Fluid Mixing Apparatus for Catalytic Bed Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices for mixing and distributing fluids in downflow catalytic reactors are inefficient, particularly at high fluid flow rates, and are bulky, leading to suboptimal catalyst usage and potential hot spots in exothermic reactions.
Innovation Solution
A device comprising a collection zone, a mixing zone with a specific length ratio to an exchange enclosure, and a distribution zone with horizontal panels and chimneys, designed to enhance fluid mixing and distribution efficiency while maintaining compactness, including a beveled mixing chamber and lateral passage sections for improved fluid flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a complex quenching device with multiple components (deflector, baffle, perforated bowl, dispensing tray) is used to mix fluids, then fluid mixing efficiency is improved, but the device becomes bulky and wastes reactor space
Solution Approach 1:
The patent merges multiple separate components (collection means, injection means, mixing zone, distribution zone) into an integrated device where the collection pipe serves both as a collection conduit and mixing chamber, and the distribution plate combines chimneys and dispensing functions. This consolidation maintains mixing efficiency while reducing overall device volume and maximizing catalyst space.
Solution Approach 2:
The collection pipe is designed to serve multiple functions: collecting reaction fluid from the catalyst bed, injecting quenching fluid, providing a mixing zone for the two fluids, and distributing the mixed fluid to the catalyst bed below. This multi-functionality eliminates the need for separate components, reducing device bulk while maintaining mixing efficiency.
2Productivity
If a bulky quenching device is installed in the reactor, then fluid distribution is improved, but the quantity of catalyst that can be used is reduced
Solution Approach 1:
The distribution plate integrates multiple functions (fluid distribution, catalyst support, reactor sealing) into a single component that occupies minimal space. The chimneys and horizontal panels are arranged to provide effective fluid distribution while maximizing the remaining volume for catalyst placement.
Solution Approach 2:
The device utilizes vertical stacking of functional zones (collection zone at top, mixing zone in middle, distribution zone at bottom) to minimize the horizontal footprint. This vertical arrangement allows effective fluid mixing and distribution while maximizing the radial space available for catalyst beds.
3Productivity
If the mixing chamber length L1 is increased to improve mixing, then fluid mixing efficiency is improved, but the exchange enclosure length L2 must be proportionally increased, creating a taller device
Solution Approach 1:
The patent optimizes the L1/L2 length ratio parameter to achieve effective mixing within a compact height. By carefully selecting specific length values that maintain the proper ratio, the device achieves thorough fluid mixing while minimizing the overall vertical dimension to maximize catalyst loading space.
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 solution achieves better fluid mixing and distribution efficiency, maintaining homogeneous temperature gradients and allowing for increased catalyst usage without increasing the reactor's size, thereby preventing thermal runaways and maintaining reaction selectivity.
Implementation Method 1
at least one collection zone (A) comprising at least one collection means (5); at least one substantially vertical collection pipe (7) capable of receiving a reaction fluid collected by said collection means (5) and at least one injection means (8) opening into said collection pipe (7) to inject a quenching fluid
Implementation Method 2
which allows a homogeneous temperature distribution of the fluids over a reactor section and cooling of the reaction fluids to a desired temperature
Implementation Method 3
said mixing zone comprising at least one chamber for mixing the fluids of length L1
Implementation Method 4
at least one distribution zone (C), located below the mixing zone, downstream of the said mixing zone in the direction of the circulation of the fluids, the said distribution zone comprising a distribution plate supporting a plurality of chimneys (13) and a plurality of horizontal panels (33)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Fluid mixing and distribution device for a downflow catalytic reactor comprising: - a collection zone (A) including a collection means (5); - a substantially vertical collection line and at least one injection means (8) opening into said collection line; - a mixing zone (B) including a fluid mixing chamber (15) of length L1, said mixing zone (15) including a first end in communication with said collection line and a second end in communication with a fluid exchange chamber (16) of length L2, located below said mixing chamber (15), the length L2 of said exchange chamber (16) being strictly greater than the length L1 of said mixing chamber (15);- a distribution zone (C), located below the mixing zone (B), comprising a distribution tray (12) supporting a plurality of chimneys (13), and a plurality of horizontal panels (33) located above or on the chimneys (13).