catalyst material with an upper inlet opening (12) and a lower outlet opening (13); a distribution device (14, 114) which is rotatably arranged below the feed container (11) for distributing the particulate catalyst material in the chemical reactor by centrifugal force about a vertical axis of rotation (A), wherein the distribution device (14) comprises at least one first annular distribution element (15, 16; 115, 116) which has an upper annular, substantially horizontal inlet opening (40, 41) with a clear width (w1, w2), a substantially vertical outlet opening (18, 19) directed radially outwards with respect to the axis of rotation (A) with a clear height (h1, h2) and a deflecting element (43, 44) arranged between the inlet opening and the outlet opening, wherein the deflecting element deflects a substantially vertical particle stream coming from the feed container (11) into a radially outwards directed particle stream; a drive bearing (33) arranged radially symmetrically to the axis of rotation (A), comprising a fixed bearing ring (56) directly or indirectly connected to the feed container (11) and a rotary bearing ring (57) connected to the distribution device (14); and a drive device (34) comprising a drive motor (35) arranged laterally offset to the vertical axis of rotation (A) outside the feed container (11) and a belt drive (36), wherein the drive motor (35) drives the rotary bearing ring (57) of the drive bearing (33) via the belt drive (36); characterized by , that the clear height (h1,h2) of the exit opening (18,19,119) is greater than the clear width (w1,w2) of the entrance opening (40,41); and / or that the drive bearing (33) is arranged within a rotating bearing housing (37) which can be supplied with a purge gas stream; and / or that the lower end of the feed container (11) has at least one ring insert (49) which directs the particle flow to the at least one distribution element (15, 16, 17). [2] Filling device according to claim 1, characterized by , that the clear height (h1,h2) of the exit opening (18,19) is at least 1.25 times greater than the clear width (w1,w2) of the entrance opening (40,41). [3] Filling device according to one of claims 1 or 2, characterized by , that the deflecting element (43,44) has a guide surface (46,47) which has a substantially vertical tangent (t1) at the inlet opening (40,41) and a radially outwardly directed tangent (t2) at the outlet opening (18,19), wherein the radius of curvature of the guide surface (46,47) increases continuously from the inlet opening (40,41) to the outlet opening (18,19). [4] Filling device according to claim 3, characterized by , that the conducting surface (46,47) is formed as a clothoidal transition surface. [5] Filling device according to one of the preceding claims, wherein the lower end of the feed container has at least the ring insert (49) which directs the particle flow to the at least one distribution element (15, 16; 115, 116), characterized by , that the ring insert (49) consists of at least one concentric, radially symmetrical ring tube (50,51) arranged around the axis of rotation (A), which supplies a partial flow of the particle flow to an associated distribution element (15,16;115,116). [6] Filling device according to one of the preceding claims, wherein the drive bearing (33) is arranged within the rotating bearing housing (37), which can be supplied with a purging gas stream, characterized by , that the rotating bearing housing (37) can be pressurized with purging gas, wherein the bearing housing (37) includes a connection (38) for the supply of the purging gas. [7] Filling device according to claim 6, characterized by, that the purge gas is at least partially diverted from the bearing housing (37) into the particle stream inside the filling device. [8] Filling device according to claim 7, characterized by , that the drive motor (35) and the drive bearing (33) are attached to a radial support plate (39) arranged between the feed container (11) and the distribution device (14), wherein the support plate (39) forms the top of the bearing housing (37), wherein in particular the fixed bearing ring (56) of the drive bearing (33) is connected to the support plate (39), wherein openings (64) for the purge gas are provided between the support plate and the fixed bearing ring; and wherein the purge gas is directed into the particle stream in particular via an intermediate space (66) formed between the rotary bearing ring (57) of the drive bearing and the ring insert (49). [9] Filling device according to one of the preceding claims, wherein the drive motor (35) is mounted on the carrier plate (39) so as to be radially displaceable relative to the vertical axis of rotation (A). [10] Filling device according to one of the preceding claims, characterized by , that the distribution device (14) also has a central, lower distribution element (17,117) with a central circular inlet opening (42). [11] Filling device according to claim 10, characterized by , that the sum of the areas of the inlet openings (40,41,42) of the distribution elements (15,16,17) essentially corresponds to the area of ​​the outlet opening (13) of the feed container (11). [12] Filling device according to one of the preceding claims, characterized by, that the at least one distribution element (15,16,17) has a plurality of vertical, spaced apart and radially outward extending rigid webs (21,22,23) distributed over its circumference, which divide the distribution element into a plurality of radially symmetric sectors (24,25,26). [13] Filling device according to one of the preceding claims, characterized by , that the at least one distribution element (15,16,17) has at its lower edge a circumferential radial, in particular horizontal, elastic extension (27,28,29) extending radially outwards from the outlet opening (18,19,20), wherein in particular the radial extension (27,28,29) has a radius that increases continuously over its circumference or over at least one circular segment, and wherein in particular Furthermore, elastic vertical extensions (30,31,32) are provided, which extend radially outwards at the end of each of the vertical rigid webs (21,22,23). [14] Distribution device comprising a first annular distribution element having an upper annular, substantially horizontal inlet opening with a clear width (w), a substantially vertical outlet opening directed radially outwards with respect to the axis of rotation (A) with a clear height (h) and a deflecting element arranged between the inlet opening and the outlet opening, wherein the deflecting element deflects a substantially vertical particle stream into a radially outwards particle stream; wherein the clear height (h) of the outlet opening is greater than the clear width (w) of the inlet opening.

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