Filter Plate for Fixed-Bed Reactor with Co-Current Gas-Liquid Downflow

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Solution Overview

Problem

Chemical reactors with downward co-current gas and liquid flows face issues with clogging due to impurities, leading to reduced catalytic bed void fraction, increased pressure loss, and heterogeneous flow distribution, which disrupts chemical reactions and requires frequent catalyst replacement.

Innovation Solution

A distributor plate with a filtration bed integrated into the distribution system, featuring vertical chimneys with lateral slots or orifices for gas and liquid entry, and a granular filtration bed that traps clogging particles, ensuring homogeneous flow distribution and extended catalyst cycle life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a catalytic bed is used to process liquid feed containing impurities, then chemical reactions can be performed, but clogging particles deposit on the bed and reduce the interstitial volume

Engineering Contradiction:

Improvechemical reaction throughputVSAvoidcatalytic bed void fraction

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The distributor plate is segmented into multiple functional zones: a filtration bed zone with granular material to trap particles, a distribution zone with channels to homogenize flow, and a catalytic bed zone for chemical reactions. This segmentation allows the system to filter impurities before they reach the catalytic bed, maintaining void fraction while preserving reaction productivity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A filtration bed consisting of granular material (inert particles or adsorbents) is introduced as an intermediary layer between the liquid feed inlet and the catalytic bed. This intermediary traps clogging particles through physical filtration and adsorption, preventing them from depositing on the catalytic bed and reducing interstitial volume

Inventive Principle:

Principle #24Intermediary (Mediator)

2Duration of action of stationary object

If clogging particles are present in the feed flow, then the reactor can operate continuously, but pressure loss increases and flow homogeneity is disrupted

Engineering Contradiction:

Improvereactor operational durationVSAvoidpressure loss

Core Design Contradiction:

Duration of action of stationary objectVSLoss of energy

Solution Approach 1:

The filtration bed performs preliminary action by trapping clogging particles before they enter the catalytic bed. This pre-filtration prevents subsequent pressure loss increases and flow heterogeneity, allowing the reactor to operate continuously at stable pressure conditions for extended periods

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The filtration bed uses porous granular materials with controlled pore sizes to filter particles from the feed. The porous structure allows liquid and gas to pass through while trapping solid particles, maintaining low pressure loss while extending operational duration by preventing bed clogging

Inventive Principle:

Principle #31Porous materials

3Quantity of substance

If particles are deposited within the catalytic bed, then the interstitial volume is reduced, but the flow distribution becomes heterogeneous

Engineering Contradiction:

Improvecatalyst loadingVSAvoidflow distribution homogeneity

Core Design Contradiction:

Quantity of substanceVSStability of the object's composition

Solution Approach 1:

Clogging particles are extracted from the feed stream by the filtration bed before the feed reaches the catalytic bed. This extraction prevents particle deposition within the catalytic bed, maintaining both catalyst loading and flow distribution homogeneity over extended operational periods

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If a filtration system is added to trap particles, then pressure loss is reduced, but the device complexity increases

Engineering Contradiction:

Improvepressure loss controlVSAvoiddistributor plate structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The filtration function, distribution function, and catalytic reaction function are merged into a single integrated reactor system. The distributor plate incorporates both filtration bed and distribution channels, eliminating the need for separate filtration equipment and reducing overall device complexity while maintaining pressure loss control

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively traps clogging particles, maintaining flow homogeneity, reducing pressure loss, and extending catalyst cycle duration by up to 80% compared to systems without filtration, while allowing for controlled gas and liquid distribution.

Implementation Method 1

a distributor plate with a filtration bed integrated into the distribution system, featuring vertical chimneys with lateral slots or orifices for gas and liquid entry, and a granular filtration bed that traps clogging particles

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentEP1922391B1Filter plate for a fixed-bed reactor with a co-current gas-liquid downflow

Publication Date: 2014.12.31 IFP ENERGIES NOUVELLES

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AI summary

The invention relates to a device for trapping clogging particles contained in the liquid charge used to feed a reactor with a co-current gas-liquid downflow, using a specific feed plate comprising a filter medium. The invention is particularly suitable for the selective hydrogenation treatment of charges containing diene and acetylene compounds.