Automated Catalyst Delivery System for Reformer Tubes
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Solution Overview
Problem
Existing tube loading systems for catalysts in reformer heaters are prone to human error, inconsistency, and inefficiency, requiring manual operation and lacking automation for dust removal and adaptability to different tube configurations.
Innovation Solution
An automated delivery device with a hopper, slide gate, primary and secondary ramps, dust collection system, and electronic controls that can adjust volume and speed to match any tube diameter, featuring a vibrator for efficient catalyst delivery and dust removal, allowing for both automated and manual operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation is used for catalyst delivery, then flexibility in operation is maintained, but human error and inconsistency increase
Solution Approach 1:
The system uses a vibrator connected to the box to automatically facilitate catalyst flow through the ramp and screen, eliminating the need for manual intervention while ensuring consistent delivery. The electronic controls enable the system to self-regulate the delivery process.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated electronic control system that operates the slide gate and vibrator, substituting human mechanical actions with automated mechanical and electronic systems to eliminate human error.
2Reliability
If automated delivery system is implemented, then human error is eliminated, but device complexity increases
Solution Approach 1:
The box serves multiple functions: it holds the catalyst, supports the ramp and screen assembly, houses the vibrator, and provides structural support for the entire delivery system. This multi-functionality reduces the need for separate components.
Solution Approach 2:
The ramp and screen are combined into a single assembly where the screen is positioned on the ramp, and both are mounted together on the box. The slide gate, vibrator, and discharge mechanism are integrated into a unified delivery system.
3Object-affected harmful factors
If dust collection is added to the system, then dust and fines are removed from catalyst, but device complexity increases
Solution Approach 1:
The screen is positioned on the ramp to extract and separate dust and fines from the catalyst as it flows down the ramp. The dust collection cone is attached to collect the separated dust, extracting the harmful component from the catalyst stream.
Solution Approach 2:
The screen acts as an intermediary component between the catalyst flow and the dust collection system, facilitating the separation of dust and fines from the catalyst particles through physical filtration.
4Adaptability or versatility
If adjustable volume and speed controls are implemented, then adaptability to different tube configurations is improved, but device complexity increases
Solution Approach 1:
The slide gate is made adjustable to change the opening size, allowing dynamic control of catalyst flow rate. The electronic controls enable dynamic adjustment of delivery parameters to match different tube configurations and filling requirements.
Solution Approach 2:
The system allows adjustment of delivery parameters including volume and speed through the electronic controls and slide gate positioning, changing the operational parameters to adapt to different tube diameters and filling specifications.
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 ensures consistent, fast, and efficient catalyst loading with reduced manpower, eliminating human error and dust issues, and can operate on various tube configurations with adjustable settings for volume and speed.
Implementation Method 1
A vibrator is connected to the box
Implementation Method 2
The primary ramp also has a screen
Implementation Method 3
The primary ramp has an angle of inclination and extends to a lower end of the box
Data Source
AI summary
Automation of the delivery of a particulate to a tube contained in a reformer type heater with vertical tubes is disclosed and includes a hopper having an opening at the lower end. A slide gate is mounted on the hopper and selectively projects over the opening in the hopper. A box mounted below the hopper. A primary ramp is mounted in the box and underlaps the opening in the hopper. The primary ramp has an angle of inclination and extends to a lower end of the box. The primary ramp also has a screen. A cone is connected to the box proximate to one end of the primary ramp and a tube is connected to the lower end of the cone for conveying particulate to a tube loading adaptor. A dust collection cone is connected to the box underlapping the primary ramp and a discharge port is connected to the lower end of the dust collection cone. The tube loading adaptor is positioned for connection to the tube in the reformer type heater with vertical tubes. A vibrator is connected to the box.