Convex Catalyst Particle Geometry for Tubular Reactor Heat Transfer

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Solution Overview

Problem

Tubular reactors with catalytic particles face challenges in heat transfer efficiency due to poor packing and gas flow issues caused by flat end surfaces and the formation of 'bridges' across the reactor, leading to uneven flow distribution and performance problems in industrial chemical processes.

Innovation Solution

Catalyst particles with optimized geometric forms, such as convex end faces and curved sidewalls with specific radii of curvature, are designed to match the curvature of the tubular reactor, reducing flat surfaces and preventing bridging, thereby enhancing heat transfer and gas flow efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If catalyst particles are manufactured via extrusion with flat end surfaces, then manufacturing is simplified, but gas flow is blocked and packing is poor

Engineering Contradiction:

Improveease of manufactureVSAvoidgas flow efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent applies curvature by replacing flat end surfaces with convex curved surfaces having a radius of curvature between 0.01 to 0.1 times the particle length. This curvature prevents gas flow blockage while maintaining ease of manufacture through controlled drying and calcination processes that naturally form the convex shape.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Ease of manufacture

If catalyst particles have flat end surfaces, then manufacturing is easier, but bridging occurs across reactor internal space

Engineering Contradiction:

Improveease of manufactureVSAvoidflow distribution uniformity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The convex curved end surfaces prevent particle bridging across the reactor by eliminating flat contact planes. The curvature radius (0.01 to 0.1 times particle length) is specifically designed to prevent bridge formation while maintaining reliable flow distribution in multi-parallel reactor systems.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Quantity of substance

If catalyst particles are densely packed, then reactor space utilization improves, but heat transfer efficiency decreases

Engineering Contradiction:

Improvepacking densityVSAvoidheat transfer efficiency

Core Design Contradiction:

Quantity of substanceVSUse of energy by moving object

Solution Approach 1:

The patent applies local quality by creating non-uniform particle geometry with convex curved ends rather than uniform cylindrical shapes. This local geometric modification optimizes both packing density and inter-particle void distribution, enabling improved heat transfer while maintaining high space utilization.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The convex curved surfaces create optimal packing arrangements that balance density with heat transfer. The specific radius of curvature (0.01 to 0.1 times particle length) generates controlled void spaces that facilitate heat transfer pathways while maximizing reactor space utilization.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS11731097B2Catalyst particle shape

Publication Date: 2023.08.22 HALDOR TOPSOE AS

AI summary

A catalytic system is provided which comprises a tubular reactor and at least one catalyst particle located within the tubular reactor. The catalyst particles have a particular geometric form which promotes heat transfer with the tubular reactor. Certain specific catalyst particles are also provided.