Adjustable-Guide Conveyor for Uniform Catalyst Tube Filling
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Solution Overview
Problem
Existing belt conveyor machines for filling catalyst material into industrial reactor tubes face issues such as clumping, uneven filling, damage to tubes and filler sections, and difficulty in adjusting to different pipe levels, leading to operational inefficiencies and inconsistent filling.
Innovation Solution
The belt conveyor machine features a height-adjustable filling area, adjustable guide sections, and funnel-shaped, flexible filler pipes to ensure uniform and reproducible filling, reducing clumping and damage by allowing for precise positioning and flexible operation across varying tube arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inlet section protrudes into the catalyst tube during filling, then the outlet connection to the catalyst tube is improved, but the inlet section can be damaged or deformed during movement
Solution Approach 1:
The filling area is made height-adjustable relative to the chassis, allowing the inlet section to dynamically change its position. During movement, the filling area is in a first height position where the inlet section does not protrude, protecting it from damage. During filling, the filling area is lowered to a second height position where the inlet section protrudes into the catalyst tube for proper connection.
2Ease of operation
If the belt conveyor machine is moved on the chassis, then repositioning is enabled, but the inlet section is pulled over the tube surface causing damage
Solution Approach 1:
The system uses dynamic height adjustment of the filling area to protect the inlet section during movement. When the belt conveyor machine is being repositioned, the filling area is raised so the inlet section does not contact the tube surface. When filling is required, the filling area is lowered to enable proper inlet section insertion into the catalyst tube.
3Adaptability or versatility
If the distance between adjacent inlet sections is adjusted for different pipe levels, then adaptability to different reactor configurations is improved, but plastically deformable filler pipes require deformation that creates flow resistance
Solution Approach 1:
The guide sections are made laterally adjustable, allowing dynamic adaptation to different catalyst tube spacings without deforming the filler pipes. The guide sections can be positioned to match various pipe arrangements, enabling the system to adapt to different reactor configurations while maintaining optimal flow conditions and conveyor capacity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures uniform and reproducible filling of catalyst material, reduces clumping and damage, and allows for efficient operation across different pipe levels, enhancing the reliability and capacity of the conveyor system.
Implementation Method 1
a conveyor belt (4) for conveying catalyst material from the pre-chamber area (3) to the filling area (5)
Implementation Method 2
the at least one filler pipe (6) is funnel-shaped over at least most of its extent
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a belt conveyor 1 for filling catalyst material into a catalyst tube 8 of an industrial reactor, comprising: - at least one pre-chamber section 3 with at least one pre-chamber 21 for receiving catalyst material to be filled, - a filling section 5 with at least two filling pipes 6.1,..., 6.5, each with an outlet 9 opening into an upper opening 14 of a catalyst tube to be filled, - a conveyor belt 4 for conveying catalyst material from the pre-chamber section 3 to the filling section 5, and - at least two guide sections 18.1, 18.2 for laterally guiding catalyst material on the conveyor belt 4 transversely to the conveying direction 15, wherein a filling pipe 6.1,..., 6.5 of the filling section 5 is connected to each guide section 18.1, 18.2, so that, starting from the pre-chamber section 3, the catalyst material is conveyed to the filling section 5. a pathway is given to the filling catalyst tube 8, characterized in that the guide sections 18.1, 18.2 are adjustable in their distance to each other transversely to the conveying direction 15, so that by changing the distance of the guide sections 18.1, 18.2 the distance of the filling pipes 6.1,..., 6.5 is also changed accordingly.