Device and system for collecting solid particulate material

Abstract

The present invention relates to a device (1) and system (10) for collecting and filtering solid particles, having the aim of removing solid particulate material from chemical reactors, more specifically catalysts from multi-tubular reactors, promoting safe removal, preserving the structure of the catalysts, proceeding at an acceptable speed and overcoming the problems of the prior art, by way of a device (1) comprising a main duct (2) connected to suction tips (4) with elongate tubes (41) for insertion into the reactor.

Description

SOLID PARTICULATE MATERIAL COLLECTION DEVICE AND SYSTEM

[0001] The present invention relates to a device and system for collecting and filtering solid particles, more specifically catalysts in multi-tubular reactors, for subsequent reuse. Technical Domain

[0002] Currently, several chemical industries use catalysts to speed up chemical processes, such as those producing formaldehyde or phthalic anhydride. Most processes that use solid catalysts use fixed-bed catalytic reactors or multi-tubular reactors. Multi-tubular reactors are generally used in highly exothermic processes, where a series of parallel tubes contain the catalysts, with cooling occurring outside the tubes.

[0003] Periodically, these catalysts must be removed for recovery. This process discards residual particles and then regenerates and reuses the catalysts. This catalyst removal process is quite laborious and dangerous, as it requires removing the material from a large number of long, narrow tubes and the resulting waste is highly toxic.

[0004] Currently, this catalyst removal process is carried out in two ways, by gravity or by high-power aspiration, the latter also called supervacuum.

[0005] The gravity removal process is manual and consists of opening the lower portion of the reactor, with a tarp already positioned on the floor beneath the reactor, allowing the catalysts and residue to fall by gravity onto the tarp. After the material is completely removed, operators manually transfer the catalysts to drums. This process, in addition to being time-consuming, exposes operators to the catalysts and the particulate residue they generate, which are toxic and even considered carcinogenic. In addition to these disadvantages, during removal, the catalyst is contaminated by machine oil, resulting in lower recovery of the removed catalyst. Furthermore, this removal system does not allow for the control of particulate matter generated by the catalyst falling onto the floor.

[0006] The supervacuum process involves connecting a large vacuum cleaner to the reactor and sucking its contents into a vacuum truck reservoir, then transferring the catalysts to drums for regeneration by the manufacturer. Although faster than the gravity process, the supervacuum process is also time-consuming because it involves an additional step of removing the catalyst from the vacuum truck and storing it in drums for subsequent catalyst treatment. Furthermore, this process facilitates the breakdown of catalysts, releasing particulates into the environment due to the high velocity, allowing operators to come into contact with the catalyst's particulate matter. Catalyst breakdown is also inconvenient because it reduces the efficiency of its recovery for reuse, generating additional costs for the industry.

[0007] An example of a prior art document is US 5,228,484, which discloses a device with a lance that is inserted into the tubes of a multitubular reactor and injects air to dislodge and break up the catalysts, which are then aspirated. Disadvantageously, as described, US 5,228,484 favors catalyst breakage and fails to describe how the residue would be filtered or sieved.

[0008] The present invention aims to remove catalysts from chemical reactors, more specifically multi-tubular reactors, promoting safe removal at an acceptable speed, preserving the structure of the catalysts and overcoming the problems of the prior art.

[0009] Figure 1 represents a schematic view of the device (1) with its main duct (2), side nozzles (21), opening at the larger end (22), dotted line representing a suction hose (3), and suction tip (4), with its elongated tube (41), thread (42) and handle (43).

[0010] Figure 2 illustrates the main duct (2) with angle (α) formed between the axis of said duct (2) and lateral connections (21); and the angle (β) of the generator of the main duct (2).

[0011] Figure 3 illustrates side holes (411) in detail of the elongated tube (41) of the suction tip (4).

[0012] Figure 4 illustrates a schematic view of the system (10) with the device (1), multitubular reactor (9), cyclone type collector (5), set of bag filters (6), drums (7) and vacuum generating medium (8). Detailed description

[0013] The present invention relates to a device for collecting solid particulate material and a system for collecting and filtering solid particles, more specifically catalysts in multi-tubular reactors, for subsequent reuse.

