Flexible Extraction Sleeve for Spent Catalyst Removal
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Solution Overview
Problem
Industrial reactors face challenges in completely emptying spent catalyst particles due to their sticky nature and reactivity, leading to incomplete removal and hazardous human intervention, which can result in accidents and catalyst damage.
Innovation Solution
A method involving a two-step process using a flexible extraction sleeve with protuberances, where the first step involves gravity flow or assisted flow of catalyst particles, followed by the second step of using a flexible extraction sleeve to completely remove the remaining catalyst, minimizing human intervention and ensuring safety and catalyst preservation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gravity flow emptying is used to remove spent catalyst, then the operation is simple and quick, but incomplete removal occurs leaving 15-20 wt% of catalyst inside the reactor
Solution Approach 1:
The emptying operation is divided into multiple sequential phases: initial gravity flow phase followed by a secondary removal phase using a retrieval device. This segmentation allows each phase to address specific aspects of catalyst removal - the gravity phase handles bulk removal efficiently while the retrieval phase addresses the remaining digout material that gravity cannot remove.
Solution Approach 2:
Before the secondary retrieval phase, the reactor is prepared by introducing an inert gas atmosphere and positioning the retrieval device. This preliminary action ensures safety conditions are established and the retrieval mechanism is ready to immediately address the remaining catalyst after gravity flow stops, preventing incomplete emptying.
2Manufacturing precision
If human intervention is used to manually remove the digout, then complete emptying is achieved, but safety hazards increase due to nitrogen atmosphere and self-heating catalyst
Solution Approach 1:
The retrieval device operates autonomously within the reactor to remove the digout catalyst without requiring human entry. The device is actuated by external mechanisms or pre-programmed sequences, allowing the system to complete the emptying operation itself under controlled inert atmosphere conditions, eliminating exposure risks to operators.
Solution Approach 2:
Manual mechanical removal by human operators is replaced with an automated mechanical retrieval device that can be controlled from outside the reactor. This substitution maintains the mechanical action needed for catalyst removal while eliminating the harmful human exposure to nitrogen atmosphere and self-heating catalyst.
3Manufacturing precision
If spent catalyst is handled manually in nitrogen atmosphere, then complete removal is possible, but the risk of self-ignition and fatal accidents increases
Solution Approach 1:
The retrieval device acts as an intermediary between the operator and the hazardous spent catalyst. It performs the dangerous function of contacting and removing the self-heating catalyst under nitrogen atmosphere without exposing human operators to these hazards, while still achieving complete emptying.
Solution Approach 2:
The reactor is maintained under an inert nitrogen atmosphere throughout the emptying operation, and the retrieval device operates within this protected environment. This inert atmosphere prevents oxidation and self-ignition of the spent catalyst during the complete removal process, eliminating the fire hazard while achieving thorough emptying.
4Reliability
If the reactor is shut down regularly to renew catalyst beds, then catalyst activity is maintained, but reactor downtime increases operational costs
Solution Approach 1:
The emptying operation maintains continuous action throughout both the gravity flow phase and the retrieval phase without interruption. The seamless transition between phases and the efficient design of the retrieval mechanism minimize the time the reactor remains non-operational, reducing downtime losses while ensuring complete catalyst removal for reliable performance.
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 method allows for complete, rapid, and safe removal of spent catalyst, reducing reactor downtime and preserving catalyst properties for potential reuse, while eliminating the need for hazardous human intervention inside the reactor.
Implementation Method 1
The sleeve is provided on its external surface with protuberances and is able to move, inside the reactor, translationally and rotationally with respect to the dump tube
Implementation Method 2
a first step consisting in causing a proportion of the bed of catalyst to flow out of the reactor via the said dump tube
Data Source
AI summary
The present invention provides a method for emptying a reactor containing at least one bed of spent catalyst particles, wherein the reactor comprises at least one dump tube that opens into the reactor. The method comprising the steps of:(a) causing a portion of the bed of spent catalyst particles to flow out of the reactor via the dump tube; and(b) extracting the remainder of the spent catalyst particles from the reactor by driving the remainder of the spent catalyst particles toward the opening of the dump tube using a removable device comprising at least one flexible extraction sleeve introduced into the reactor via the said dump tube and connected to an extraction system situated outside the reactor, the sleeve being provided on its external surface with protuberances and being able to move, inside the reactor, translationally and rotationally with respect to the dump tube.