Airflow Particle Sorter for Catalyst Separation
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Solution Overview
Problem
Current adsorption desulfurization processes face challenges in effectively removing fine catalyst powder from the reaction system, leading to catalyst consumption and operational instability due to secondary crushing and inefficient separation in fluidized bed reactors.
Innovation Solution
An airflow particle sorter with a top-sealed main body, comprising a straight tube zone and a cone zone, along with directing-intake and directing-outtake ports, creates a stable centrifugal force field for separating larger catalyst particles from the gas stream, reducing the likelihood of secondary crushing and enabling effective removal of fine catalyst powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional cyclone separator is used to separate catalyst particles, then separation efficiency is improved, but catalyst crushing increases due to high gas flow rate and intense particle collision
Solution Approach 1:
The patent changes the operating parameters of the separator by reducing the gas flow rate from high velocity (cyclone) to low velocity (0.5-5 m/s), and changes the separation mechanism from centrifugal force to gravity-based settling, thereby preventing catalyst crushing while maintaining separation efficiency
Solution Approach 2:
The patent replaces the mechanical centrifugal separation system (cyclone) with a gravity-based settling system, substituting high-velocity mechanical forces with low-velocity gravitational forces to avoid catalyst particle damage
2Manufacturing precision
If a metal filter with small pore diameter is used to recover catalyst, then fine powder recovery is improved, but larger particles (>2 μm) remain in the reaction system causing operational issues
Solution Approach 1:
The patent segments the catalyst recovery process into two stages: first removing larger particles through gravity settling in the airflow particle sorter, then capturing fine powder through the metal filter, ensuring comprehensive particle removal while maintaining operational stability
Solution Approach 2:
The patent introduces an intermediary device (airflow particle sorter) between the reactor and metal filter that pre-separates particles by size, allowing the metal filter to focus on fine powder while larger particles are removed by gravity, improving overall system reliability
3Productivity
If the fluidized bed reactor operates with high gas flow rate, then reaction efficiency is improved, but catalyst particle abrasion increases leading to fine powder formation
Solution Approach 1:
The patent extracts the particle separation function from the fluidized bed reactor by introducing a dedicated airflow particle sorter, allowing the reactor to maintain high gas flow rates for reaction efficiency while the sorter removes fine powder to prevent accumulation and loss
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 airflow particle sorter effectively separates and sorts catalyst particles, reducing catalyst consumption and ensuring stable operation by minimizing secondary crushing and accumulating fine powder, thus enhancing the desulfurization process efficiency and extending apparatus lifespan.
Implementation Method 1
An airflow particle sorter with a top-sealed main body, comprising a straight tube zone and a cone zone, along with directing-intake and directing-outtake ports, creates a stable centrifugal force field for separating larger catalyst particles from the gas stream
Data Source
AI summary
The present invention relates to an airflow particle sorter, comprising: a top-sealed sorter main body, a discharge port, an outtake tube and at least one directing-intake port; the inner space of the sorter main body, from the above to the bottom, includes, a straight tube zone and a cone zone, the conical bottom of the cone zone is connected to the straight tube zone; the discharge port is located at the bottom of the cone zone; the directing-intake port is installed in the upper part of the straight tube zone in a tangential direction of the straight tube zone, and is communicated with the inner space of the sorter main body; the outtake tube is hermetically inserted into the top of the sorter main body, and extends downwardly to the lower part of the straight tube zone, and the outtake tube has a sealed bottom end; the lower part of the outtake tube is installed with at least one directing-outtake port, which communicates the outtake tube with the inner space of the sorter main body, the directing-outtake port is installed in a tangential direction of the outtake tube. The present invention further relates to a fluidized bed reactor and an adsorption desulfurization reaction apparatus as well as an adsorption desulfurization process.