Convex Catalyst Support Structure for Dead-Space-Free Hydroprocessing
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Solution Overview
Problem
Conventional hydroprocessing reactors face issues with empty or dead spaces at the bottom, limited catalyst loading capacity, and high operational costs due to the use of inert materials that degrade over time.
Innovation Solution
An upwardly convex porous fixed-bed catalyst support system with an annular-shaped perforated plate and removable manway cover assembly, allowing increased catalyst loading and reducing dead spaces, while maintaining accessibility for maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a horizontal catalyst tray is used to support the lower catalyst bed, then the catalyst bed is supported, but empty or dead spaces are created at the bottom of the reactor and catalyst loading capacity is limited
Solution Approach 1:
The patent applies a convex curved surface at the bottom of the reactor vessel instead of a flat horizontal tray. This curvature allows the catalyst bed to extend downward into the curved region, eliminating dead spaces and maximizing the volume available for catalyst loading while maintaining proper support and fluid distribution.
Solution Approach 2:
The invention transitions from a two-dimensional flat tray support to a three-dimensional curved surface support. This dimensional change allows the catalyst bed to utilize the vertical space more effectively, filling the curved bottom region and eliminating the empty space that would exist with a flat tray configuration.
2Quantity of substance
If inert materials are used as lower catalyst bed support, then more active catalyst can be loaded, but operational costs increase due to material degradation and replacement requirements
Solution Approach 1:
The reactor vessel's own curved bottom surface serves as the support structure, eliminating the need for separate inert support materials. The vessel structure itself provides the necessary support for the catalyst bed, reducing operational costs by avoiding material degradation and replacement issues associated with inert supports.
Solution Approach 2:
The curved bottom surface of the reactor vessel serves multiple functions: it provides structural support for the catalyst bed, eliminates dead spaces, and eliminates the need for separate support materials. This multi-functionality reduces operational complexity and costs.
3Reliability
If a fixed catalyst support structure is used, then catalyst bed stability is maintained, but maintenance accessibility is reduced
Solution Approach 1:
The catalyst support system is segmented into the fixed curved bottom surface and the removable catalyst tray assembly. This segmentation allows the support structure to remain fixed and stable while the catalyst-containing tray can be removed for maintenance, combining stability with accessibility.
Solution Approach 2:
The system combines fixed and dynamic elements: the curved bottom surface is fixed to provide stability, while the catalyst tray assembly is designed to be removable for maintenance. This dynamic design allows the system to transition between stable operation and maintenance modes.
Data Source
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AI summary
The present invention is directed to an upwardly convex fixed-bed catalyst support (18) for a hydroprocessing reactor (10). The catalyst bed support (18) includes an upwardly convex annular-shaped perforated plate having an outer end in communication with the reactor inner surface (14), and an inner end in communication with a horizontal hub assembly.