Fluid Distribution Device with Tapered Vapor Chimneys
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Solution Overview
Problem
In co-current flow reactors, especially in hydroprocessing, the existing systems face challenges in efficiently mixing and distributing fluids between catalyst beds due to limited space, leading to uneven temperature and composition distribution, which can result in hot spots and reduced catalyst life, and require significant space for effective quenching and mixing.
Innovation Solution
The introduction of a device and method that includes a collection tray, mixing chamber, rough distribution tray, and vapor chimneys with a radially inwardly tapered cross-section to facilitate the mixing and distribution of fluids, reducing the height of the mixing zone while maintaining effective fluid distribution and temperature uniformity, by collecting fluid from a superior reactor bed, swirling it in a mixing chamber, and distributing it through vapor chimneys to minimize radial pressure gradients and enhance fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If complex mixing and distribution systems are used to achieve good temperature and composition distribution, then fluid mixing and distribution is improved, but the space required in the reactor chamber increases
Solution Approach 1:
The mixing and distribution system is segmented into multiple functional components: a collection tray for receiving fluid, a mixing chamber for thorough mixing, a rough distribution tray for initial distribution, and vapor chimneys for vapor-liquid contact. This segmentation allows each component to perform its specific function efficiently within a compact overall structure, reducing the total space required while maintaining effective mixing and distribution.
Solution Approach 2:
The vapor chimneys are positioned to extend through the rough distribution tray, with their lower ends below the tray and upper ends above it. This nested configuration allows vapor to rise through the chimneys while liquid distributes through the tray, maximizing the utilization of vertical space and enabling effective quenching and mixing within a reduced interbed height.
2Volume of stationary object
If the space between catalyst beds is reduced to maximize catalyst loading, then reactor size and capital expenditure are reduced, but the ability to mix and distribute fluids effectively is compromised
Solution Approach 1:
The invention transitions from horizontal space utilization to vertical space utilization by implementing a multi-level stacked configuration. The collection tray, mixing chamber, rough distribution tray, and vapor chimneys are arranged vertically, allowing effective mixing and distribution functions to be performed within a reduced horizontal footprint and reduced interbed height, thereby maximizing catalyst loading while maintaining operational effectiveness.
Solution Approach 2:
The radially inwardly tapered cross-section of the vapor chimneys is designed to reduce restriction of outward fluid flow along the rough distribution tray. This geometric parameter optimization minimizes pressure gradients and enhances fluid flow characteristics, enabling effective mixing and distribution within a compact vertical space.
3Ease of manufacture
If existing reactor internals are installed in fixed-height interbed spaces, then installation is straightforward, but mixing of fluids is insufficient and catalyst life is reduced due to hot spots
Solution Approach 1:
The vapor chimneys are designed with a radially inwardly tapered cross-section that dynamically adapts to fluid flow patterns. This tapered geometry optimizes vapor-liquid contact and reduces pressure gradients, enhancing mixing efficiency and preventing hot spot formation, thereby extending catalyst life while maintaining ease of installation as a complete assembled unit.
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 allows for improved fluid distribution and temperature uniformity between catalyst beds, reducing the height of the mixing zone by up to 200 mm, extending catalyst life, and optimizing catalyst loading without sacrificing performance, thus reducing capital expenses and reactor size.
Implementation Method 1
a vapor chimney body having a radially inwardly tapered cross section to reduce restriction of outward fluid flow along the rough distribution tray
Implementation Method 2
swirling it in a mixing chamber
Implementation Method 3
In hydrocarbon processing, the quench gas is often a cool hydrogen/hydrocarbon stream
Data Source
AI summary
A fluid distribution device is presented for the collection and distribution of fluid between reactor beds. According to various aspects, the device includes a collection tray, a mixing chamber in fluid communication with the collection tray, a rough distribution tray in fluid communication with the mixing chamber, and a fine distribution tray in fluid communication with the rough distribution tray. The rough distribution tray includes a vapor chimney.