Corrugated Catalyst Structure for Parallel Reactor Flow Equalization
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Solution Overview
Problem
In parallel reactor configurations, uneven flow rate distribution and catalyst degradation due to carbon deposition lead to reduced reaction efficiency, and dust contamination can render some passages unusable, decreasing overall reactor performance.
Innovation Solution
The reactor incorporates a catalyst structure with a thin plate material bent in a corrugated shape, dividing reaction flow passages into partial passages that communicate with each other through gaps or cutouts, allowing for equalization of flow rates and reducing catalyst degradation and dust-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple reaction flow passages are arranged in parallel with uniform catalyst distribution, then the reaction rate and yield are improved due to large specific surface area, but uneven flow rate distribution causes difference in reaction efficiency between passages
Solution Approach 1:
The reaction flow passage is segmented into multiple partial flow passages by the corrugated catalyst structure main body, creating a more distributed flow pattern that reduces uneven flow rate distribution while maintaining high surface area contact
Solution Approach 2:
The corrugated shape with communicating portions creates dynamic flow redistribution, allowing flow rates to equalize across passages through the communicating portions while maintaining overall high productivity
2Productivity
If catalyst is uniformly arranged over entire area of reaction flow passage, then catalytic activity is maximized, but carbon deposition on catalyst surface causes deterioration and reduces reaction efficiency
Solution Approach 1:
The catalyst structure divides the reaction flow passage into multiple partial flow passages, distributing the reactant flow more evenly across the catalyst surface and preventing localized carbon deposition that would occur with uniform arrangement
Solution Approach 2:
The communicating portions enable dynamic redistribution of flow and reactant distribution across the catalyst surface, preventing hot spots and carbon deposition while maintaining high catalytic activity throughout
3Productivity
If dust is mixed in the reaction fluid, then some reaction flow passages may be closed by dust, but this renders those passages unusable and decreases overall reactor efficiency
Solution Approach 1:
The corrugated structure with multiple partial flow passages creates redundant flow paths, so if dust blocks one passage, reactant can still flow through other partial passages maintaining overall reactor usability
Solution Approach 2:
The communicating portions allow dynamic flow redistribution around blocked areas, enabling the system to adapt to dust contamination and maintain productivity by redirecting flow through available passages
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 configuration maintains high catalyst activity, reduces the frequency of catalyst replacement, and minimizes the impact of dust contamination, thereby maintaining reactor efficiency and extending catalyst life.
Implementation Method 1
a catalyst for accelerating reaction of a reactant
Implementation Method 2
the main body of each of the plurality of catalyst structures divides the reaction flow passage along the flow direction of the reaction fluid and defines a plurality of partial flow passages in parallel
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(c)
Figure 3(a)~3(b)
AI summary
Provided is a reactor that a catalyst to accelerate reaction of a reactant is allowed to act on a reaction fluid having the reactant. The reactor has a partition that defines, in a parallel form, a plurality of reaction flow passages through which the reaction fluid flows, and a plurality of catalyst structures each having a catalyst and being respectively provided in each of the plurality of reaction flow passages. The partition has a communicating portion allowing the plurality of reaction flow passages to communicate mutually.