Fischer-Tropsch Reactor Module with Corrugated Plates
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Solution Overview
Problem
Catalytic reactors for Fischer-Tropsch synthesis face challenges in maintaining catalyst structure integrity under pressure differences and ensuring efficient heat transfer, leading to reduced catalyst-bearing channel volume and impaired heat transfer.
Innovation Solution
A reactor module with a stack of plates featuring alternating flow channels for synthesis gas and coolant, where the synthesis gas channels contain a removable gas-permeable catalyst structure with a metal substrate that forms an adherent alumina coating for protection, and the coolant channels are defined between spaced plates to facilitate uniform coolant flow and minimize temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the plates are made thicker and/or channels narrower to resist pressure difference, then the structural strength is improved, but the catalyst-bearing channel volume as a proportion of total reactor volume decreases
Solution Approach 1:
The patent employs thin corrugated sheets instead of thick rigid plates to provide structural support. The corrugated structure provides sufficient mechanical strength to resist pressure differences while maintaining thin plate thickness, thereby preserving maximum channel volume for catalyst placement.
Solution Approach 2:
The patent introduces corrugation in the z-dimension (thickness direction) to provide structural strength without increasing the overall plate thickness. This dimensional transformation allows the plates to resist pressure loads while maintaining thin profiles that maximize the channel volume available for catalyst.
2Strength
If the plates are made thicker to resist pressure difference, then the structural strength is improved, but the heat transfer between catalyst structure and plates is impeded
Solution Approach 1:
By using thin corrugated sheets instead of thick plates, the patent minimizes the thermal resistance between the catalyst structure and the cooling channels. The thin plate configuration ensures efficient heat transfer from the catalyst to the coolant while still providing adequate structural support through corrugation.
Solution Approach 2:
The corrugated structure provides thermal pathways that facilitate heat transfer from the catalyst to the cooling channels. The increased surface area and conductive pathways in the corrugated design enhance thermal coupling between the catalyst-bearing channels and the coolant channels.
3Strength
If the plates are made narrower channels to resist pressure difference, then the structural strength is improved, but the catalyst structure becomes difficult to remove or replace
Solution Approach 1:
The thin corrugated sheets enable the catalyst structures to be easily inserted and removed from the channels. The flexibility and thinness of the plates allow for simple assembly and disassembly operations while maintaining structural integrity during operation.
4Strength
If the plates are made thicker to resist pressure difference, then the structural strength is improved, but synthesis gas may bypass the catalyst structure
Solution Approach 1:
The thin corrugated plate configuration eliminates gaps and bypass pathways that would exist in thicker plate designs. The close spacing and thin profile ensure that synthesis gas is forced to flow through the catalyst structure rather than bypassing it, maximizing conversion efficiency.
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 design allows for efficient heat transfer, easy catalyst replacement, and maintains reactor performance despite pressure differences, ensuring consistent Fischer-Tropsch synthesis conditions and accommodating fluctuations in gas flow rates.
Implementation Method 1
the metal substrate for the catalyst structure is a steel alloy that forms an adherent surface coating of aluminium oxide when heated
Implementation Method 2
the second flow channels are defined between successive flat plates that are spaced apart by edge strips and by corrugated sheets
Implementation Method 3
the first fluid being a gas mixture which undergoes Fischer-Tropsch synthesis
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
A reactor module for Fischer-Tropsch synthesis consists of a generally rectangular reactor block (10) comprising a stack of plates (12) defining flow channels (15) for coolant and flow channels (17, 117) for the synthesis reaction arranged alternately in the block. The synthesis flow channels (17, 117) extend in a generally vertical direction between upper and lower faces of the reactor block (10) and are defined by plates (12) in combination with either bars (18) or sheets (119) such that each channel is of width no more than 200 mm. The coolant flow channels (15) are oriented in the same direction, and communicate through distributor chambers (26) with inlet and outlet ports at side faces of the reactor block. A plant may contain a multiplicity of such reactor modules operating in parallel, the modules being interchangeable and replaceable. The temperature control is enhanced by allowing the coolant flow to be parallel to the synthesis gas flow.