Corrugated Catalyst Structure with Communication Holes
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Solution Overview
Problem
In compact reactors, the partitioned flow passages lead to laminar flow of reaction fluids, resulting in low mass transfer coefficients and high diffusion resistance, limiting contact efficiency with catalysts and causing uneven reaction efficiency due to flow rate distribution deviations.
Innovation Solution
A reactor design featuring a corrugated plate-shaped catalyst structure with communication holes and grooves that facilitate mixing of flow passages, promoting turbulent flow and improving contact efficiency between reaction fluids and catalysts, while maintaining heat transfer efficiency through a heat-medium-side flow passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the reaction-side flow passage is partitioned by a metal plate into multiple flow passages, then the specific surface area per unit volume increases and heat transfer efficiency improves, but the mass transfer coefficient decreases and diffusion resistance increases
Solution Approach 1:
The metal plate is designed with through-holes forming a porous structure, allowing reaction fluid to pass through while maintaining the partitioning function. This resolves the contradiction by enabling mass transfer through the plate structure itself, preventing the formation of stagnant laminar flow zones that would otherwise cause high diffusion resistance
Solution Approach 2:
The metal plate is segmented into multiple partition walls with through-holes, creating multiple flow passages. This segmentation maintains the heat transfer advantages of multiple passages while the through-holes ensure continuous fluid communication, preventing mass transfer limitations
2Productivity
If the reaction-side flow passage is partitioned by a metal plate, then flow passages are formed for catalyst arrangement, but flow rate distribution deviation increases and reaction efficiency decreases
Solution Approach 1:
The through-holes in the partition walls act as flow redistribution channels that provide feedback control. Fluid flowing through one passage can redistribute through the through-holes to other passages, automatically balancing flow rate distribution and preventing localized efficiency losses
Solution Approach 2:
The through-holes serve as intermediary channels between adjacent flow passages. They mediate the flow distribution by allowing fluid to transition between passages, ensuring uniform flow rates across all catalytic surfaces
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
Enhances mass transfer coefficients, reduces diffusion resistance, and equalizes flow rate distribution, thereby improving overall reaction efficiency and maintaining heat transfer efficiency.
Implementation Method 1
flows of the reaction fluids that flow through the flow passages become a laminar flow
Implementation Method 2
a diffusion resistance on the catalyst surface becomes large
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)~3(d)
AI summary
A reactor includes: a reaction-side flow passage (210) through which a fluid as a reaction object flows; and a catalyst structure (300) provided in the reaction-side flow passage (210). The catalyst structure (300)includes: a body part (310) formed in a raised and depressed plate shape to partition the reaction-side flow passage into a plurality of flow passages disposed side by side in a direction perpendicular to a flow direction of the fluid; a catalyst carried on the body part (310) to promote a reaction of the fluid; and one or more communication holes (grooves) (330) to make the plurality of flow passages partitioned by the body part (310) communicate with each other.