[0014] The solid particulate material collection device (1) comprises a main duct (2), with several side nozzles (21), which receive suction hoses (3), which are connected to suction tips (4).

[0015] During the catalyst collection or removal process, the main duct (2) is suspended above the reactor (9), while the suction tips (4) are free for handling, connected only to the flexible suction hoses (3). With this arrangement, technicians perform the collection simultaneously by inserting each suction tip (4) into a reactor tube (9), without interference from the main duct (2).

[0016] In order to ensure adequate suction of the catalysts, minimizing catalyst breakage, said main duct (2) has a frustoconical shape and is equipped with an opening at the larger end (22), which is connected to a vacuum source for the rest of the system (10), detailed below. Said frustoconical shape preferably has an inclination angle (β) of the generator in a range between 0.5º and 10º, even more preferably of 1.04º.

[0017] Furthermore, to prevent catalyst breakage and improve air flow, said side nozzles (21) form an acute angle (α) in relation to the axis of the main duct (2). It was possible to observe that by tilting the duct (2) and the nozzles (21), a smooth path for the flow of catalysts was created, without right angles, which thus eliminates the impact of the catalyst on the walls of the duct (2). Thus, this inclination of the main duct (2) and the nozzles (21) prevents the impact and, consequently, the breakage of the catalyst. Said angle (α) is preferably in a range between 15º and 60º, more preferably it is 45º.

[0018] Taking into account the fact that the multitubular reactors (9) are equipped with narrow and long tubes, so that the suction tips (4) can be inserted into the tubes and collect the catalysts, said tips (4) are each equipped with an elongated tube (41) at their elongated end. Said elongated tubes (41) preferably have a diameter between 18.0 mm and 21.0 mm, more preferably 19.60 mm, so that they can be inserted into 1-inch tubes. However, the person skilled in the art will understand that said diameter must be adjusted according to the size of the reactor in question.

[0019] Furthermore, for the connection between the suction tips (4) and the suction hoses (3), said suction tips (4) are each equipped with a thread (42) at their connection end, opposite the elongated tube (41), which allows the hoses (3) to be screwed onto the tips, maintaining a firmer connection. And to facilitate the work of the technicians, said suction tips (4) are each equipped with a handle (43) in the form of lateral projections, perpendicular to the axis of the tip (4), near the connection with the hose, where it is possible to hold to handle the tips (4).

[0020] During the collection process, the catalyst may become compacted and consequently block the main duct (2). To unclog the main duct (2) is equipped with a knife gate valve (23) at the end with the smallest diameter, i.e., opposite the opening (22). Thus, when the knife gate valve (23) is opened, the main duct (2) is unclogged.

[0021] Furthermore, in cases where the catalysts are very compacted, said elongated tube (41) of each suction tip (4) is equipped with side holes (411) that allow air flow. Thus, the air flow occurs from the reactor tube, through said side holes (411), even if the hole at the end of the elongated tube (41) is blocked by the catalyst and residues, facilitating the decompaction of the catalyst and residues, increasing the speed of the collection process and avoiding blockages in the elongated tube (41). Preferably, in each elongated tube (41) 5 side holes (411) of 6 mm in diameter each are arranged, 15 cm from the free end.

[0022] In a situation where not all side nozzles (21) are used, to avoid loss of suction force due to the non-use of some nozzle (21), said nozzles (21) are each equipped with a valve (211), preferably a split ball valve. In this way, the nozzles (21) that are not going to be used can be closed by their valves (211) at the time of collection. The valves (211) are also useful when installing the system (1), as they can be kept closed until the catalyst removal process begins.

[0023] The present invention also deals with a solid particulate material collection system (10) in which said device (1) is used.

[0024] For the collection of particulate material to occur, said device (1) is used by inserting the suction tips (4) into the reactor tubes (9), with said tips (4) being connected to the main duct (2) by suction hoses (3).

