Downflow Reactor Distributor Tray for Uniform Polyphasic Flow
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Solution Overview
Problem
Conventional distributor plates in downflow reactors are prone to non-uniform fluid distribution due to sensitivity to out-of-levelness, leading to hot spots and reduced catalyst efficiency, and require frequent maintenance due to clogging issues.
Innovation Solution
A distributor apparatus with a plurality of distributor units, featuring an inner tube and outer tube configuration, including a solid insert and venturi insert, which reduces fluid flow sensitivity to tray levelness and minimizes clogging by using gas velocity to control liquid flow, enhancing mixing and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional distributor plates are used, then fluid distribution is achieved, but non-uniform distribution occurs due to sensitivity to out-of-levelness
Solution Approach 1:
The distributor plate is segmented into multiple distributor units, each with independent inner and outer tubes. This segmentation allows each unit to function independently, reducing the overall sensitivity to tray levelness and improving fluid distribution uniformity across the catalyst bed.
Solution Approach 2:
The invention introduces a vertical dimension with inner tubes extending below the distributor plate and outer tubes above it. This three-dimensional configuration creates a more robust fluid distribution system that is less sensitive to horizontal tray levelness variations.
2Productivity
If conventional distributor plates with orifices are used, then fluid passes through the distributor, but clogging occurs frequently requiring maintenance
Solution Approach 1:
The invention extracts the clogging-prone orifice function from the traditional flat distributor plate and replaces it with a three-dimensional tube system. The inner and outer tubes provide multiple flow paths that are less susceptible to clogging, reducing maintenance frequency and improving reactor operational continuity.
Solution Approach 2:
The invention changes the flow path parameters from two-dimensional orifice flow to three-dimensional tubular flow with multiple apertures. This parameter change increases the hydraulic radius and provides alternative flow paths, reducing the likelihood of clogging and extending operational intervals between maintenance.
3Reliability
If gas and liquid flow through conventional distributors, then distribution is achieved, but hot spots develop reducing catalyst efficiency
Solution Approach 1:
The distributor units are designed with specific local characteristics including inner tubes with apertures at predetermined positions and outer tubes with slots. This local quality optimization ensures uniform gas and liquid distribution at specific locations, preventing hot spots and maintaining catalyst efficiency.
4Manufacturing precision
If simple distributor plates are used, then device complexity is low, but fluid distribution uniformity is poor
Solution Approach 1:
The distributor units employ a nested configuration where inner tubes are positioned within outer tubes. This nesting arrangement achieves complex fluid distribution functionality while maintaining a compact structure that does not excessively increase device complexity.
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
Ensures uniform fluid distribution across the catalyst bed, reduces reactor downtime, and increases catalyst efficiency by minimizing hot spots and clogging, thereby improving reaction rates and yield.
Implementation Method 1
venturi insert, which reduces fluid flow sensitivity to tray levelness and minimizes clogging by using gas velocity to control liquid flow, enhancing mixing and distribution
Data Source
AI summary
The present subject matter relates an apparatus (120) for distributing polyphasic fluid mixture to a catalyst bed in a downflow reactor (100). The apparatus (120) comprises a distributor tray (140) comprising a plurality of distributor units (150). The distributor unit (150) comprises an inner tube (210), an outer tube (220) disposed outside and concentric to the inner tube (210), a cover (346), a cap plate (350), and a gas inlet (358). The inner tube comprises a first aperture (314) to allow liquid to enter the inner tube (210) and a solid insert (326). The solid insert (326) forms a narrow passage (330). The outer tube (220) comprises a slot (338) to allow liquid from the distributor tray (140) to enter an annular portion (342).