Vertical Converter Shell Extension for Multiple Internal Heat Exchangers
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Solution Overview
Problem
Legacy vertical quench converters face limitations in efficiency and catalyst volume due to fixed volume constraints, restricting the addition of process beds and cooling steps, as existing pressure shell extensions cannot accommodate multiple heat exchangers without reducing catalyst volume.
Innovation Solution
Replace the existing pressure shell extension with a larger one that can house multiple heat exchangers, including intercoolers, and add nozzles to increase the volume and flexibility for additional process beds and cooling steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the existing pressure shell extension is reused to house heat exchangers, then manufacturing cost is reduced, but the volume available for heat exchangers and catalyst is limited
Solution Approach 1:
The patent extends the pressure shell extension vertically by adding a second bonnet section above the first bonnet. This dimensional extension in the vertical direction provides additional volume for installing multiple heat exchangers (including two intercoolers and a feed-effluent exchanger) while maintaining compatibility with the existing converter body flange connection, thus resolving the volume limitation without significantly increasing manufacturing cost.
2Productivity
If the pressure shell extension is enlarged to house multiple heat exchangers, then conversion efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The pressure shell extension is divided into modular bonnet sections (first bonnet and second bonnet) that can be independently designed, manufactured, and assembled. Each bonnet section houses specific heat exchangers, allowing for standardized production and easier installation while achieving the volume needed for multiple heat exchangers to improve conversion efficiency.
Solution Approach 2:
By adding vertical height through a second bonnet section rather than expanding horizontally, the patent achieves increased volume for heat exchangers in a space-efficient manner that minimizes impact on the existing converter footprint and reduces overall manufacturing complexity.
3Adaptability or versatility
If additional nozzles are added to increase flexibility for process beds, then adaptability is improved, but device complexity increases
Solution Approach 1:
The bonnet sections are designed with multi-functional nozzles that can serve multiple purposes - feed injection, effluent extraction, intercooler connections, and catalyst bed distribution. This universal design allows the same nozzle structure to support various process configurations without requiring separate dedicated nozzles for each function, thereby improving adaptability while controlling complexity.
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 approach allows for increased catalyst installation, enhanced conversion efficiency, and energy savings by accommodating more intercoolers and process beds within the revamped converter system without significant mechanical modifications.
Implementation Method 1
indirect cooling step using a heat exchanger (intercooler)... indirect quench cooling steps with an internal feed/effluent heat exchanger
Data Source
AI summary
A method of revamping vertical converters having a bolt-on flanged pressure shell extension for housing an internal heat exchanger is performed by replacing an existing pressure shell extension with a larger pressure shell extension for housing a plurality of internal heat exchangers.