[0025] In addition to the device (1), the system (10) comprises a cyclone-type collector (5), connected to the opening (22) of the main duct (2) by a suction hose; a set of bag filters (6) connected to the upper portion of the cyclone (5); drums (7) to the lower outlet of the cyclone (5); and a vacuum generating means (8) connected to said bag filter set (6).

[0026] This construction allows these devices to be in a vacuum or suction circuit, from the vacuum generator (8) to the suction tips (4).

[0027] With this arrangement, the catalysts are removed from the reactor tubes (9), through the suction tips (4), pass through the suction hoses (3), entering the main duct (2). Then, the air flow with catalysts enters the cyclone (5), the heavier materials, that is, the catalysts, are released through the lower outlet of said cyclone (5), entering the drums (7); the powder goes to the side outlet of the cyclone (5) passing through the set of bag filters (6), where the residues are retained, which will later be discarded, while the catalysts are separated in the drums (7) for later reuse.

[0028] The present system (10) presents a 60% reduction in removal time when compared to the supervacuum removal system and, close to 100% of the time in relation to gravity removal; taking into account the entire procedure from the removal of the catalyst directly from the reactor tubes (9) to the accommodation in drums (7) for later reuse.

[0029] It was possible to observe that this system (1) does not generate particulate material, which is an advantage over prior art systems, as it avoids any contact between operators and the catalytic material.

[0030] Furthermore, the present system (10) is more compact, automated and clean in operation.

[0031] Having described a preferred embodiment example and its variants or particularities, it should be understood that the scope of the present innovation is limited only by the content of the attached claims, including possible equivalents.

Claims

SOLID PARTICULATE MATERIAL COLLECTION DEVICE (1) characterized by the fact that it comprises a main duct (2), of frustoconical shape, with at least two side nozzles (21) and an opening (22) at the larger end, said side nozzles (21) forming an acute angle (α) in relation to the axis of the main duct (2); said side nozzles (21) receive suction hoses (3) connected to suction tips (4). SOLID PARTICULATE MATERIAL COLLECTION DEVICE (1) according to claim 1, characterized in that each suction tip (4) is equipped with an elongated tube (4.1) at its elongated end. SOLID PARTICULATE MATERIAL COLLECTION DEVICE (1) according to any one of claims 1 to 2, characterized in that each suction tip (4) is provided with a thread (42) at the connection end with said hose (3) and a handle (43) in the form of projections perpendicular to the axis of each tip (4). SOLID PARTICULATE MATERIAL COLLECTION DEVICE (1) according to any one of claims 1 to 3, characterized in that opposite said opening (22) of said main duct (2) there is a knife gate valve (23). SOLID PARTICULATE MATERIAL COLLECTION DEVICE (1) according to any one of claims 1 to 4, characterized in that said side nozzles (21) are each provided with a split ball valve (211). SOLID PARTICULATE MATERIAL COLLECTION DEVICE (1) according to any one of claims 1 to 5, characterized in that the acute angle (α) between the axis of the main duct (2) and the side nozzles (21) is preferably in a range between 15º and 60º. SOLID PARTICULATE MATERIAL COLLECTION DEVICE (1) according to any one of claims 1 to 6, characterized in that the inclination angle (β) of the main duct generator (2) is in a range between 0.5º and 10º. SOLID PARTICULATE MATERIAL COLLECTION DEVICE (1) according to any one of claims 1 to 7, characterized in that the diameter of the elongated tube (41) of said tips is in a range between 15 mm and 25 mm. SOLID PARTICULATE MATERIAL COLLECTION DEVICE according to any one of claims 1 to 8, characterized in that the sides of said elongated tube (41) of the tips are provided with side holes (411). SOLID PARTICULATE MATERIAL COLLECTION SYSTEM (10) provided with a device (1) according to any one of claims 1 to 9, characterized in that it also comprises a cyclone-type collector (5) connected to said device (1) by a suction hose; provided with a set of bag filters (6) connected to the upper portion of the cyclone (5); provided with drums (7) at the lower outlet of the cyclone (5); and also provided with a vacuum generating means (8) connected to said bag filter set (6).

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