Dual-Tray Cooling Device for Fixed Catalyst Bed Temperature Control
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Solution Overview
Problem
Current devices for cooling and distributing mixed charges in descending flow catalytic reactors are complex, large, and prone to erosion, leading to inefficient temperature reduction and distribution issues, which complicates the operation and maintenance of these reactors.
Innovation Solution
A compact, simple device comprising two flat trays with perforations and collector tubes, allowing for efficient mixing and distribution of cooling fluids with the reactor charge, reducing temperature differences and improving distribution over the catalyst beds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional distribution devices with multiple components are used, then distribution of charge over catalyst bed is improved, but device complexity increases
Solution Approach 1:
The device is divided into two separate flat trays (upper and lower) with distinct functions. The upper tray handles distribution while the lower tray handles collection, simplifying each component's design while maintaining overall distribution effectiveness. This segmentation allows each tray to be simpler in structure compared to a single complex multi-component device.
2Manufacturing precision
If large distribution devices are used, then charge distribution is improved, but ease of installation and maintenance deteriorates
Solution Approach 1:
By dividing the distribution system into two smaller, separate flat trays rather than one large complex device, each tray becomes easier to install and maintain. The segmented design allows for simpler handling, positioning, and potential replacement of individual trays without requiring manipulation of a large cumbersome assembly.
3Manufacturing precision
If complex distribution devices are used, then charge distribution is improved, but ease of maintenance deteriorates
Solution Approach 1:
The segmented two-tray design isolates potential maintenance issues to specific trays rather than requiring inspection and repair of a complex multi-component device. Each flat tray's simplicity makes them easier to access, inspect, and maintain independently, reducing overall maintenance complexity.
Solution Approach 2:
By extracting the distribution function into a simple two-tray system separate from the catalyst beds and other reactor components, the distribution device becomes an independent, easily maintainable unit. This extraction simplifies maintenance procedures by isolating the distribution function from other complex reactor systems.
4Temperature
If conventional cooling devices are used, then temperature reduction is achieved, but temperature uniformity deteriorates
Solution Approach 1:
The cooling function is segmented into the upper tray (cooling fluid injection) and lower tray (charge collection), creating a more uniform cooling path. This segmentation ensures that cooling fluid is distributed evenly across the upper tray surface and contacts the charge uniformly as it flows to the lower tray, improving temperature uniformity while achieving effective temperature reduction.
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 device effectively reduces temperature differences by 1-2°C, enhancing the efficiency and conversion of reactions, while being easier to install and maintain due to its compact design.
Implementation Method 1
As it mixes with the very hot reaction liquid this fluid reduces its temperature to more appropriate levels for satisfactory conduct of the process
Implementation Method 2
distributing it radially over the surface of the plates and causing it to flow through different holes onto the surface of the catalytic bed
Data Source
AI summary
This invention relates to a device for cooling and distributing mixed charges on fixed catalyst beds for use in the cooling zone of descending flow reactors which comprises a flat tray fitted with collector and distributor tubes for liquid superimposed upon and connected to another flat tray of similar design to the upper tray. The device, which is of smaller size in comparison with other commercially available devices, is extremely simple to install industrially and compact, and has as its main characteristic the efficiency with which it promotes reduction of the temperature of the reaction medium when it receives the cooling fluid within the catalytic reactor.