Catalyst Reactor Basket Segmentation for Multi-Catalyst Testing
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Solution Overview
Problem
Existing catalyst reactor systems lack the ability to efficiently test and utilize multiple catalyst combinations in a single setup, limiting the evaluation of different catalyst properties and reaction stages within a single pass of fluid.
Innovation Solution
A catalyst reactor basket with a cylindrical design featuring fluid-permeable outer and inner walls, a dividing wall creating two chambers with radially extending partitions that define multiple compartments, allowing axial fluid flow and separate catalyst contact, and removable covers for easy loading and unloading of catalyst materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-chamber catalyst reactor basket is used, then the device complexity is low, but the ability to test multiple catalyst combinations and simulate two-stage reactions is limited
Solution Approach 1:
The catalyst reactor basket is divided into multiple chambers (first chamber and second chamber) separated by a dividing wall, with each chamber containing multiple compartments for different catalysts. This segmentation allows simultaneous testing of multiple catalyst combinations and simulation of two-stage reactions, directly resolving the contradiction by enabling versatile multi-catalyst testing while maintaining a relatively simple overall basket structure.
Solution Approach 2:
The basket design incorporates both axial division (chambers along the flow direction) and radial division (compartments within chambers), creating a multi-dimensional catalyst arrangement. This dimensional approach allows fluid to sequentially contact different catalysts in different chambers, enabling comprehensive catalyst evaluation without requiring multiple separate reactors.
2Productivity
If fluid-permeable walls and partitions are used to enable multi-stage catalysis, then the reaction efficiency is improved, but the structural complexity of the basket increases
Solution Approach 1:
The dividing wall and partitions are designed as fluid-permeable structures that allow reactants to pass through from one chamber to another and from one compartment to another. This permeability enables sequential multi-stage catalytic reactions to occur as fluid flows through the basket, improving reaction efficiency while the integrated wall design keeps the overall structure manageable.
Solution Approach 2:
The basket structure employs nested compartments within chambers, where partitions create smaller catalytic zones within the larger chamber volume. This nesting arrangement allows multiple catalytic stages to be packed into a single basket, enhancing productivity without proportionally increasing external dimensions or overall structural complexity.
3Adaptability or versatility
If multiple chambers and compartments are created to test different catalysts, then the evaluation capability is improved, but the manufacturing complexity increases
Solution Approach 1:
The basket is manufactured as a segmented structure with a dividing wall creating separate chambers, and partitions creating compartments within chambers. This segmentation allows for modular assembly and standardized manufacturing of individual components that can be combined to form the complete multi-chamber structure, reducing overall manufacturing complexity while maintaining high evaluation capability.
Solution Approach 2:
The dividing wall and partitions serve multiple functions simultaneously: they physically separate chambers and compartments for different catalysts, provide structural support, and act as fluid permeable barriers. This multi-functionality reduces the number of separate components needed, simplifying manufacturing while maintaining comprehensive catalyst evaluation capability.
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
Enables efficient testing of various catalyst combinations and two-stage reactions within a single pass of fluid, allowing for the identification of suitable catalysts for future reactions by simulating a once-thru hydrocracking unit with multiple catalyst layers and compartments.
Implementation Method 1
At least a portion of the outer side wall is fluid permeable. At least a portion of the inner side wall is fluid permeable. At least a portion of the dividing wall is fluid permeable. At least a portion of the first and second covers being fluid permeable
Data Source
AI summary
A catalyst reactor basket is provided that includes an outer side wall extending along the outer circumferential periphery and an inner side wall disposed within the outer side wall. An aperture is sized and shaped to allow a fluid to flow axially with respect to the basket. First and second covers are disposed on opposite ends of the outer side wall and inner side wall and a dividing wall is disposed between the first and second covers. The dividing wall defines a first and second chamber within the inner volume of the basket. A plurality of partitions are disposed within the first and second chambers. The plurality of partitions define a plurality of compartments within the first and second chambers, each compartment being sized and shaped to receive a catalyst.