Catalyst Support System Anti-Blocking Labyrinth Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Catalyst support systems in chemical reactors are prone to damage and blockage due to contact with catalysts or other reactor particles, leading to excessive stress, cracking, and increased pressure loss, which existing technologies fail to adequately address.
Innovation Solution
A catalyst support system with anti-blocking means, such as a geometrical flow labyrinth with a larger outer cross-sectional flow area than the flow channels, and ramparts to prevent blocking and mechanical damage, ensuring process fluid flow while protecting against catalyst or reactor particle entry/exit and maintaining minimal pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the catalyst support system uses thin-walled structural elements to reduce weight and material usage, then manufacturing cost and material consumption are reduced, but the structural strength and resistance to mechanical damage from catalyst contact are insufficient
Solution Approach 1:
The catalyst support system combines ceramic materials with high strength-to-weight ratio properties to create a composite structure that provides both mechanical strength and resistance to thermal shock, while maintaining reasonable material consumption levels
Solution Approach 2:
The catalyst support elements feature rounded edges and curved surfaces instead of sharp corners, which distributes stress more evenly and prevents stress concentration points that would lead to cracking under catalyst particle impact
2Volume of stationary object
If the catalyst support system uses a compact design to reduce reactor volume, then space utilization is improved, but the flow channels become more prone to blockage by catalyst particles
Solution Approach 1:
The catalyst support system incorporates localized anti-blocking features such as protrusions and ledges at critical locations where catalyst particles are most likely to accumulate, while maintaining compact overall dimensions. These local structural modifications prevent complete flow channel blockage without significantly increasing reactor volume
Solution Approach 2:
The support structure utilizes three-dimensional geometric features including vertical ledges, horizontal protrusions, and multi-level platforms that create complex flow paths. This dimensional complexity prevents particle accumulation in any single plane while maintaining compact volumetric efficiency
3Ease of manufacture
If the catalyst support system uses simple geometric structures to reduce manufacturing complexity, then ease of manufacture is improved, but the ability to prevent catalyst blockage and mechanical damage is insufficient
Solution Approach 1:
The catalyst support system is divided into modular segments or individual support elements that can be manufactured separately using standard ceramic forming processes. Each segment incorporates anti-blocking features like ledges and protrusions that are integrated into the basic forming operation, maintaining manufacturing simplicity while providing protective functionality
Solution Approach 2:
The support structure incorporates intermediary geometric features such as ledges, protrusions, and labyrinthine flow paths that act as mediators between the catalyst particles and the main flow channels. These intermediary structures intercept and redirect catalyst particles before they can block critical flow paths or damage the support system
4Device complexity
If the catalyst support system uses conventional designs without anti-blocking features, then device complexity is reduced, but pressure loss increases due to blockage by catalyst particles
Solution Approach 1:
The catalyst support system incorporates anti-blocking features such as ledges, protrusions, and filtered flow paths during the initial design and manufacturing stage. These features proactively prevent catalyst particle accumulation before it can occur during operation, thereby maintaining low pressure loss without requiring complex active control systems or additional components
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a chemical reactor comprising at least one catalyst support system and anti-blocking means arranged around and above a reactor opening, which prevents catalyst or other reactor parts to enter or exit a reactor opening.