Flexible Internal Wall Panels for Catalytic Reactors
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Solution Overview
Problem
The construction of internal walls in partially open catalytic reactors, particularly the outer collector of radial or axial-radial flow reactors, is costly and time-consuming due to the need for multiple sections and extensive welding, with existing solutions like the scallops design causing hot spots and increased costs.
Innovation Solution
A non-self-supporting internal wall composed of flexible and deformable panels that can be inserted through a manhole, resting on a load-bearing wall, allowing for reduced panel count, simpler assembly, and elimination of longitudinal welds, with panels made from thin metal sheets that can be rolled for easier access and featuring ribs for gas flow and section-breaker rings for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the outer collector is made in sections to pass through the manhole, then the reactor can be assembled in a partially open design, but the number of parts and welding operations increases significantly
Solution Approach 1:
The outer collector is divided into multiple sections that can be assembled separately and then joined together inside the reactor vessel. Each section is sized to pass through the manhole, and the sections are connected using welding operations to form the complete cylindrical collector structure.
Solution Approach 2:
The sectional outer collector sections are designed to be nested or stacked during assembly, with each section fitting within the assembly space available through the manhole opening, allowing progressive construction of the full-size collector from smaller components.
2Ease of operation
If more sections are used to form the outer collector, then the wall can be assembled through the manhole, but the assembly time and cost increase
Solution Approach 1:
The outer collector sections are prepared and fitted with connection features in advance before being introduced into the reactor vessel through the manhole. This preliminary preparation reduces the complexity and time of on-site assembly and welding operations.
Solution Approach 2:
The sectional design with standardized connection features enables the sections to be self-assembling to some extent, where each section has built-in attachment mechanisms that facilitate straightforward connection to adjacent sections, reducing the need for complex welding procedures inside the vessel.
3Adaptability or versatility
If the manhole is positioned laterally or inclined, then the reactor can accommodate gas inlet tubes, but the introduction of wall sections becomes more difficult
Solution Approach 1:
The outer collector sections are designed with curved or cylindrical geometries that allow them to be flexed or rotated during insertion through the lateral or inclined manhole, facilitating passage through the constrained opening angle while maintaining the structural integrity of the sections.
Solution Approach 2:
The wall sections are designed with flexible joints or deformable connection features that allow dynamic adjustment during the insertion process, enabling the sections to be maneuvered through the lateral manhole at various angles and then locked into their final positions.
4Device complexity
If the outer collector is made as a single large piece, then the assembly is simpler, but it cannot be introduced through the manhole
Solution Approach 1:
The outer collector is divided into multiple sections that can be assembled separately and then joined together inside the reactor vessel. Each section is sized to pass through the manhole, and the sections are connected using welding operations to form the complete cylindrical collector structure.
Solution Approach 2:
The single large collector is transformed into multiple smaller sections that can be introduced through the manhole opening, utilizing the spatial dimension of the opening to constrain the maximum size of individual components while achieving the same overall functional structure through assembly.
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 significantly reduces assembly time and costs by allowing larger panels to be used, ensuring complete catalyst coverage without hot spots, and enabling cost-effective perforation and easier maintenance, while maintaining mechanical strength and flexibility to accommodate thermal expansion.
Implementation Method 1
The deformation of the panels is elastic or partially elastic and partially plastic. After being introduced into the reactor, the panels recover their original configuration elastically
Implementation Method 2
The deformation of the panels is elastic or partially elastic and partially plastic
Implementation Method 3
The panels are provided with ribs and section-breaker rings and are perforated
Data Source
AI summary
Reactor (1) for catalytic chemical reactions, comprising: a partially open outer vessel (2) comprising a manhole (6) for accessing to the interior, and at least one internal wall (5) comprising a plurality of panels (5.1, 5.2, . . . 5.n) assembled inside the vessel (2) so as to form said wall (5); the panels are flexible and deformable so that they may be inserted through said manhole (6), and the resulting wall (5) is not self-supporting and rests against a load-bearing wall (7) of the reactor.