Air Lance with Rigid Poker for Breaking Stuck Catalyst Pellets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for unloading catalyst pellets from reactor tubes are time-consuming and inefficient, as pressurized air alone may not be sufficient to dislodge the pellets, leading to prolonged reactor shutdowns and increased costs.
Innovation Solution
A conduit system that delivers pressurized fluid and includes a rigid member with a claw for delivering hammer blows to break up pellets, combined with upwardly-directed openings to lift dislodged pellets out, enhances the unloading process by transmitting force to the pellets and facilitating their removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pressurized air is used to dislodge catalyst pellets from tubes, then the pellets can be fluidized and evacuated, but pressurized air alone is not sufficient to dislodge the pellets stuck in the tubes
Solution Approach 1:
The patent combines multiple removal mechanisms into a single air lance device: pressurized air delivery through the conduit, mechanical impact capability via the rigid member extending beyond the tube, and vacuum evacuation through the same conduit. This merging of fluidization, mechanical disruption, and removal capabilities resolves the insufficiency of pressurized air alone by integrating complementary mechanisms that work together to dislodge and remove stubborn pellets.
Solution Approach 2:
The air lance device performs multiple functions through a single integrated structure: it delivers pressurized air to fluidize pellets, provides mechanical impact capability through the rigid member to break up stuck pellets, and facilitates vacuum evacuation. This multi-functionality allows the device to handle various pellet conditions (loose, bridged, stuck) that single-function devices cannot address effectively.
2Reliability
If manual fish tape method is used to jostle catalyst pellets, then pellets can be dislodged, but the process is time-consuming and inefficient
Solution Approach 1:
The patent replaces the manual mechanical fish tape method with a combined pneumatic-mechanical system. Instead of manually pushing fish tape to jostle pellets, the system uses pressurized air delivered through the conduit to fluidize pellets, combined with automated mechanical impact capability. This substitution eliminates manual labor and significantly reduces the time required while maintaining effective pellet dislodgement.
Solution Approach 2:
The device employs periodic alternating action between pressurized air delivery and vacuum evacuation. The pressurized air phase fluidizes and dislodges pellets, followed by the vacuum phase that evacuates them. This periodic cycling continues until complete removal is achieved, providing an efficient automated process that replaces time-consuming manual operations.
3Productivity
If air lance is inserted from the top of the tube to dislodge pellets, then pellets can be fluidized, but the upwardly-directed force is needed to lift dislodged pellets out
Solution Approach 1:
The patent incorporates upwardly-directed openings at specific locations along the conduit to provide localized upward force where needed. These openings are strategically positioned to deliver upward-directed pressurized air that lifts dislodged pellets out of the tube. This local quality approach applies upward force precisely where required rather than relying on general downward insertion force.
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
This solution significantly reduces the time required for catalyst change operations, minimizing production losses and costs by effectively breaking up and removing pellets from the tubes, even when they form bridges or are stuck.
Implementation Method 1
pressurized air is used to dislodge and fluidize the catalyst pellets, which are then evacuated from the top of the tube using a vacuum arrangement
Implementation Method 2
a rigid member extending down to a claw so that an operator can deliver one or more hammer blows to the rigid member where it extends outside the tube, transmitting the force down to the claw, to break up the pellets, or to break up bridges formed by the pellets
Implementation Method 3
the conduit has a plurality of upwardly-directed openings at spaced intervals along its length, which assist in lifting the dislodged pellets up and out the top of the tube
Data Source
AI summary
An air lance for removing pellets from tubes includes a conduit body having an inlet end and a bottommost discharge opening, and a poker fixed relative to the conduit body and projecting beyond the bottommost discharge opening to serve as a spacer and poker; wherein a rigid member extends along said conduit body, such that that a hammering force applied to said rigid member where it extends outside of the tube will be transmitted through said rigid member to said poker for dislodging and breaking pellets.