Catalyst Dumping Spool Assembly with Fluidization
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Solution Overview
Problem
Current methods for removing used catalyst from hydroprocessing reactors are inefficient, often resulting in prolonged shutdown times and posing risks to personnel and equipment due to issues like nozzle plugging and catalyst clumping, with existing solutions like mechanical devices and vacuum methods being either ineffective or damaging to the reactor.
Innovation Solution
A catalyst dumping spool assembly with a gas fluidization inlet and a water fluidization inlet is used to facilitate the removal of used catalyst, featuring controlled transfer devices at both ends to manage the flow efficiently, allowing for faster and more complete catalyst removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical devices or vacuum methods are used to control catalyst dumping, then catalyst removal is attempted, but the reactor may be damaged or the methods are ineffective
Solution Approach 1:
The patent applies pneumatic principles by introducing gas (inert gas or process gas) through the gas fluidization inlet to fluidize the catalyst bed and facilitate catalyst removal. This pneumatic approach replaces damaging mechanical devices and avoids reactor damage while effectively controlling catalyst dumping through gas flow control.
Solution Approach 2:
The patent changes physical parameters by controlling gas flow rate and water flow rate to regulate catalyst fluidization and removal. By adjusting these flow parameters, the system achieves efficient catalyst removal without mechanical stress on the reactor, resolving the contradiction between productivity and harmful effects.
2Reliability
If catalyst dumping is stopped to prevent overflowing or change collection vessels, then safety is maintained, but shutdown time increases
Solution Approach 1:
The patent enables continuous catalyst removal by using gas and water fluidization to maintain steady catalyst flow through the spool assembly. The controlled fluidization prevents sudden stops and overflows, allowing continuous operation until the collection vessel is full, thereby reducing shutdown time while maintaining safety.
Solution Approach 2:
The system uses flow control devices that respond to catalyst flow conditions and collection vessel fill level, providing feedback control to prevent overflowing. This automated feedback mechanism eliminates the need for manual intervention and extended shutdowns, reducing time loss while ensuring reliability.
3Productivity
If vibrating devices are used to shake catalyst out of the reactor, then catalyst removal is facilitated, but the reactor is damaged
Solution Approach 1:
The patent replaces mechanical vibration devices with pneumatic fluidization using controlled gas flow. The gas enters through the gas fluidization inlet and creates upward flow that lifts and transports catalyst particles, achieving rapid removal without mechanical vibration that would damage the reactor structure.
Solution Approach 2:
The patent substitutes mechanical vibration systems with a pneumatic-hydraulic system using gas and water flow to achieve catalyst removal. This replacement eliminates the harmful mechanical vibrations while maintaining high removal rates through fluid dynamic forces.
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 catalyst dumping spool assembly enables faster and more complete removal of used catalyst, reducing shutdown time and minimizing risks to personnel and equipment, while also allowing for safer and more efficient reactor cooling and maintenance.
Implementation Method 1
a gas fluidization inlet and a water fluidization inlet located between the first and second devices
Implementation Method 2
a gas fluidization inlet and a water fluidization inlet located between the first and second devices
Data Source
AI summary
Disclosed herein is a catalyst dumping spool assembly for unloading used catalyst from an inside of a reactor, comprising: a reactor, and a catalyst dumping spool comprising a first end operatively connected to the reactor, the first end having a catalyst inlet through which the used catalyst is introduced into, a second end having a catalyst discharge outlet whereby the used catalyst exits the catalyst dumping spool, wherein a first device for controlling used catalyst transfer into the catalyst inlet is positioned proximate the first end, and a second device for controlling the used catalyst transfer from inside the catalyst inlet through the catalyst discharge outlet is positioned proximate the second end, and further wherein the catalyst dumping spool further comprise a gas fluidization inlet and a water fluidization inlet located between the first and second devices.