Catalytic Distillation Tray with Integrated Catalyst Bed
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing catalytic distillation systems face inefficiencies due to low mass transfer rates and complex designs, which limit the distribution of the liquid reaction mixture and contact with the catalyst, leading to suboptimal performance and increased costs.
Innovation Solution
A catalytic distillation apparatus with a vessel featuring support decks, trays with integrated distillation, mixing, and reaction sections, where the liquid reaction mixture is distributed uniformly through a catalyst bed via a downpipe, enhancing contact between the liquid and catalyst, and utilizing a pressure equalizer to balance pressures between sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalyst containers or packed beds are used, then catalytic reaction can be performed, but the structure becomes complex and cost increases
Solution Approach 1:
The patent combines the catalyst support function with the tray structure itself. The tray includes a catalyst bed layer integrated directly into the tray body, eliminating the need for separate catalyst containers or packed beds. This merging of functions reduces structural complexity while maintaining catalytic reaction performance.
Solution Approach 2:
The tray is designed to perform multiple functions simultaneously: it serves as a support structure, contains the catalyst bed, facilitates liquid distribution, and enables vapor-liquid contact. This multi-functionality eliminates the need for separate dedicated catalyst containment structures, reducing overall system complexity.
2Reliability
If catalyst beds are used in conventional configurations, then catalytic reaction occurs, but liquid distribution and contact with catalyst is insufficient
Solution Approach 1:
The tray design incorporates specific local features including liquid distribution channels, spargers for vapor introduction, and a catalyst bed layer with controlled porosity. These localized structural qualities ensure uniform liquid distribution and maximize liquid-catalyst contact throughout the catalyst bed, enhancing mass transfer rates.
Solution Approach 2:
The tray structure acts as an intermediary between the liquid phase and catalyst bed. It includes liquid distribution channels that guide liquid flow and spargers that introduce vapor, mediating the interaction between phases to maximize contact with the catalyst and improve mass transfer efficiency.
3Adaptability or versatility
If multiple separate components are used for distillation and reaction, then functions are performed, but overall system cost increases
Solution Approach 1:
The patent merges the distillation tray and reaction vessel into a single integrated structure. The tray contains both the catalyst bed for reaction and the structure for vapor-liquid distillation contact. This combination eliminates the need for separate distillation and reaction equipment, reducing system cost while maintaining both functions.
Solution Approach 2:
The tray is designed as a universal component that simultaneously performs distillation (vapor-liquid contact) and catalytic reaction. This multi-functionality allows a single component to replace multiple separate equipment pieces, reducing overall system complexity and cost.
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 design improves the distribution and contact of the liquid reaction mixture with the catalyst, increasing the efficiency and capacity of the catalytic distillation process while reducing pressure drop and overall system costs.
Implementation Method 1
at least one catalyst bed situated within receiving pans of one or more trays so that the trays perform the functions of both the reaction section and distillation section
Implementation Method 2
for distillation of components of a reaction mixture obtained within one vessel
Implementation Method 3
at least one mixing section for mixing the liquid reaction mixture
Data Source
AI summary
The invention disclosed relates to catalytic distillation column internals providing improved liquid reaction mixture and catalyst contacting for simultaneous catalytic reaction and separation of the reaction mixture. The invention is an improved catalytic distillation apparatus providing optimum balance of catalytic reaction and mass transfer steps, wherein distribution, mixing and feeding of liquid reaction mixture to the reaction zone and distillation section are better controlled and more uniformly applied. At least one catalyst bed is situated in at least one receiving pan of a distillation tray so that the tray performs the functions of both of the reaction section and the distillation section of the catalytic distillation column simultaneously within a stage.