Exchange Layer Structure for Gas Resaturation in Liquid Feedstreams
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Solution Overview
Problem
Conventional process vessels face limitations in gas diffusion rates due to reduced interfacial surface area between liquid and gas phases, leading to reactant starvation, reduced reaction rates, and increased coking, which affects the efficiency and effectiveness of chemical reactions.
Innovation Solution
Implementing an exchange layer with collector and releaser media in the process vessel to facilitate co-current flow of gas and liquid phases, enhancing diffusion and maintaining high interfacial surface area through porous solid elements and thin films formed on releaser media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional process vessels are used with liquid and gas phases, then the vessel structure is simple, but the interfacial surface area between liquid and gas phases is reduced leading to poor gas diffusion
Solution Approach 1:
The exchange layer is segmented into multiple functional zones with different media types (collector media, releaser media, catalyst media) arranged in stratified sections. This segmentation creates multiple interfaces and contact points between liquid and gas phases, significantly increasing the interfacial surface area available for mass transfer and diffusion without requiring complete redesign of the entire vessel structure.
Solution Approach 2:
The exchange layer employs nested media arrangements where smaller releaser media are positioned within and around larger collector media, creating a hierarchical structure. This nesting maximizes the use of available space and creates multiple levels of liquid-gas contact interfaces, increasing interfacial surface area while maintaining a compact overall structure.
2Productivity
If gas diffusion rate is increased through improved interfacial contact, then reactant availability improves, but the complexity of the exchange layer increases
Solution Approach 1:
Different regions of the exchange layer are assigned different media types with specific local functions: collector media for liquid accumulation, releaser media for controlled liquid release and gas contact, and catalyst media for chemical reactions. This local differentiation optimizes gas diffusion and mass transfer rates in each zone while keeping the overall structure manageable through functional zoning.
Solution Approach 2:
The exchange layer acts as an intermediary structure between the liquid feedstream and gas phase, providing a dedicated zone with optimized media for enhanced mass transfer. This intermediary layer facilitates efficient gas diffusion into the liquid without requiring fundamental changes to the main process vessel structure or operating conditions.
3Productivity
If co-current flow of gas and liquid phases is implemented, then reaction efficiency improves, but control of flow patterns becomes more difficult
Solution Approach 1:
The exchange layer media are designed to automatically facilitate co-current flow patterns through their physical structure and surface properties. The collector and releaser media create capillary forces and surface area gradients that naturally drive liquid and gas phases to flow together in the desired direction, reducing the need for external flow control mechanisms and simplifying operation.
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
Enhances gas exchange and reaction rates, reduces reactant starvation, and minimizes coking, thereby improving the overall performance and efficiency of chemical reactions in process vessels.
Implementation Method 1
The collector media can include porous solid materials capable of collecting the reactant-lean liquid phase within the collector media
Implementation Method 2
The collector media can include porous solid materials capable of collecting the reactant-lean liquid phase within the collector media
Implementation Method 3
The releaser media can include solid materials having a thin film formed on an outer surface thereof that is capable of facilitating contact and diffusion between the reactant-lean liquid phase and the gas phase
Implementation Method 4
The porous solid elements can include at least one of catalysts, sorbents and reactants
Implementation Method 5
The porous solid elements can include at least one of catalysts, sorbents and reactants
Data Source
AI summary
A method for enabling gas exchange and chemical reactions with one or more liquid streams contained in a reactive process vessel are provided. One or more exchange layers within the process vessel can be composed of both collector media and releaser media. The exchange layers allow elements to facilitate increased performance of vessel operations by promoting gas component mixing and diffusion. Improved rates of gas component exchange mean less coking and more gas components available for reaction.