Catalyst Roller Disc Geometry for Attrition Control
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Solution Overview
Problem
Existing systems for catalyst particle transport in reaction systems, such as moving bed reactors, face challenges like catalyst attrition due to collisions and the difficulty in controlling flow rates, especially with gas phase fluids, leading to inefficiencies and increased replacement costs.
Innovation Solution
A catalyst roller system with a rotating disc configured within a roller volume to manage catalyst flow, minimizing attrition by maintaining specific clearances and angles to prevent compressive forces and abrasion, and allowing controlled rotation speeds for efficient transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If L-valve systems are used for catalyst particle transport, then catalyst flow control is achieved, but dead zones occur at the 90° angle and high gas flow rates are required
Solution Approach 1:
The L-valve is segmented into multiple sections with different angles and characteristics. The first section has a 90° angle for initial direction change, while the second section has a shallower angle (30-60°) for smooth particle transition, eliminating dead zones and improving flow control
Solution Approach 2:
The system uses variable gas flow rates dynamically adjusted to match catalyst flow requirements. Gas flow can be increased during startup or high-demand periods and reduced during normal operation, optimizing both control capability and energy efficiency
2Productivity
If gas flow is increased to induce catalyst particle movement through the L-valve, then particle transport is achieved, but flow rate control becomes difficult and energy consumption increases
Solution Approach 1:
The system changes the geometric parameters of the L-valve, specifically using a shallower angle in the second section (30-60° instead of 90°), which reduces the gas flow rate required for particle transport and improves flow control precision
3Productivity
If catalyst particles are transported through the L-valve, then catalyst replacement and regeneration is enabled, but catalyst attrition occurs due to collisions
Solution Approach 1:
The system design anticipates particle collisions and uses the gas flow field to cushion and dampen impact forces. The controlled gas atmosphere provides a protective medium that reduces direct particle-to-particle and particle-to-wall collisions throughout the transport path
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 roller system reduces catalyst attrition and enables precise control over flow rates, even at low speeds, minimizing dead spaces and clogging, and allowing continuous transport without the need for high gas flow rates.
Implementation Method 1
a catalyst roller system for transporting catalyst particles from a reactor to a reactor inlet
Implementation Method 2
The plurality of catalyst particles can have an average catalyst particle diameter, an angle of repose and an angle of internal friction
Implementation Method 3
The contour clearance can be less than half of the average catalyst particle diameter for at least one location, in order to prevent catalyst from traveling past the catalyst roller disc in the direction opposite to the direction of rotation
Data Source
AI summary
Systems and methods are provided for controlling the flow and transport of catalyst particles within a reaction system. The flow of catalyst particles can be managed using a rotating disc or wheel that is configured within a roller volume to allow for control over the rate of catalyst flow while reducing or minimizing attrition of the catalyst particles. This can be achieved in part by maintaining a relationship between the center of the rotating disc, the inlet for catalyst particles to the roller volume, and the top wall of the roller volume so that catalyst particles are not exposed to compressive forces and/or abrasion during rotation of the disc. Additionally or alternately, the disc and roller volume surfaces can be configured to reduce or minimize the potential for catalyst particles to become trapped in “dead space” regions within the roller volume. By using a disc to provide force for transport of particles through the roller volume, the speed of catalyst movement can be controlled at relatively slow catalyst flow rates with a reduced or minimized risk for clogging or plugging within the roller volume.