Cyclone Quench Box with Cool Hydrogen Propulsion
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Solution Overview
Problem
Current quench boxes in hydrogenation reactors face inefficiencies in gas-liquid mixing and heat transfer due to insufficient swirling intensity, underutilization of cool hydrogen as a propelling medium, restrictive downcomer diameters, and lack of mixing elements within the mixing chamber, leading to uneven temperature distribution and reduced catalyst lifespan.
Innovation Solution
A cool hydrogen-propelled cyclone quench box design featuring rectangular gas-liquid downcomers and swirling vanes in the mixing chamber and exit, utilizing cool hydrogen to enhance cyclone intensity and improve mixing efficiency by converting one-dimensional fluid flow into three-dimensional cyclones, with curved cyclone blades to enhance mixing within the chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional quench box structures are used with basic mixing chambers, then the device complexity is low, but the mixing efficiency and heat transfer performance are insufficient leading to uneven temperature distribution
Solution Approach 1:
The quench box is segmented into multiple functional zones: a mixing chamber for initial gas-liquid mixing, a cyclone separation chamber for centrifugal separation, and a heat exchange zone. This segmentation allows each zone to perform its specific function optimally, improving overall mixing efficiency while maintaining manageable structural complexity through modular design
Solution Approach 2:
The invention introduces a vertical dimension to the mixing process by implementing a cyclone structure that creates three-dimensional swirling flow patterns. The gas-liquid mixture is introduced tangentially to generate rotational motion in the vertical direction, transforming simple horizontal mixing into complex three-dimensional mixing that significantly enhances heat transfer performance
2Temperature
If the downcomer diameter is reduced to increase cyclone effect, then the cyclone intensity is improved, but the flow resistance increases and mixing efficiency decreases
Solution Approach 1:
The downcomer is divided into two distinct sections: an upper section with a smaller diameter to generate strong cyclone effect and temperature uniformity, and a lower section with a larger diameter to reduce flow resistance and maintain adequate fluid velocity. This segmentation resolves the contradiction by allowing each section to optimize for its specific functional requirement
Solution Approach 2:
Different diameter specifications are applied to different locations of the downcomer based on local functional requirements. The upper downcomer has smaller diameter locally to maximize cyclone intensity where temperature uniformity is critical, while the lower downcomer has larger diameter locally to minimize flow resistance where velocity maintenance is important
3Temperature
If cool hydrogen flow rate is increased to improve cooling effect, then the temperature control is enhanced, but the gas-liquid mixing efficiency decreases due to insufficient retention time
Solution Approach 1:
The introduction of cool hydrogen is transformed from simple linear flow into three-dimensional cyclonic flow by tangential injection. This dimensional change increases the path length and residence time of the gas-liquid mixture within the mixing chamber, allowing effective mixing even at higher cool hydrogen flow rates. The swirling motion creates multiple passes through the mixing zone, effectively utilizing retention time
Solution Approach 2:
The gas-liquid mixture undergoes preliminary cyclonic mixing in the mixing chamber before entering the separation zone. This preliminary action ensures that the cool hydrogen is already well-distributed and mixed with the liquid phase before the separation process begins, maximizing the cooling effect while maintaining adequate retention time for mixing
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
The design increases oxygen absorption efficiency by approximately 20% at low gas-liquid flow rates and 15% at high flow rates, improving temperature uniformity and extending catalyst life by enhancing mixing and heat transfer processes.
Implementation Method 1
converting one-dimensional fluid flow into three-dimensional cyclones
Implementation Method 2
enhancing cyclone intensity
Implementation Method 3
high efficient heat exchanging between the cool hydrogen and reactant material
Implementation Method 4
mixing and heat transfer between the cool hydrogen for a hydrofining or hydrocracking reactor and the hot fluid in the reactor
Implementation Method 5
enhancing mixing and heat transfer processes
Data Source
AI summary
A cool hydrogen-propelled cyclone quench box comprises: a mixing chamber (7) arranged at the center of a lower support plate (11); swirl tubes (6) arranged above the lower support plate (11) and outside the mixing chamber (7), the tubes being in tangential communication with the body of the mixing chamber (7) along a horizontal direction; a gas-liquid downcomer (5) perpendicularly arranged outside each swirl tube (6), the bottom portions of the downcomers and the outer walls of the swirl tubes (6) being in tangential communication along a perpendicular direction, and the top portions of the gas-liquid downcomers (5) being connected to fluid inlets (4) arranged on an upper support plate (3). The bottom end of a cool hydrogen branch pipe (8) is arranged outside each swirl tube (6), and is tangentially connected to the swirl tube (6) along a horizontal direction. By means of a flange (2) arranged on the upper support plate (3), the top ends of the cool hydrogen branch pipes (8) connect to a cool hydrogen pipe (1) arranged outside the upper support plate (3). Upper-level cyclone blades (12) are installed within the mixing chamber (7). The bottom ends of the blades (12) are perpendicularly arranged on the upper-level blade support plate (13). Lower-level cyclone blades (9) are installed at the mixing chamber (7) outlet; the bottom ends of the blades (9) are perpendicularly arranged on the lower-level blade support plate (10).