Flat Element Flow Distribution Device for High-Temperature Reactors
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Solution Overview
Problem
Conventional uniform distribution devices in reactors lead to increased pressure losses and higher costs, especially at high temperatures, while failing to maintain uniform velocity distribution across the reactor cross-section during high volume flows.
Innovation Solution
A reactor design featuring three or more largely flat components arranged perpendicular to the main flow direction, with specific hydraulic diameters and spacing, upstream of the internals, to ensure uniform fluid distribution with minimal pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional uniform distribution devices are installed to ensure uniform velocity distribution, then velocity distribution uniformity is improved, but pressure loss increases
Solution Approach 1:
The distribution device is segmented into multiple flat components (at least three) arranged in sequence along the flow direction. Each component has openings that divide the fluid stream into multiple smaller streams, progressively improving distribution uniformity while distributing the pressure loss across multiple stages rather than one large pressure drop
Solution Approach 2:
The invention transitions from conventional three-dimensional distributed structures to largely flat (two-dimensional) components. These flat components with small thickness in the flow direction create multiple flow paths in the cross-sectional plane, achieving uniform distribution with minimal pressure loss by utilizing geometric arrangement rather than complex 3D structures
2Productivity
If reactor loading is increased to enhance performance, then productivity is improved, but velocity distribution uniformity deteriorates
Solution Approach 1:
The uniform distribution device is installed upstream of the internals, before the fluid enters the reaction zone. This preliminary action of distributing the flow uniformly at the inlet allows the reactor to handle higher loads while maintaining velocity distribution uniformity throughout the reaction zone, preventing maldistribution that would occur with simple inlet configurations
3Temperature
If compressor stages are used to handle high temperature applications, then operating capability is improved, but cost increases
Solution Approach 1:
The distribution device enables the reactor to self-regulate flow distribution uniformly across the cross-section, handling high temperature applications and variable loads without requiring additional compressor stages or complex control systems. The system serves itself by using the inherent flow dynamics through the flat components to maintain uniform distribution under varying operating conditions
Data Source
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AI summary
Reactor comprises at least one supply line (1) for at least one fluid stream exhibiting a temperature of >= 200[deg] C at one end of the reactor, at least one discharge line (2) for the reaction mixture at the other end of the reactor, baffles (5) for supplying or discharging the heat and/or increasing the surface area, and an uniform distribution means. A main flow direction (3) is defined through the reactor. The total cross-sectional area for the supply lines ( Ai) is less than the maximum cross-sectional area (AR) of the reactor. Reactor comprises at least one supply line (1) for at least one fluid stream exhibiting a temperature of >= 200[deg] C at one end of the reactor, at least one discharge line (2) for the reaction mixture at the other end of the reactor, baffles (5) for supplying or discharging the heat and/or increasing the surface area, on which the reaction is carried out, an uniform distribution means, which is arranged in the main flow direction in front of the baffles in the reactor, and an opening for the passage of at least one fluid stream. A main flow direction (3) is defined through the reactor. The total cross-sectional area for the supply lines ( Ai) is less than the maximum cross-sectional area (AR) of the reactor. The uniform distribution means has at least two flat elements (4). The uniform distribution means has an expansion in the main flow direction through the reactor. The expansion is less than the extension direction perpendicular to the main flow direction through the reactor by at least a factor 2, preferably at least a factor 10. The uniform distribution means extends through the entire cross section of the reactor and is arranged perpendicular to the main flow direction through the reactor. The hydraulic diameter (dh) of at least two flat elements is defined by an equation comprising (dh) is equal to 4 V1/ O1, where V1 is the fluid-flow volume of the flat element and O1 is surface of the flat element wetted by the fluid. The value of (dh) is 0.5 mm to 1/10 of the hydraulic diameter of the reactor. At least two successive flat elements are mutually spaced in the main flow direction through the reactor by less than half the hydraulic diameter of the reactor, greater than 10 times the hydraulic diameter of directly positioned upstream flat element, and 1/4 the hydraulic diameter of the supply line with the maximum cross-sectional area. An independent claim is also included for using the reactor for carrying out reactions at reaction temperatures of 200-1000[deg] C, preferably 500-1000[deg] C.