Fluidized Bed Reactor Deposit Removal via Inert Gas Injection
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Solution Overview
Problem
In fluidized bed reactors used for manufacturing carbon nanotubes, deposits formed on the dispersion plate obstruct gas flow, leading to defects and malfunctions, and existing methods to address this, such as vibration or impeller use, pose fire risks and are inefficient in crushing deposits at high temperatures.
Innovation Solution
A fluidized bed reactor design incorporating a sensing unit, such as thermometers, to detect deposits and a nozzle unit that injects inert gas to crush them, allowing for controlled operation to prevent deposit accumulation and enhance carbon nanotube production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vibrator or impeller is used to crush deposits, then deposit removal capability is improved, but fire risk increases due to physical impacts at high temperatures with flammable gases
Solution Approach 1:
The patent replaces the mechanical vibrator or impeller system with a gas injection system. Gas nozzles inject gas directly onto deposits to crush and remove them through fluid dynamic forces rather than mechanical vibration or rotation, eliminating the fire risk associated with mechanical impacts in the presence of flammable gases at high temperatures
Solution Approach 2:
The patent uses pneumatic pressure through gas nozzles to crush and remove deposits. The gas injection system utilizes high-velocity gas flow to impact and fragment deposits on the dispersion plate, providing an effective alternative to mechanical methods while maintaining safety in flammable environments
2Reliability
If mechanical vibration or rotation is applied to crush deposits, then deposit breakdown is improved, but complete crushing is difficult to achieve
Solution Approach 1:
The gas injection system delivers high-velocity gas directly onto deposits through multiple nozzles positioned at different locations. This pneumatic approach creates intense localized forces that effectively fragment and remove deposits more completely than mechanical vibration or rotation, achieving thorough deposit removal without leaving residual aggregates
3Device complexity
If deposits are allowed to accumulate on the dispersion plate, then device complexity is reduced, but gas flow obstruction increases leading to synthesis defects
Solution Approach 1:
The gas injection system operates proactively to prevent deposit accumulation by continuously or periodically injecting gas to crush and remove deposits before they can block the punched holes in the dispersion plate. This preliminary action maintains gas flow uniformity and prevents synthesis defects without requiring complex reactor redesign
Solution Approach 2:
The system uses the reaction gas or a separate gas supply to automatically crush and remove deposits through the injection nozzles, enabling self-maintenance of the dispersion plate functionality without requiring external mechanical intervention or complex control systems
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 effectively senses and crushes deposits on the dispersion plate, minimizing flow obstruction and improving carbon nanotube synthesis efficiency by using inert gas injection, reducing the risk of fire and ensuring reliable operation at high temperatures.
Implementation Method 1
a sensing unit configured to sense the deposits on the dispersion plate
Implementation Method 2
a nozzle unit mounted on one surface of the dispersion plate to receive an inert gas from outside the reactor body and inject the inert gas so as to crush deposits on the dispersion plate
Implementation Method 3
the metal catalyst reacts while flowing above the dispersion plate 2
Data Source
AI summary
A fluidized bed reactor includes: a reactor body; a dispersion plate mounted within the reactor body to partition the inside of the reactor body in a traverse direction and having a plurality of holes through which a reaction gas passes; a nozzle unit mounted on one surface of the dispersion plate to receive an inert gas from outside the reactor and inject the inert gas so as to crush deposits on the dispersion plate; a sensing unit configured to sense the deposits on the dispersion plate; and a control unit configured to control operation of the nozzle unit according to information sensed in the sensing unit.