Equal Flow Scale Catcher for Reactor Fluid Distribution
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Solution Overview
Problem
Conventional scale catching devices in hydroprocessing reactors face challenges in maintaining uniform fluid delivery and efficient particle capture, leading to increased pressure drop and reactor shutdowns due to particle buildup, which existing technologies like catalyst grading and proprietary scale catching technologies have not adequately addressed.
Innovation Solution
The Equal Flow Scale Catcher (EFSC) employs a modular structure with multiple scale catching modules that ensure equal fluid flow and efficient particle capture, preventing particles from reaching the active catalyst bed, and allowing for optimal configuration and easy installation/uninstallation, thereby maintaining uniform fluid delivery and static pressure across the reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional scale catching devices are used, then particle capture is achieved, but fluid delivery uniformity deteriorates and pressure drop increases
Solution Approach 1:
The device is divided into multiple independent scale catching modules arranged in parallel, where each module contains scale catching elements. This segmentation allows fluid to be distributed evenly across multiple pathways, maintaining uniform fluid delivery while each module independently captures particles, thus resolving the contradiction between particle capture efficiency and fluid delivery uniformity.
2Reliability
If catalyst grading is used to store particles, then particle protection is improved, but reactor active space is reduced
Solution Approach 1:
The scale catching function is extracted from the reactor active space and placed in a separate device positioned above the catalyst bed. The scale catching elements are contained in removable modules that can be installed and maintained without disrupting the catalyst bed, thus protecting particles while preserving the full reactor active space for catalytic reactions.
3Reliability
If proprietary scale catching technology is used, then particle capture is improved, but device complexity and installation difficulty increase
Solution Approach 1:
The scale catching device is segmented into standardized modular units that can be independently installed and removed. Each module contains scale catching elements and can be handled as a discrete unit, simplifying installation and maintenance procedures while maintaining effective particle capture across the entire reactor cross-section.
Solution Approach 2:
The modular scale catching units are designed with universal interfaces and standardized dimensions that allow them to be applied across different reactor sizes and configurations. This universality reduces installation complexity by enabling the use of the same basic module design in various applications, while the modular nature allows flexible arrangement to match specific reactor requirements.
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 EFSC achieves substantial uniformity of fluid delivery and static pressure, effectively capturing solid particles, reducing the risk of reactor shutdowns and operational costs by maintaining low pressure drop and efficient filtration, even as the scale catching modules become saturated.
Implementation Method 1
The EFSC of the present invention can efficiently and effectively capture solid particles of any type that enter the reactor in the incoming fluid
Implementation Method 2
the EFSC of the present invention offers equal flows to a catalyst bed and/or a distribution tray of the reactor, independent of each module's degree of saturation with particles
Data Source
AI summary
An equal flow scale catcher device, or EFSC, is designed based on a unique scale catching technology for a reactor. With multiple scale catching modules, the EFSC offers equal flows to a catalyst bed or distribution tray of the reactor, independent of each module's degree of saturation with particles of an incoming fluid during operation. Thus, the innovative EFSC system achieves substantial uniformity of fluid delivery across the distribution tray of the reactor and the static pressure field above the liquid level on the distribution tray. Further, the EFSC effectively captures solid particles in the incoming fluid to the reactor and solid particles that form at the top head of the reactor. The EFSC employs a modular structure that allows optimal configuration of the scale catching modules and scale catching units inside each scale catching module, thus efficiently facilitating simple and efficient installation, maintenance, and/or replacement of the EFSC.