Filtration Tray for Catalytic Reactor Pressure Drop Management

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Solution Overview

Problem

Chemical reactors face operational challenges due to particle impurities in the inlet fluid stream, leading to pressure drop increases and frequent maintenance needs, which disrupts continuous operation and increases costs.

Innovation Solution

A particle separation system combining sedimentation and filtration with overfill systems to maintain constant pressure drop and limit liquid load, featuring interconnected basins with composite filtering media and overfill gates that expose fresh filtration sections as needed, along with initial sedimentation for large particles and a dispersion system for gas and liquid distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If particles are removed using a filter or particle separation equipment prior to sensitive equipment, then particle accumulation and plugging in the reactor bed is reduced, but device complexity and space requirements increase

Engineering Contradiction:

Improvereactor operation continuityVSAvoidparticle separation equipment

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the filtration function with the existing reactor distributor tray, merging two separate functions (reaction distribution and particle separation) into a single integrated component. This eliminates the need for a separate upstream filter while maintaining particle removal capability, directly resolving the contradiction between reliability improvement and device complexity increase.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The distributor tray is designed to perform multiple functions simultaneously: it distributes the liquid feed across the catalyst bed, supports the catalyst layer, and filters out particles from the feed stream. This multi-functionality approach allows particle separation without adding dedicated equipment, addressing the contradiction by achieving reliable operation through an existing component rather than additional equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If filtration media is used to trap particles, then particle capture efficiency improves, but pressure drop across the reactor increases

Engineering Contradiction:

Improveparticle capture efficiencyVSAvoidpressure drop

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The filtration system is designed with dynamic characteristics where the filtration area effectively increases as particles accumulate on the initial filtration surfaces. The liquid flow naturally redistributes to unused filtration areas, maintaining relatively constant pressure drop while continuing to capture particles. This dynamic adaptation resolves the contradiction between particle capture efficiency and pressure drop increase.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent utilizes the horizontal plane of the distributor tray by incorporating multiple filtration sections arranged in parallel. When one section becomes blocked, the liquid flow transitions to other sections in the same dimensional plane, effectively increasing the active filtration area without adding vertical height. This dimensional approach maintains low pressure drop while achieving high particle capture efficiency.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Duration of action of moving object

If multiple filtration sections are used to maintain constant pressure drop, then reactor operation duration extends, but device complexity increases

Engineering Contradiction:

Improvereactor operation durationVSAvoidfiltration system structure

Core Design Contradiction:

Duration of action of moving objectVSDevice complexity

Solution Approach 1:

The distributor tray is divided into multiple discrete filtration sections (first, second, third sections) that are spatially separated and can be independently utilized. This segmentation allows the system to progress through sections sequentially as particles accumulate, extending operational duration. The segmented design is integrated into the existing tray structure, minimizing additional complexity while achieving extended operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The distributor tray is pre-configured with multiple filtration sections during installation, ready to handle particle accumulation over time. This preliminary arrangement of multiple sections ensures that when particles begin to block the first section, the system can immediately transition to subsequent sections without requiring complex real-time reconfiguration, thereby extending operation duration with minimal added complexity.

Inventive Principle:

Principle #10Preliminary action

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

This solution effectively captures particles while maintaining a constant pressure drop, reducing the need for frequent maintenance and minimizing space and material costs, ensuring prolonged reactor operation and efficient chemical reactions.

Implementation Method 1

The device can trap plugging particles contained in the liquid feed supplying a reactor functioning in gas and liquid co-current down-flow mode using a specific distributor tray comprising a filtration medium

Methodology Applied

Scientific EffectFiltration: Filter (physical)