Cylindrical Reactor Sector Design for Endothermic Reaction
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Solution Overview
Problem
Current catalytic reforming and dehydrogenation processes face challenges such as cracking and coking of catalysts, leading to reduced yields and frequent regeneration needs, especially at high pressures, and are inefficient due to the use of steam furnaces which are costly and require maintenance.
Innovation Solution
A cylindrical reactor design that alternates heating sections with adiabatic catalytic sections, using pressurized combustion gases for indirect heat exchange, allowing catalyst circulation by gravity and integrating electricity production, reducing equipment and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure is used in catalytic reforming, then catalyst activity is maintained, but cracking reactions increase and yield decreases
Solution Approach 1:
The reactor is divided into multiple sectors (first sector with heating zone, second sector with catalytic zone, third sector with collection zone, fourth sector with exchange zone) that perform different functions sequentially. This segmentation allows the process to operate at lower pressures while maintaining catalyst activity through controlled catalyst circulation and localized heating, thereby reducing cracking reactions and improving yield.
2Temperature
If steam furnaces are used for heating, then high temperature is achieved, but equipment complexity and maintenance costs increase
Solution Approach 1:
The heating function is merged with the reaction zone by using combustion gases generated within the reactor itself (from hydrogen combustion) to heat the reaction mixture directly in the first sector. This eliminates the need for separate steam-generating furnaces, reducing equipment complexity and maintenance requirements while maintaining the necessary temperature for endothermic reactions.
Solution Approach 2:
Combustion gases act as an intermediary heat transfer medium between the heat source and the reaction mixture. Instead of using direct steam furnace heating, the combustion gases transfer heat indirectly through the reactor walls and internal structures, achieving high temperature heating with simpler equipment and lower maintenance costs.
3Productivity
If multiple reactors and furnaces are used in series, then reaction completion is improved, but equipment quantity and floor footprint increase
Solution Approach 1:
Multiple functional zones (heating, catalytic reaction, collection, and heat exchange) are merged into a single integrated reactor unit. The reactor contains all necessary sectors in one structure, eliminating the need for multiple separate reactors and furnaces while maintaining reaction completion through the sequential process within the unified device.
Solution Approach 2:
The single reactor performs multiple functions simultaneously: heating the reaction mixture (first sector), facilitating catalytic reactions (second sector), collecting products (third sector), and exchanging heat with combustion gases (fourth sector). This multi-functionality reduces the total number of equipment pieces and minimizes floor footprint while achieving complete reaction conversion.
4Duration of action of stationary object
If catalyst circulates continuously, then regeneration frequency is reduced, but reactor design complexity increases
Solution Approach 1:
The reactor is segmented into distinct zones including a catalytic zone where reactions occur and a collection zone where spent catalyst accumulates. This segmentation enables continuous catalyst circulation from the catalytic zone to the collection zone and back to the heating zone, extending catalyst operational life while managing the added design complexity through modular zone construction.
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 design enhances yield and reduces catalyst regeneration frequency, improves energy efficiency, and eliminates the need for large steam-generating furnaces, resulting in a more cost-effective and efficient process.
Implementation Method 1
The process uses pressurized combustion gas to heat the reactor by indirect heat exchange inside the reactor
Implementation Method 2
the catalyst being able to circulate by gravity in the reactor
Implementation Method 3
catalytic reforming reactions consist mainly of dehydrogenating the naphthenes and paraffins present in the feed to transform them into aromatics which have a high octane number
Data Source
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AI summary
The invention relates to a reactor for carrying out a gaseous-phase endothermal reaction that has a cylindrical shape along a vertical axis and comprises at least four annular areas centred on the vertical axis and following each other from the edge to the centre of the reactor: a first so-called feeding area (201), a second so-called catalytic area (202), a third so-called collecting area (203) and a fourth so-called exchange area (204). The reactor also includes vertical sealed panels (65) located along the radii of the cylindrical reactor diving said reactor into sectors, said sectors each including at least one exchange section (61) and at least one catalytic section (62). The first two exchange sections are connected and a duct (64) connects the collecting section of each sector, except for the first and last sector, to the exchange section of the following sector. The invention also relates to a method for implementing the reactor of the invention.