Catalyst Transfer Apparatus Using Seal Bag and Inert Gas
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Solution Overview
Problem
Current methods for transferring solid catalysts from a low pressure vessel to a high pressure vessel in the petrochemical industry face issues such as maintenance challenges, catalyst loss due to grinding, and 'seal loss' phenomena, especially in dusty environments, particularly with gas tight valves and complex vessel designs.
Innovation Solution
A smaller, simpler apparatus with a flow control vessel and non-gas tight solid particle transfer valves, utilizing a high pressure inert gas source to regulate pressure and control flow, eliminating the need for nuclear level detection instruments and reducing the risk of seal loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gas tight valves are used to control solid and gas flow in dusty environments, then flow control precision is improved, but maintenance frequency increases and catalyst loss through grinding increases
Solution Approach 1:
The patent extracts the gas tight sealing function from the valve mechanism itself and replaces it with an external sealing approach using a seal bag that surrounds the solid transfer line. This allows the valve to be simpler and less maintenance-prone while achieving the same flow control precision through the seal bag's flexibility and sealing capability.
Solution Approach 2:
The patent introduces a seal bag as an intermediary element between the valve and the solid/gas flow. This seal bag acts as a flexible barrier that maintains sealing without requiring the complex gas tight valve mechanisms, thereby reducing maintenance while preserving flow control precision.
2Manufacturing precision
If gas tight valves are completely closed in solid and gas lines, then flow control is improved, but catalyst loss through grinding increases
Solution Approach 1:
The patent removes the requirement for complete valve closure by using a seal bag that can maintain sealing while allowing more gradual flow control. This eliminates the grinding action associated with completely closed gas tight valves, achieving flow control without catalyst loss through grinding.
3Stress or pressure
If reverse pressure in solid transfer line is too high, then pressure differential for transfer is improved, but seal loss occurs in transfer pipe
Solution Approach 1:
The patent changes the pressure management approach by using a seal bag that can dynamically adapt to pressure differentials. The seal bag's flexibility allows it to maintain sealing integrity even when reverse pressure varies, preventing seal loss while preserving the necessary pressure differential for solid transfer.
4Reliability
If complex vessel designs with multiple compartments are used, then transfer reliability is improved, but device complexity increases
Solution Approach 1:
The patent extracts the sealing and flow control functions from the complex multi-compartment vessel structure and consolidates them into a simpler single-vessel design with a seal bag. This maintains transfer reliability by keeping the sealing function intact while eliminating the complexity of multiple compartments and associated controls.
Solution Approach 2:
The seal bag serves multiple functions simultaneously: it seals the transfer line, controls solid flow, and manages pressure differentials. This multi-functionality replaces the need for complex multi-compartment designs, achieving transfer reliability with a simpler universal sealing mechanism.
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
This solution enables efficient, cost-effective, and reliable transfer of solid catalysts between vessels, reducing maintenance needs and preventing catalyst loss, while maintaining environmental separation and preventing unwanted gas incursions.
Implementation Method 1
A high pressure inert gas source is provided for supplying inert gas to the flow control vessel to regulate the pressure in the flow control vessel and in the intermediate section of the solids transfer line
Implementation Method 2
Situated between each of the vessels are solid particle transfer valves for controlling the flow of solids through the apparatus, and for controlling the pressure levels in the flow control vessel
Data Source
AI summary
An apparatus for the transfer of solid particulate matter from a low pressure system to a high pressure system is presented. The apparatus simplifies the particle transfer process, and is useful for systems where solid catalyst particles are cycled through a reactor and a regenerator.