Catalytic Reactor Baffle Flow for Dew-Point Condensation Heat Recovery
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Solution Overview
Problem
Existing chemical reaction devices using internal condensation type reaction devices face challenges in improving thermal efficiency due to restricted progress of reactions in a gaseous phase by chemical equilibrium.
Innovation Solution
A chemical reaction device with a catalyst layer, a first heat exchange section, a dividing wall, and a flow path forming section that includes a baffle for heat exchange between reacted gases, maintaining the heat exchange section temperature below the dew point of the reacted gas to condense and collect products, and pre-cooling and pre-heating the gases to improve thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If internal condensation type reaction device is used to shift chemical equilibrium toward product, then reaction progress is improved, but thermal efficiency is insufficient
Solution Approach 1:
The patent applies preliminary action by pre-cooling the reacted gas in the space before it enters the catalyst layer, and pre-heating the gas before it exits. This preliminary temperature adjustment optimizes the thermal conditions for the reaction, improving thermal efficiency while maintaining reaction progress.
Solution Approach 2:
The patent implements feedback through the heat exchange section that maintains a temperature not higher than the dew point of the reacted gas. This feedback mechanism ensures optimal condensation conditions are met, improving both reaction progress and thermal efficiency simultaneously.
2Device complexity
If reacted gas flows directly from catalyst layer to heat exchange section, then device complexity is reduced, but thermal efficiency is insufficient
Solution Approach 1:
The patent segments the flow path by introducing a baffle that divides the reacted gas flow into multiple streams. This segmentation allows different portions of the gas to follow different paths, enabling heat exchange between them and improving thermal efficiency without significantly increasing overall device complexity.
Solution Approach 2:
The baffle acts as an intermediary element in the flow path, facilitating heat exchange between different portions of the reacted gas. This intermediary structure enables thermal efficiency improvement by mediating the heat transfer process while maintaining relatively simple device architecture.
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 device enhances thermal efficiency by effectively condensing products and optimizing gas temperature through pre-cooling and pre-heating, thereby improving the overall reaction process.
Implementation Method 1
a first heat exchange section provided apart from the catalyst layer with a space between the first heat exchange section and the catalyst layer, a temperature of a surface of the first heat exchange section on a space side being maintained not higher than a dew point of a reacted gas produced by the reaction
Implementation Method 2
a flow path forming section located within the space and forming a flow path for the reacted gas that flows from the catalyst layer into the space through the opening, the flow path forming section includes a baffle that enables heat exchange in the flow path between a portion of the reacted gas which portion flows from the catalyst layer toward the first heat exchange section and a portion of the reacted gas which portion flows from the first heat exchange section toward the catalyst layer
Data Source
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AI summary
Thermal efficiency is improved. This chemical reaction device includes: a catalyst layer (3); a first heat exchange section (52), a surface temperature of which is maintained not higher than a dew point of a reacted gas (32) produced by a reaction; a dividing wall (60); and a flow path forming section (70) located within a space (7) and forming a flow path for the reacted gas (32) that flows from the catalyst layer (3) into the space (7) through an opening (61). The flow path forming section (70) includes a baffle (71) that enables heat exchange in the flow path between a portion of the reacted gas (32) which portion flows from the catalyst layer (3) toward the first heat exchange section (52) and a portion of the reacted gas (32) which portion flows from the first heat exchange section (52) toward the catalyst layer (3).